2004 nbic-2005 addendum

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Library of Congress Catalog Card No. 52-44738

Printed in the United States of AmericaAll Rights Reserved

© 2005The National Board of Boiler

and Pressure Vessel Inspectors

Headquarters1055 Crupper Avenue

Columbus, Ohio 43229-1183614.888.8320

614.847.1828 FAX

Testing Laboratory7437 Pingue Drive

Worthington, Ohio 43085-1715614.888.8320

614.848.3474 FAX

Training and Conference Center 1065 Crupper Avenue

Columbus, Ohio 43229-1183614.888.8320

614.847.5542 FAX

Note: Pages ii through viii are not part of thisAmerican National Standard

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THE NATIONAL BOARD OF BOILER AND PRESSURE VESSEL INSPECTORS

BOARD OF TRUSTEES

OFFICERS

D.A. Douin – ChairmanR. Reetz – First Vice Chairman

M. Mooney – Second Vice ChairmanD.E. Tanner – Secretary-Treasurer

MEMBERS AT LARGE

E.D. EastmanD.J. JenkinsY. Nagpaul

M. Toth

ADVISORY COMMITTEE

G. McRaeRepresenting pressure vessel manufacturers

C.G. SchaberRepresenting authorized inspection agencies (insurance companies)

E.J. HovekeRepresenting National Board certificate holders

C.A. NeumannRepresenting Boiler and Pressure Vessel Users

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COMMITTEE ON NATIONAL BOARD INSPECTION CODE

T. ParksState of Texas

M.R. PetersonState of Alaska

J.T. PillowAPComPower Inc.

H.M. RichardsSouthern Company

J. RichardsonConsultant - Dresser Inc.

J. SekelyWelding Services, Inc.

R. SnyderARISE, Inc.

H. StaehrFactory Mutual Global

S. Staniszewski Jr.U.S. Department of Transportation

R.C. SulzerBabcock & Wilcox

H.N. Titer MIRANT Mid-Atlantic

M.J. WheelState of Vermont

C.S. Withers, ChairThe National Board of Boiler and

Pressure Vessel Inspectors

R.V. Wielgoszinski, Vice ChairHartford Steam Boiler Inspection andInsurance Co. of Connecticut

R. Heilman, SecretaryThe National Board of Boiler andPressure Vessel Inspectors

S.E. BaconConoco Phillips

D.A. CanonicoCanonico & Associates

D. Cook State of California

W.D. DotyDoty and Associates, Inc. P.D. EdwardsStone & Webster, Inc.

G.W. Galanes Midwest Generation EME, LLC

P.C. HackfordState of Utah

C. HopkinsSeattle Boiler Works

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NBIC Subcommittee on Overpressure Protection

D.A. Bowers Jr., ChairmanVelan Valve

J.F. Ball, P.E., SecretaryThe National Board of Boiler andPressure Vessel Inspectors

M. BrodeurInternational Valve & Instr.Corporation

S. CammeresiSouthern Instrument & ValveCompany

J.A. CoxDeluca Test Equipment

D.B. DeMichaelDuPont Company

R.W. DonalsonAnderson, Greenwood & Co.

F. HartFlowserve US, Inc.

NBIC Subcommittee on Mandatory Appendices

P.D. Edwards, ChairmanStone & Webster, Inc.




C. HopkinsSeattle Boiler Works




B. SchulteReliant Energy, Inc.



D.K. ParrishFM Global

J. RichardsonDresser Industries, Inc.

R. C. SulzerBabcock & Wilcox

M. WebbXcel Energy

R.V. WielgoszinskiHartford Steam Boiler Inspection andInsurance Company of Connecticut

NBIC Subcommittee on Nonmandatory Appendices

H.M. Richards, ChairmanSouthern Company

C. Walters, SecretaryThe National Board of Boiler andPressure Vessel Inspectors


W.D. DotyDoty & Associates, Inc.

G.W Galanes Midwest Generation EME, LLC


G.M. Halley, P.E.American Boiler Manufacturers As-sociation

J.P. LarsonOneBeacon Insurance

J. RichardsonConsultant – Dresser, Inc.

R. SnyderArise, Inc.

H. StaehrFactory Mutual Global




J.M. YagenDYNEGY Midwest Generation

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NBIC Subcommittee on Part RA

C.A. Neumann, ChairmanEastman Kodak Company

C. Walters, SecretaryThe National Board of Boiler andPressure Vessel Inspectors


J. RichardsonConsultant – Dresser Inc.

B. SchulteReliant Energy, Inc.

R. SnyderArise, Inc.


NBIC Subcommittee on Part RB

H. Staehr, ChairFactory Mutual Global

J.F. Ball, SecretaryThe National Board of Boiler andPressure Vessel Inspectors



J. M. RichardsSouthern Company



R.A. WackerDupont

NBIC Subcommittee on Parts RC and RD

R.V. Wielgoszinski, ChairHartford Steam Boiler Inspection andInsurance Co. of Connecticut




W.D. DotyDoty & Associates, Inc.

P.D. EdwardsStone & Webster, Inc.

G.W. Galanes Midwest Generation EME, LLC

C. Hopkins

Seattle Boiler Works

B. JuarezOneBeacon Insurance

J.P. LarsonOneBeacon Insurance


R.C. SulzerBabcock & Wilcox

M. Webb

Xcel Energy


J.M. YagenDYNEGY Midwest Generation

NBIC Task Group on DOT Requirements

C. WaltersThe National Board of Boiler andPressure Vessel Inspectors

D. DotyDoty & Associates

G. Galanes Midwest Generation, EME, LLC

M. GarrettTexana Tank Car & Mfg., LTD

R. MarvinState of Washington

G. McRaeTrinity Industries, Inc.

J. RichardsonConsultant – Dresser, Inc.

S. StaniszewskiU.S. Dept. of Transportation

N. Titer Mirant Mid-Atlantic

S. VoorhessOne Beacon American Insurance

R. WiegeloszinskiHartford Steam Boiler I & I Co.

L. WolpertBOX Gases

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NBIC Task Group on Graphite Pressure Equipment

S. Malone, ChairCarbone of America

W. BankerGraphite Repairs, Inc.

G. BraussenCarbone of America

F. BrownThe National Board of Boiler andPressure Vessel Inspectors

M. JohnsonPCS Phosphate

M. Minick FM Global

T. PindrohCarbone of America

T. SealReintjes Services, Inc.

E. SaltowSGL Carbon Group/SGL Technic, Inc.

A. StupicaSGL Carbon Group/SGL Technic, Inc.

NBIC Task Group on Steam Locomotive Repair

B. Withuhn, ChairSmithsonian Instituition

S. Butler Midwest Locomotive & Machine Works

D. ConradValley Railroad Co.

R. FrazenGreat Smoky Mountain Railroad

S. JacksonD & SNG

S. LeeUnion Pacific Railroad

D. McCormack

L. MoedingerStrasburg Railroad

G. ScerboFederal Railroad Administration

R. SchuelerThe National Board of Boiler andPressure Vessel Inspectors

R. StoneALSTOM Power

NBIC Task Group on FRP Pressure Equipment

B. ShelleyDupont Engineering

F. BrownThe National Board of Boiler andPressure Vessel Inspectors

J. BustillosThe Dow Chemical Company

T. CowleyDupont Engineering Technology

B. ShelleyDupont Engineering

R. CrawfordTroy Manufacturing

D. EisbergProgressive Composite Technology

R. YuillHistoric Machinery Services

T. FowlerThe Felicity Group

D. KeelerViatec, Inc.

H.N. MarshConsultant

J. MurphyParagon Aquatics

D. PinellABSIS

J. RichterTankinetics, Inc.

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NATIONAL BOARD MEMBERS

Alabama ............................................................................................................................................................. Ralph P. PateAlaska ..........................................................................................................................................................Mark R. Peterson

r zona war arateArkansas Gary R. MyrickCalifornia .......................................................................................................................................................Donald C. Cook Colorado .....................................................................................................................................................Randall D. Austin

onnect cut an . attDelaware James B. HarlanGeorgia ..................................................................................................................................................................Earl EverettHawaii................................................................................................................................................................Yash NagpaulIdaho Michael PoulinIllinois David A. DouinIndiana .....................................................................................................................................................................Dan WillisIowa .........................................................................................................................................................Michael Klosterman

ansas ona . en nsKentucky Rodney Handy

ou s ana ...................................................................................................................................................... Williams Owensa ne John H. Burpeeary an ar . ra t

Massachusetts .................................................................................................................................................. Mark MooneyMichigan ...................................................................................................................................................... Robert J. Aben Jr.

nnesota oe . matoss ss pp enry . c wenssour ............................................................................................................................................................. ames . ratt

Montana .................................................................................................................................................... James McGimpseye ras a an e . urns

Nevada Gerard F. MankelNew Hampshire ........................................................................................................................................... ayne BrighamNew Jersey .............................................................................................................................................. Milton Washington

ew or au . on nNorth Carolina Jack M. Given Jr.North Dakota ......................................................................................................................................................Robert ReetzOhio ...................................................................................................................................................................Dean T. JaggerOklahoma ar on . o oway

regon Michael GrahamPennsylvania ................................................................................................................................................Doug MacAdamRhode Island ............................................................................................................................................Benjamin Anthony

South Dakota owar . aennessee Martin R. Tothexas ....................................................................................................................................................................... Terry Parks

Utah ete . ac orermont Malcolm J. Wheelrg n a ..............................................................................................................................................................Fred P. Barton

Washington ................................................................................................................................................Linda Williamsonest rg n a Arthur E. Adkinsscons n Michael J. Verhagen

Chicago, IL Michael J. Ryanetro t, Michael Barber

Los Angeles, CA .................................................................................................................................................. Jovie Aclarowau ee, an a . uce

ew or , am c vney

erta en . . auBritish Columbia Malcolm BishopManitoba.........................................................................................................................................................Terry W. RiegerNew Brunswick ...................................................................................................................................................Dale E. Ross

ew oun an a ra or . enn s astmanNorthwest Territories teve onovanNova Scotia ...................................................................................................................................................Charles J. Castle

unavut err tory E. William Bachellierntar o c . e

Prince Edward Island ...................................................................................................................................Kenneth HynesQuebec .......................................................................................................................................................... Madiha M. KotbSaskatchewan r an ras un

u on err tory an e . r ce

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NATIONAL BOARD INSPECTION CODE

2004 EDITION INCLUDING 2005 ADDENDUM

DATE OF ISSUE — DECEMBER 31, 2005

This code was developed under procedures accredited as meeting the criteria for AmericanNational Standards. The Consensus Committee that approved the code was balanced toassure that individuals from competent and concerned interests had an opportunity to partici-pate. The proposed code was made available for public review and comment, which providedan opportunity for additional public input from industry, academia, regulatory and jurisdic-tional agencies, and the public-at-large. The National Board does not “approve,” “rate,” or “endorse” any item, construction, propri-etary device, or activity.

The National Board does not take any position with respect to the validity of any patent rightsasserted in connection with any items mentioned in this document, and does not undertake toinsure anyone utilizing a standard against liability for infringement of any applicable LettersPatent, nor assume any such liability. Users of a code are expressly advised that determinationof the validity of any such patent rights, and the risk of infringement of such rights, is entirelytheir own responsibility.

Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted as government or industry endorsement of this code.

The National Board accepts responsibility for only those interpretations issued in accordancewith governing National Board procedures and policies which preclude the issuance of inter-

pretations by individual committee members.

The footnotes in this document are part of this American National Standard.

R

NRR

R

� �

�

R

®

The above National Board symbols are registered with the U.S. Patent Office.

“National Board” is the abbreviation for The National Board of Boiler and Pressure VesselInspectors.

No part of this document may be reproduced in any form, in an electronic retrieval system orotherwise, without the prior written permission of the publisher.

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FOREWORD

The National Board of Boiler and Pressure Vessel Inspectors is an organization comprisedof Chief Inspectors for the states, cities and territories of the United States and provincesand territories of Canada. It is organized for the purpose of promoting greater safety to lifeand property by securing concerted action and maintaining uniformity in the construction,

installation, inspection, repair and alteration of pressure-retaining items, thereby assur-ing acceptance and interchangeability among jurisdictional authorities responsible for theadministration and enforcement of various codes and standards.

In keeping with the principles of promoting safety and maintaining uniformity, the NationalBoard originally published The National Board Inspection Code (NBIC) in 1946, establishing rulesfor inspection and repairs to boilers and pressure vessels. The National Board Inspection Code (NBIC) Committee is charged with the responsibility for maintaining and revising the NBIC.In the interest of public safety, the NBIC Committee decided, in 1995, to revise the scope of theNBIC to include rules for the repair or alteration to pressure-retaining items.

The NBIC Committee’s function is to establish rules of safety governing the repair, alterationand inspection of pressure-retaining items, and to interpret these rules when questions ariseregarding their intent. In formulating the rules, the NBIC Committee considers the needs ofusers, repair organizations, and Inspectors. The objective of the rules is to afford reasonablycertain protection of life and property, so as to give a reasonably long, safe period of usefulness.Advancements in design and material and the evidence of experience are recognized.

The rules established by the NBIC Committee are not to be interpreted as approving, recom-mending, or endorsing any proprietary or specific design, or as limiting in any way the repairorganization’s freedom to choose any method of repair or alteration that conforms to the NBICrules.

The NBIC Committee meets regularly to consider revisions of the rules, new rules, andrequests for interpretations. Requests for interpretation must be addressed to the Secretary inwriting and must give full particulars in order to receive consideration and a written inter-pretation (see Mandatory Appendix 1 covering preparation of technical inquiries). Proposedrevisions to the Code resulting from inquiries will be presented to the NBIC Committee forappropriate action.

Proposed revisions to the Code approved by the NBIC Committee are submitted to theAmerican National Standards Institute and published on the National Board Web site toinvite comments from all interested persons. After the allotted time for public review and finalapproval, revisions are published annually in Addenda to the NBIC.

Repair organizations or users of pressure-retaining items are cautioned against making use ofrevisions that are less restrictive than former requirements without having assurance that theyhave been accepted by the jurisdiction where the pressure-retaining item is installed.

The general philosophy underlying the NBIC is to parallel those provisions of the original codeof construction, as they can be applied to a repair or alteration.

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The NBIC does not contain rules to cover all details of repair or alteration. Where completedetails are not given, it is intended that the repair organization, subject to the acceptance ofthe Inspector, provide details for the repair or alteration which will be as safe as otherwiseprovided by the rules in the original code of construction.

Repairs not conforming to the rules of the original code of construction or the NBIC must receive

specific approval of the jurisdiction, who may establish requirements for design, inspection,testing and documentation.

There are instances where the NBIC serves to warn a repair organization or Inspector againstpitfalls; but the Code is not a handbook, and cannot substitute for education, experience, andsound engineering judgment.

It is intended that this Edition of the NBIC and any subsequent Addenda not be retroactive.Unless the jurisdiction imposes the use of an earlier edition, the latest effective Edition andAddenda is the governing document.

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INTRODUCTION

It is the purpose of the National Board Inspection Code (NBIC) to maintain the integrity of pres-sure-retaining items after they have been placed into service by providing rules for inspection,installation, repair and alteration, thereby ensuring that these objects may continue to be safelyused.

The NBIC is intended to provide guidance to jurisdictional Inspectors, users, and organizationsperforming repairs and alterations, thereby encouraging the uniform administration of rulespertaining to pressure-retaining items.

It provides guidance for the process of inspection, installation, repair and alteration but doesnot provide details for all conditions found in pressure-retaining items. Where complete detailsare not provided in this Code, the Code user is advised to seek technical guidance.

ADDENDA

Colored-sheet Addenda, which include revisions and additions to this Code, are publishedannually. Addenda are permissive on the date issued and become effective six months afterthe date of issue. The addenda will be sent automatically to purchasers of the Code up to thepublication of the next issue.

INTERPRETATIONS

On request, the NBIC Committee will render an interpretation of any requirement of this Code.Interpretations are not part of this Code or its addenda.

JURISDICTIONAL PRECEDENCE

Reference is made throughout this Code to the requirements of the “jurisdiction”. Where anyprovision herein presents a direct or implied conflict with any jurisdictional regulation, the jurisdictional regulation shall govern.

AMERICAN PETROLEUM INSTITUTE

The American Petroleum Institute promulgates codes and standards for the inspection, repair,alteration, rerating and fitness for service assessment of pressure vessels and piping used by

the petroleum and chemical process industries. These codes and standards include:

API 510 Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Altera-tion.

API 570 Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of Inservice Pip-ing Systems.

API 579 Fitness-for-Service

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It is the intent of the NBIC that this Code cover installations other than those covered by APIcodes and standards unless the jurisdiction rules otherwise.

UNITS OF MEASUREMENT

Both inch-pound units and SI units are used in the NBIC. The value stated in inch-poundunits or SI units are to be regarded separately as the standard. Within the text, the SI units areshown in parentheses.

US customary units or SI units may be used with this edition of the NBIC, but one system shall be used consistently throughout a repair or alteration of pressure-retaining items. The originalcode of construction should be used as the basis for selecting the units of measurement forrepair or alteration of pressure-retaining items.

ORGANIZATION

1. This book is divided into seven parts.

a. Part RA describes the administrative requirements for the accreditation of repair orga-nizations.

b. Part RB provides guidelines for inservice inspection of pressure-containing items (boil-ers, pressure vessels, piping).

c. Part RC provides requirements that apply to repairs and alterations of pressure-retain-ing items.

d. Part RD gives guidance for welding methods as alternatives to postweld heat treat-ment. Some repair methods are described to further give guidance to the owner-user,inspector, and repair organizations.

e. Mandatory appendices as identified by numerals contain specific rules that are notcovered in Parts RA, RB, RC, RD, and RE. Their requirements are mandatory whenapplicable.

f. Nonmandatory appendices as identified by letters provide information and suggestedgood practices. The information provided is not mandatory. However, if used, shall beused in its entirety to the extent applicable.

g. Interpretations are provided for information only and are not part of this code.

2. Tables, charts and figures provide relevant illustrations or supporting information for textpassages, and are designated with numbers corresponding to the paragraph they illustrateor support. Multiple tables, charts or figures referenced by the same paragraph will haveadditional numbers reflecting the order of reference.

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TABLE OF CONTENTS

Foreword .......................................................................................................................................... xi

Introduction ...................................................................................................................................xiii

Part RA A ministrative Requirements 1

Part RB Inservice Inspection of Pressure-Retaining Items ...........................................31

Part RC Repairs and Alterations of Pressure-Retaining Items ....................................89

Part RD Repair/Alteration Methods .............................................................................105

Part RE Repairs of Pressure Relief Valves ....................................................................125

Man atory Appen ces

Appendix 1 Preparation of Technical Inquiries to the National Board Inspect on Co e Committee 135

Appendix 2 Stamping and Nameplate Information ..........................................................137

Appendix 3 Steam Locomotive Firetube Boiler Inspection, Repair, and Storage ..........141

Appendix 4 Glossary of Terms ..............................................................................................175

Appendix 5 National Board Forms .......................................................................................181

Appendix 6 Examp es o Repairs an A terations 213Appendix 7 Procedures to Extend the “VR” Certificate of Authorization Stamp to ASME “NV” Stampe Pressure Re ie Devices 217

Appendix 8 Inspection, Repair, and Alteration of Graphite Pressure Equipment ........221

Appendix 9 Repair, Alteration, and Inspection of Fiber-Reinforced Thermosetting Plastic Pressure Equipment ...................................................233

Nonman atory Appen ces

Appendix A Standard Welding Procedures .........................................................................277

Appendix B Recommended Preheat Temperatures ............................................................287

Appendix C Historica Boi ers 291

Appendix D Recommended Guide for the Design of a Test System for Pressure Relief Devices in Compressible Fluid Service ...............................349

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Appendix E Recommen e Proce ures or Repairing Pressure Re ie Va ves 355

Appendix F Pressure Differential Between Safety or Safety Relief Valve Setting an Boi er or Pressure Vesse Operating Pressure 361

Appendix G Safety Valves on the Low Pressure Side of Steam Pressure-Re ucing Va ves 365

Appendix H Recommended Guide for the Inspection of Pressure Vessels in LP Gas Service ...............................................................................................371

Appendix I Installation Requirements ................................................................................377

Appendix J Guide to Jurisdictions for Authorization of Owners-Users to Make Adjustments to Pressure Relief Valves ............................................435

Appendix K Inspection, Repairs, an A terations or Yan ee Dryers 439

Appendix L Continued Service, Inspection, and Repair of DOT Vessels .....................452.1

Interpretations ..............................................................................................................................453

Index 459

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Administrative Requirements

Part RA

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PART RA — ADMINISTRATIVE REQUIREMENTS

TABLE OF CONTENTS

RA-1000 General ................................................................................................................... 3 RA-1010 Scope ....................................................................................................................... 3

RA-1020 Accreditation Process ........................................................................................... 3

RA-2000 Accreditation of Repair Organizations .............................................................. 3 RA-2010 Scope ....................................................................................................................... 3 RA-2020 Scope Issuance and Revision to Pressure-Retaining Items ..............................3 RA-2030 Scope Issuance and Revision to Pressure Relief Valves ...................................4

RA-2100 “R” Administrative Rules and Procedures ........................................................4RA-2110 Scope ....................................................................................................................... 4

RA-2120 Prerequisites for Issuing a National Board Certificate of Authorization...... 4 RA-2130 Procedure for Obtaining or Renewing a National Board Certificate of Authorization .................................................................................................... 5 RA-2140 National Board “R” Symbol Stamp .....................................................................6

RA-2150 Quality System .......................................................................................................6

RA-2200 “VR” Administrative Rules and Procedures .................................................... 9 RA-2210 Scope ....................................................................................................................... 9 RA-2220 Issuance and Renewal of the “VR” Certificate and Stamp ........................... 10 RA-2230 Use of the “VR” Stamp ...................................................................................... 12 RA-2240 Certificate of Authorization Contents ............................................................. 13 RA-2250 Quality System .................................................................................................... 13

RA-2300 “NR” Accreditation Requirements ................................................................... 18 RA-2310 Scope ..................................................................................................................... 18 RA-2320 Prerequisites for Issuing a National Board “NR” Certificate

of Authorization .................................................................................................. 19 RA-2330 Procedures for Obtaining or Renewing a National Board “NR” Certificate of Authorization .............................................................................. 19 RA-2340 National Board “NR” Symbol Stamp .............................................................. 21 RA-2350 Quality System Program .................................................................................. 22 RA-2360 Outline of Requirements for a Quality System Program for Qualification for the National Board “NR” Symbol Stamp .......................... 22 RA-2370 Interface With the Owner’s Repair/Replacement Program ........................ 29

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RA-1000 GENERAL

RA-1010 SCOPE

This part describes the administrative require-

ments for the accreditation of repair organiza-tions and for the accreditation of Owner-UserInspection Organizations.1

The National Board administers three specificaccreditation programs as shown below:

“R” ........ Repa irs and Alte rati ons toPressure-Retaining Items

“VR” ..... Repairs to PressureRelief Valves

“NR” ..... Repair and ReplacementActivities for Nuclear Items

RA-1020 ACCREDITATION PROCESS

Any organization may apply to the NationalBoard to obtain a Certificate of Authoriza-tion for the requested scope of activities. Areview shall be conducted to evaluate theorganization’s quality system. The individualassigned to conduct the evaluation shall meet

the qualification requirements prescribed by the National Board. Upon completion ofthe evaluation, any deficiencies within theorganization’s quality system will be docu-mented and a recommendation will be madeto the National Board regarding issuance ofa Certificate of Authorization.

RA-2000 ACCREDITATION OF REPAIR ORGANIZATIONS

RA-2010 SCOPE

The National Board administers accreditationprograms for authorization of organizationsperforming repairs and alterations to pres-sure-retaining items and/or pressure reliefvalves.

As part of the accreditation process, an appli-cant’s quality system is subject to a review.National Board procedures provide for theconfidential review resulting in recommen-dations to issue or not issue a Certificate of

Authorization.When the quality system requirements of theappropriate section of Part RA have been met,a Certificate of Authorization and appropri-ate National Board symbol stamp shall beissued.

The accreditation programs provide require-ments for organizations performing repairsand alterations to pressure-retaining items.Depending upon the expected scope of ac-

tivities at the time of review, organizationsmay be authorized to perform design only,metallic or non-metallic repairs, and/or al-terations either in the shop only, field only, orshop and field. Repairs and/or alterations tometallic and non-metallic pressure-retainingitems are made by welding, bonding and/ormechanical assembly.

RA-2020 SCOPE ISSUANCE ANDREVISION TO PRESSURE-

RETAINING ITEMS

Any scope revision shall require authorizedinspection agency acceptance of qualitysystem changes. These changes shall be sub-mitted to the National Board for acceptance.A program review may be required by theNational Board or the jurisdication to assure

1 Caution, some jurisdictions may independently ad-minister a program of authorization for organiza-tions to perform repairs and alterations within that

jurisdiction.

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quality system requirements are met for scopechanges. Upon acceptance of the changes,the National Board will issue a Certificate ofAuthorization with a revised scope.

RA-2030 SCOPE ISSUANCE ANDREVISION TO PRESSURERELIEF VALVES

The “VR” accreditation program providesrequirements for organizations performingrepairs to pressure relief valves. For scope is-suance and revisions, refer to RA-2200.

RA-2100 “R” ADMINISTRATIVERULES AND PROCEDURES

RA-2110 SCOPE

This section provides requirements thatmust be met by organizations in orderto obtain a National Board Certificate ofAuthorization to use the “R” Symbol Stampfor the repair or alteration of pressure-retain-ing items. Organizations may be authorizedto perform repairs only, or repairs and altera-

tions.

For further information contact:

Accreditation DepartmentThe National Board of Boiler and Pressure Vessel Inspectors1055 Crupper AvenueColumbus, OH 43229-1183

Phone — 614.888.8320Fax — 614.847.1828

The issuance of the “R” Stamp is not restrictedto organizations whose primary business isto repair and alter pressure-retaining items,nor to manufacturers of pressure-retainingitems. Owners and Users of pressure-retain-ing items and other organizations that qualifyin accordance with these rules may also obtainthe “R” Stamp.

Owners or users may be accredited for both arepair and inspection program provided theowner or user complies with the requirementsof the “R” program and the National Boardrequirements for an Owner-User InspectionOrganization. The requirements of RA-2120(a)

do not apply if the owner or user chooses touse the Owner-User Inspection Organizationto accept the repair quality system when:

a. There is no conflict with jurisdictionalrequirements.

b. The line of authority for the Owner-UserInspection Organization shall be indepen-dent of the organization responsible forexecution of “R” program work.

c. The process and Inspector limitationsare described in the written Owner-UserInspection Organization’s quality systemmanual.

RA-2120 PREREQUISITES FOR ISSUING A NATIONAL

BOARD CERTIFICATE OFAUTHORIZATION

Before an organization can obtain a NationalBoard “R” Certificate of Authorization, theorganization shall:

a. Have and maintain an Inspection Agree-ment with an Authorized InspectionAgency;

b. Have, in the English language, a writtenQuality System which complies with therequirements of this section and includesthe expected scope of activities;

c. Have the current edition of the NationalBoard Inspection Code; and

d. Have available a copy of the code ofconstruction appropriate to the intendedscope of work.

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RA-2130 PROCEDURE FOR OBTAINING OR RENEWING

A NATIONAL BOARD CERTIFICATE OF

AUTHORIZATION

Prior to issuance or renewal of a NationalBoard “R” Certificate of Authorization, theorganization and its facilities are subject to areview of its Quality System. The implemen-tation of the Quality System shall be satis-factorily demonstrated by the organization.The National Board reserves the absoluteright to cancel, refuse to issue, or renew suchauthorization.

Organizations desiring to obtain a NationalBoard Certificate of Authorization shall applyto the National Board using forms obtainedfrom the National Board. Application forrenewal shall be made prior to the expirationdate of the Certificate of Authorization. Ap-plications may be obtained from the NationalBoard.

When an organization has plants or shops inmore than one location, the organization shallsubmit separate applications for each plant orshop. The organization may perform repairs

or alterations in its plants, shops, or in thefield, provided such operations are describedin the organization’s Quality System.

Upon notification of the review dates fromthe National Board, it is the responsibility ofthe organization to make arrangements forthe review.

The Review Team, as a minimum, shallconsist of one representative each from theAuthorized Inspection Agency and the Ju-

risdiction.2

The Review Team shall conduct an evalu-ation of the organization’s Quality System.The organization shall demonstrate sufficientimplementation of the Quality System toprovide evidence of the organization’s knowl-edge of welding, nondestructive examination,

postweld heat treatment, and other repair oralteration activities performed appropriate forthe requested scope of work. The demonstra-tion may be performed using current work,a demonstration mock-up, or a combinationof both.

A recommendation to issue, renew or with-hold the National Board Certificate of Autho-rization shall be included in a Review Reportprepared by the Review Team. The completedReview Report shall be forwarded to the Na-tional Board.

If proper administrative fees are paid andall other requirements are met, a Cer-tificate of Authorization will be issuedevidencing permission to use the “R” SymbolStamp. The Certificate shall expire on thetriennial anniversary date.

When an organization holding a NationalBoard Certificate of Authorization changes

ownership, name, location, or address, theNational Board shall be notified. The Cer-tificate of Authorization may be revised bysubmitting an application for National Board“R” Certificate of Authorization; however, are-review may be required.

The holder of an ASME Code Symbol Stamp,whose facilities were reviewed by the juris-diction, (with the exception of “V”, “UV”,“HV”, “NV”, “RP”, and “H” [cast iron]) mayobtain National Board authorization without

a review of its facilities, provided:

a. The organization has a Quality System tocover the scope of the repairs or altera-

2 Jurisdiction: The National Board member jurisdiction where the organization is located. Alternatively, where the jurisdiction elects not to perform the review or where there is no jurisdiction or where the jurisdiction is theorganization’s Authorized Inspection Agency, the National Board of Boiler and Pressure Vessel Inspectors willrepresent the jurisdiction. At the jurisdiction’s discretion, the jurisdiction may choose to be a member of thereview team if the jurisdiction chooses not to be the team leader.

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tions to be made, subject to review by the jurisdiction; and

b. The application for the “R” Certificate ofAuthorization is submitted within twelvemonths from the issuance of the ASME

Certificate of Authorization. The initialCertificate of Authorization shall be is-sued to expire concurrent with the ASMECertificate of Authorization. Subsequentcertificates shall be renewed upon a suc-cessful review and implementation ofits quality system by a National Boardrepresentative.

The jurisdiction may audit the Quality Sys-tem and activities of an organization upon avalid request from an owner, user, inspectionagency, or the National Board.

The NBIC Committee may at any time changethe rules for the issuance of Certificates ofAuthorization and use of the “R” SymbolStamp. These rules shall become binding onall certificate holders.

RA-2140 NATIONAL BOARD “R”SYMBOL STAMP

All “R” Symbol Stamps shall be obtainedfrom the National Board of Boiler andPressure Vessel Inspectors. Authoriza-tion to use the “R” Symbol Stamp may be granted by the National Board at itsabsolute discretion.

The “R” Symbol Stamp is furnished on loan by the National Board for a nominal fee. Eachorganization shall agree, if authorization touse the “R” Symbol Stamp is granted, that the

“R” Symbol Stamp is at all times the propertyof the National Board and will be promptlyreturned upon demand. If the organizationdiscontinues the use of the “R” Symbol Stamp,inspection agreement with an AuthorizedInspection Agency, or if the Certificate of Au-thorization has expired and no new certificate

has been issued, the “R” Symbol Stamp shall be returned to the National Board.

The organization’s Quality System shall pro-vide for adequate control of the “R” SymbolStamp. Provisions may be made for the is-

suance of the “R” Symbol Stamp for use atvarious field locations.

The holder of a Certificate of Authoriza-tion may obtain more than one “R” SymbolStamp provided the organization’s QualitySystem describes how the use of such stampsis controlled from the location shown on thecertificate.

An organization shall not permit others touse the “R” Symbol Stamp loaned to it by theNational Board.

RA-2150 QUALITY SYSTEM

A holder of a National Board Certificate ofAuthorization shall have and maintain awritten Quality System. The System shallsatisfactorily meet the requirements of theNBIC and shall be available for review. TheQuality System may be brief or voluminous,

depending on the circumstances. It shall be treated confidentially by the NationalBoard.

RA-2151 OUTLINE OF REQUIREMENTS FOR A QUALITY SYSTEM FOR

QUALIFICATION FOR THENATIONAL BOARD “R”

SYMBOL STAMP

The following is a guide to features of aQuality System that should be included inthe organization’s Quality System Manual.Each organization should address the fea-tures as needed for the scope of work to beperformed:

a. Title Page The name and complete address of the

company to which the National Board

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Certificate of Authorization is issued shall be included on the Title Page of the Qual-ity System Manual.

b. Contents Page The manual should contain a page listing

the contents of the manual by subject,number (if applicable) and revision number of each document.

c. Scope of Work The manual shall clearly indicate the scope

and type of repairs or alterations the orga-nization is capable of and intends to carryout.

d. Statement of Authority and Responsibility A dated Statement of Authority, signed

by an officer of the organization, shall beincluded in the manual. Further, the State-ment of Authority shall include:

1. A statement that all repairs or altera-tions carried out by the organizationshall meet the requirements of theNBIC and the jurisdiction as appli-cable.

2. A statement that if there is a disagree-

ment in the implementation of theQuality System, the matter is to bereferred for resolution to a higherauthority in the company.

3. The title of the individual who will beresponsible to ensure that (1) aboveis followed and has the freedom andauthority to carry out the responsibil-ity.

e. Manual Control

The manual shall include the necessaryprovisions for revising and issuing docu-ments to maintain the manual current.The title of the individual authorized toapprove revisions shall be included in themanual. Revisions must be accepted bythe Authorized Inspection Agency prior to

issuance of the manual and implementa-tion.

f. Organization1. An organizational chart shall be in-

cluded in the manual. It shall include

the title of the heads of all departmentsor divisions that perform functionswhich can affect the quality of the re-pair or alteration, and it shall show therelationship between each departmentor division.

2. The manual shall identify the titleof those individuals responsible forpreparation, implementation, orverification of the Quality System. Theresponsibilities shall be clearly definedand the individuals shall have theorganizational freedom and authorityto fulfill those responsibilities.

g. Drawings, Design and Specifications The manual shall contain controls to

ensure that all design information,applicable drawings, design calcula-tions, specifications and instructions areprepared or obtained, controlled and in-terpreted in accordance with the original

code of construction.

h. Repair and Alteration Methods The manual shall include controls for

repairs and alterations, including theselection of the welding procedurespecification, materials, nondestructiveexamination methods, preheat and post-weld heat treatment. Special requirementsfor graphite and fiber reinforced pressurevessels shall be addressed.

i. Materials The manual shall describe the method

used to assure that only acceptable materi-als (including welding material) are usedfor repairs and alterations. The manualshall include a description of how exist-ing material is identified and new mate-

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rial is ordered, verified and identified.The manual shall identify the title of theindividual(s) responsible for each functionand a brief description of how the functionis to be performed.

j. Method of Performing Work The manual shall describe the methods for

performing and documenting repairs andalterations in sufficient detail to permitthe Inspector to determine at what stagesspecific inspections are to be performed.The method of repair or alteration musthave prior acceptance of the Inspector.

k. Welding, NDE and Heat Treatment The manual shall describe controls for

welding, nondestructive examination,and heat treatment. The manual is toindicate the title of the individual(s)responsible for the welding procedurespecification and its qualification, andthe qualification of welders and weldingoperators. It is essential that only weldingprocedure specifications and welders orwelding operators qualified, as required by the NBIC, be used in the repair or al-teration of pressure-retaining items. It isalso essential that welders and welding

operators maintain their proficiency asrequired by the NBIC, while engaged inthe repair or alteration of pressure-retain-ing items. The manual shall also describecontrols for assuring that the requiredWPS or SWPS is available to the welderor welding operator prior to welding.Similar responsibility for nondestructiveexamination and heat treatment shall bedescribed in the manual.

l. Examinations and Tests

Reference shall be made in the manual forexaminations and tests upon completionof the repair or alteration.

m. Calibration The manual shall describe a system for

the calibration of examination, measuring,and test equipment used in the perfor-mance of repairs and alterations.

n. Acceptance and Inspection of Repair orAlteration

The manual shall specifically indicate that before the work is started, acceptance ofthe repair/alteration shall be obtainedfrom an Inspector who will make therequired inspections and confirm NBICcompliance by signing and dating the ap-plicable NBIC Code Report Form3 uponcompletion of the work.

o. Inspections The manual shall make provisions for

the Inspector to have access to all draw-ings, design calculations, specifications,procedures, process sheets, repair oralteration procedures, test results, andother documents as necessary to assurecompliance with the NBIC. A copy of thecurrent manual shall be available to theinspector.

p. Report of Repair or Alteration Form

The manual shall indicate the title of theindividuals responsible for preparing,signing and presenting the NBIC ReportForms to the Inspector. The distribution ofthe NBIC Report Forms shall be describedin the manual.

q. Exhibits Any forms referenced in the manual shall

be included. The form may be a part ofthe referencing document or included asan appendix. For clarity, the forms may

be completed and identified as examples.The name and accepted abbreviations ofthe “R” Certificate Holder shall be in-cluded in the manual.

3 NBIC Report Form: National Board Form R-1 forRepairs, Form R-2 for Alterations, or Form R-3 forParts Fabricated by Welding.

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r. Construction Code The manual shall include provisions for

addressing the requirements that pertainto the specific construction code for theequipment being repaired or altered.

s. Nonconforming Items There shall be a system acceptable to the

Inspector for the correction of noncon-formities. A nonconformity is any con-dition which does not comply with theapplicable rules of the NBIC, constructioncode, jurisdictional requirements or thequality system. Nonconformities must becorrected or eliminated before the repairedor altered component can be consideredin compliance with the NBIC.

RA-2200 “VR” ADMINISTRATIVE RULES AND PROCEDURES

RA-2210 SCOPE

These administrative rules and proceduresare provided for those who wish to obtain aNational Board Certificate of Authorizationfor use of the “VR” (Repair of Pressure Relief

Valves) symbol stamp. It should be notedthat the issuance of the “VR” stamp is notrestricted to companies whose primary busi-ness is the repair of pressure relief valves,nor to manufacturers or assemblers thathold an ASME “V”, “HV”, “UV”, or “NV”Code symbol stamp. Owners and users of boilers and pressure vessels and other orga-nizations that qualify in accordance with theNational Board Rules and Regulations mayalso obtain the “VR” Certificate and stamp.

In order to provide due process in theissuance, renewal, and revocation of “VR”symbol stamps and certificates of authoriza-tion, the National Board Appeals Committeeprocedures provide an affected “VR” Certifi-cate of Authorization applicant the right ofappeal, or to provide additional informationwhich may affect the Committee’s decision.


Pressure Relief DepartmentThe National Board of Boiler and Pressure Vessel Inspectors7437 Pingue Drive

Worthington, OH 43085-1715

Phone — 614.888.8320Fax — 614.848.3474

RA-2212 JURISDICTIONAL PARTICIPATION

The National Board member jurisdiction inwhich the “VR” organization is located isencouraged to participate in the review anddemonstration of the applicant’s qualitysystem. The jurisdiction may require partici-pation in the review of the repair organiza-tion and the demonstration and acceptanceof the repair organization’s quality systemmanual.

RA-2213 GENERAL RULES

The general rules of the National Board “VR”

certification program apply only to the repairof National Board capacity certified ASMECode Section I “V” stamped, Section IV “HV”marked, and Section VIII “UV” stamped pres-sure relief valves that:

a. Have been in service or have beenexposed to environmental or other condi-tions such that there is reason to questiontheir ability to perform equivalent to thestandards for new valves; or

b. Any or all of the valve’s external adjust-ment seals have been broken, opened orotherwise disturbed regardless of thevalve’s age or service status.

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RA-2214 REPAIR OF NUCLEAR VALVES

Provided that the requirements of Appendix7 and applicable requirements of these rulesare met, the “VR” certificate may be extended

to apply to the repair of any ASME CodeSection III, Class 1, 2, or 3 pressure reliefdevices that have been capacity certified bythe National Board and have been in service,regardless of their intended function, in anuclear system.

RA-2215 TECHNICAL INQUIRIES

Refer to Appendix 1 for information on pre-paring technical inquiries on the subject ofvalve repair.

RA-2220 ISSUANCE AND RENEWAL OF THE “VR” CERTIFICATE

AND STAMP

RA-2221 GENERAL

Authorization to use the stamp bearing the

official National Board “VR” symbol as shownin Appendix 2 will be granted by the NationalBoard pursuant to the provisions of the fol-lowing administrative rules and procedures.Appendix 7 provides rules for the repair ofASME Section III “NV” stamped pressurerelief devices.

RA-2222 ISSUANCE OF CERTIFICATE

Repair organizations, manufacturers,

assemblers, or users that make repairs to theAmerican Society of Mechanical Engineers(ASME) Code symbol stamped or marked (asapplicable), and The National Board of Boilerand Pressure Vessel Inspectors (NationalBoard) capacity certified pressure relief valvesmay apply to the National Board for a Certifi-cate of Authorization to use the “VR” symbol.

The National Board may at any time, throughthe NBIC Committee, modify the regulationsconcerning the issuance and use of such ValveRepair symbol. All such modified regulationsshall become binding upon holders of validValve Repair Certificates of Authorization.

Authorization to use the “VR” stamp may begranted or withheld by the National Boardin its absolute discretion. If authorization isgranted and proper administrative fees paid,a certificate of authorization will be issuedevidencing permission to use such a symbol,expiring on the triennial anniversary date.The certificate will be signed by the Chairmanof the National Board Board of Trustees, theexecutive director or any other duly autho-rized officer.

The certificate shall list the physical, per-manent address of record for the certificateholder’s shop/plant. For field-only scopes,this address of record shown on the Certifi-cate of Authorization is where administrative,technical, and quality aspects of the businessare controlled.

RA-2223 RENEWAL OF CERTIFICATE

The certificate of authorization is renewableevery three (3) years subject to a review ofthe quality system by a representative of theNational Board, review and acceptance of therepresentative’s report by the National Board,and successful completion of capacity verifi-cation tests. See RA-2256 for exceptions. Theapplicant should apply to the National Boardfor renewal of authorization and reissuance ofthe certificate prior to the date of expiration.The National Board reserves the absolute

right to cancel, refuse to issue, or renew suchauthorization.

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RA-2224 REVIEW OF APPLICANT’SFACILITY

Before issuance or renewal of pressure relief“VR” Certificates of Authorization, the repairorganization, its written quality system and its

facilities are subject to a review and verifica-tion of implementation of its quality system by a representative of the National Board.The implementation demonstration shallinclude, as a minimum, disassembly, inspec-tion, repair, application of special processes,reassembly, setting, and testing of valveswithin the scope of the applicant’s qualitysystem.

The applicant shall repair and submit forverification testing one (1) valve for eachCode section (except Section III) and test fluid(steam, air/gas, liquid) which will appear onthe certificate of authorization. A minimumof two (2) valves are required regardless ofCode sections or test fluid. The valves shall bewithin the capabilities of the National Boardaccepted laboratory. When an applicant isusing the provisions of RE-2020 , the appli-cant shall submit one additional Section VIIIsteam valve set on air for verification testingon steam.

The applicant shall have a copy of the NationalBoard Pressure Relief Device Certifications publi-cation NB-18 dated within one year (availablefrom the National Board Web page) , the lat-est edition and addenda of the National BoardInspection Code (NBIC), and the ASME Codesection(s) that the organization is includingin its scope.

It is the responsibility of the valve repair orga-nization to make arrangements for this review.

Certificates cannot be issued or renewed untilthe National Board is in receipt of approvalof this review. Wherever possible, NationalBoard reviews of valve repair organizationsshall be coordinated with ASME reviews,when applicable.

For field-only repair scopes, the review shallencompass both the applicant’s address of

record and field repair demonstration site.The demonstration site shall be representativeof that typically encountered by the applicant(See RA-2226).

RA-2225 VERIFICATION TESTING

Before the “VR” Certificate of Authoriza-tion and stamps may be issued or renewed,the demonstration valves must successfullycomplete capacity and operational verifica-tion tests at a National Board accepted test-ing laboratory. See RA-2226 and RA-2256 forexceptions. The valves shall be typicalof those repaired by the organizationand within the capabilities of the testinglaboratory. Tests conducted at the accepted testinglaboratory shall be witnessed by a rep-resentative of the National Board. Thepurpose of the tests is to ensure that the re-pairs have been satisfactorily carried out andthe function and operation of the valves meetthe requirements of the section of the ASMECode to which they were manufactured. Valves not meeting the function or operational

requirements of the section of the ASME Codeto which they were manufactured shall beconsidered to have failed. Replacement valvesshall be repaired and selected for testing asstated above, at a rate of two (2) valves foreach one (1) that failed.

a. If either or both of these replacementvalves fail to meet the above criteria,the applicant shall document the causeof the noted deficiencies and actionstaken to guard against future occurrence.

Upon acceptance of this information bythe National Board, one (1) additionalvalve for each replacement valve thatfailed shall be repaired and tested. Thevalve(s) shall be of the same ASME Codesection, fluid and set pressure scope, asthe valve previously failing to meet thetest requirement.

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b. Fa ilure of th is va lve(s) to meet th eASME Code to which the valve wasmanufactured shal l be cause forconsideration by the National Board ofrevocation of the “VR” Certificate of Au-thorization or acceptance of alternative

corrective action.

RA-2226 VERIFICATION TESTINGALTERNATIVES

In such cases where all valves repaired bythe applicant for a specified ASME Codesection or test fluid exceed the capabilitiesof the accepted testing laboratory, valves forthat ASME Code section or test fluid shall beselected as specified in RA-2224 , and a dem-onstration test shall be successfully performedin lieu of verification testing specified inRA-2225 above. The demonstration tests shall be conducted at a facility mutually agreeableto the National Board representative, the fa-cility owner, and the applicant. The purposeof these tests is to demonstrate, in the pres-ence of a National Board representative, thatthe repaired valves shall have adequate seattightness at the maximum expected operatingpressure prior to lifting, shall open within the

required set pressure tolerance, operate con-sistently without chatter, and reclose withinthe required blowdown.

If a valve lift-assist device is used by the ap-plicant to establish set pressure after repairs,this device must also be used to set the dem-onstration valves.

If either of these valves fail to meet the abovecriteria, then replacement valves shall be re-paired and tested at a rate of two valves for

each one that failed.

a. If either or both of these replacementvalves fail to meet the above criteria, theapplicant shall document the cause of thenoted deficiencies and actions taken toguard against future occurrence. Upon

acceptance of this information by the Na-tional Board, one (1) additional valve foreach replacement valve that failed shall berepaired and tested. The valve(s) shall beof the same ASME Code section, fluid, andset pressure scope as the valve previously

failing to meet the test requirement.

b. Fai lure of thi s va lve(s) to meet theASME Code to which the valve wasmanufactured shall be cause for con-sideration by the National Boardof revocation of the “VR” Certificate ofAuthorization or acceptance of alternativecorrective action.

RA-2230 USE OF THE “VR” STAMP

RA-2231 TECHNICALREQUIREMENTS

The administrative requirements of PartRA-2200 for use of the “VR” stamp shall beused in conjunctin with the technical require-ments for valve repair as described in Part REof the NBIC. Those requirements shall be man-datory when a “VR” repair is performed.

RA-2232 STAMP USE

Each “VR” symbol stamp shall be used only by the repair firm within the scope, limita-tions, and restrictions under which it wasissued.

RA-2233 RETURN OF STAMP

Each applicant shall agree, if authorization touse the stamp is granted, that the stamp is atall times the property of the National Boardand will be promptly returned upon demand.If the applicant discontinues the repair of suchvalves or if the “VR”Certificate of Authoriza-

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tion issued to such applicant has expired andno new certificate has been issued, the stampwill be returned to the National Board.

RA-2234 MULTIPLE LOCATIONS

A holder of a National Board “VR” stampshall not permit any others to use the“VR” symbol stamp loaned to it by theNational Board. When a repair organization,manufacturer, or user has a repair departmentand/or equipment in fixed plants or shopslocated in more than one geographical area,it must submit separate applications for eachplant or shop with the addresses of all suchrepair locations.

RA-2240 CERTIFICATE OFAUTHORIZATIONCONTENTS

Qualification for repair location (shop, shopand field, or field only), code section (SectionI, III, IV, and/or VIII valves), special pro-cesses, and test media shall be specified onthe repair organization’s “VR” Certificate ofAuthorization.

RA-2241 CHANGES TO CERTIFICATESOF AUTHORIZATION

When a “VR” Certificate Holder intends tochange the address of record (location), thecertificate holder shall notify the NationalBoard in writing prior to relocating. The newfacilities and related quality system for thenew location shall be reviewed in accordancewith RA-2224. Issuance of a new Certificate

of Authorization is subject to the proceduresherein.

When a “VR” Certificate Holder intends tochange ownership or scope, the certificateholder shall notify the National Board inwriting prior to the change. A review, in

accordance with RA-2224 , may be requireddepending upon the nature and extent of thechange to the quality system manual, repairprocedures or facilities. Issuance of a newCertificate of Authorization is subject to theprocedures herein.

RA-2242 ISSUANCE OF MORE THANONE “VR” SYMBOL STAMPTO A CERTIFICATE OFAUTHORIZATION HOLDER

The holder of a Certificate of Authorizationmay obtain more than one “VR” symbolstamp provided its quality system manualcontrols the use of such stamps from the ad-dress of record shown on the Certificate ofAuthorization.

RA-2250 QUALITY SYSTEM

RA-2251 GENERAL

Each applicant for a new or renewed “VR”Certificate of Authorization shall have andmaintain a quality system which shall estab-

lish that all of these rules and administra-tive procedures and applicable ASME Coderequirements, including material control,fabrication, machining, welding, examina-tion, setting, testing, inspection, sealing, andstamping will be met.

RA-2252 WRITTEN DESCRIPTION

A written description, in the English language,of the system the applicant will use shall be

available for review and shall contain, as aminimum, the features set forth in RA-2255. This description may be brief or voluminous,depending upon the circumstances, and shall be treated confidentially. In general, the qual-ity system shall describe and explain whatdocuments and procedures the repair firmwill use to validate a valve repair.

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date, description and section of revision,company approval, and National Boardacceptance.

c. Contents Page The contents page should list and refer-

ence, by paragraph and page number, thesubjects and exhibits contained therein.

d. Statement of Authority and Responsibility A statement of authority and responsibil-

ity shall be dated and signed by an officerof the company. It shall include:

1. A statement that the “VR” stampshall be applied only to pressure reliefvalves which meet both of the follow-ing conditions:

a. Are stamped with an ASME “V”,“UV”, or “NV” Code symbol ormarked with an ASME “HV”symbol and have been capacitycertified by the National Board;and

b. Have been di sassem bl ed, in-

spected, and repaired by thecertificate holder such that thevalves’ condition and perfor-mance are equivalent to thestandards for new valves.

2. The title of the individual responsibleto ensure that the quality system isfollowed and who has authority andfreedom to effect the responsibility;

3. A statement that if there is a disagree-ment in the implementation of thewritten quality system, the matter is

to be referred to a higher authority inthe company for resolution; and

4. The title of the individual authorizedto approve revisions to the writtenquality system and the method bywhich such revisions are to be sub-

RA-2253 REVIEW

A review of the applicant’s quality systemwill be performed by a representative of theNational Board. The review will include ademonstration of the implementation of the

provisions of the applicant’s quality system.

RA-2254 MAINTENANCE OFCONTROLLED COPY

Each applicant to whom a “VR” Certificateof Authorization is issued shall maintainthereafter a controlled copy of the acceptedquality system manual with the Nation-al Board. Except for changes that do notaffect the quality system, revisions to the qual-ity system manual shall not be implementeduntil such revisions are accepted by the Na-tional Board.

RA-2255 OUTLINE OF REQUIREMENTS FOR A

QUALITY SYSTEM

The following establishes the minimum re-quirements of the written description of the

quality system. It is required that each valverepair organization develop its own qualitysystem that meets the requirements of its or-ganization. For this reason it is not possible todevelop one quality system that could applyto more than one organization. The writtendescription shall include, as a minimum, thefollowing features:

a. Title Page The title page shall include the name and

address of the company to which the

National Board Certificate of Authoriza-tion is to be issued.

b. Revision Log A revision log is required to assure revi-

sion control of the quality system manual.The log should contain sufficient space for

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mitted to the National Board for ac-ceptance before implementation.

e. Organization Chart A chart showing the relationship between

management, purchasing, repairing,

inspection, and quality control personnelis required and shall reflect the actualorganization in place.

f. Scope of Work

1. The scope of work section shall in-dicate the scope and type of valverepairs, including conversions, theorganization is capable of and intendsto perform. The location of repairs(shop, shop and field, or field only),ASME Code Section(s) to which therepairs apply, the test medium (air, gas,liquid, or steam, or combinations there-of) and special processes (machining,welding, postweld heat treatment, ornondestructive examination, or combinations thereof) shall be specificallyaddressed.

2. The types and sizes of valves to berepaired, pressure ranges and other

limitations, such as engineeringand test facilities, should also beaddressed.

g. Drawings and Specification Control The drawings and specification control

system shall provide procedures assur-ing that the latest applicable drawings,specifications, and instructions requiredare used for valve repair, including con-versions, inspection, and testing.

h. Material and Part Control The material and part control section shall

describe purchasing, receiving, storageand issuing of parts.

1. State the title of the individual re-sponsible for the purchasing of allmaterial.

2. State the title of the individual respon-sible for certification and other recordsas required.

3. All incoming material and parts shall be checked for conformance with the

purchase order and, where applicable,the material specifications or draw-ings. Indicate how material or part isidentified and how identity is main-tained by the quality system.

i. Repair and Inspection Program The repair and inspection program sec-

tion shall include reference to a document(such as a report, traveler or checklist)which outlines the specific repair and in-spection procedures used in the repair ofpressure relief valves. Repair proceduresshall require verification that the criti-cal parts meet the valve manufacturer’sspecification. Appendix E outlines rec-ommended procedures covering somespecific items. Provisions shall be madeto retain this document for a period of atleast five years.

.1. Each valve or group of valves shall

be accompanied by the document re-

ferred to above for processing throughthe plant. Each valve shall have aunique identifier (e.g., repair serialnumber, shop order number, etc.) ap-pearing on the repair documentationand repair nameplate such that trace-ability is established.

2. The document referred to aboveshall describe the original nameplateinformation, including the ASMECode symbol stamping and the repair

nameplate information, if applicable.In addition, it shall include materialchecks, replacement parts, conversionparts (or both), reference to items suchas the welding procedure specifica-tions (WPS), fitup, NDE technique,heat treatment, and pressure testmethods to be used. Application of the

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“VR” stamp to the repair nameplateshall be recorded in this document.Specific conversions performed withthe new Type/Model number shall be recorded on the document. Thereshall be a space for “signoffs” at each

operation to verify that each step has been properly performed.

3. The system shall include a method ofcontrolling the repair or replacementof critical valve parts. The methodof identifying each spring shall beindicated.

4. The system shall also describe the con-trols used to ensure that any personnelengaged in the repair of pressure reliefvalves are trained and qualified in ac-cordance with RE-3000.

j. Welding, NDE, and Heat Treatment (when applicable) The quality system manual shall indicate

the title of the person(s) responsible forand describe the system used in the selec-tion, development, approval, and quali-fication of welding procedure specifica-tions, and the qualification of welders and

welding operators in accordance with theprovisions of RE-1100 through RE-1160.

The quality system manual may includecontrols for the “VR” Certificate Holderto have the pressure relief valve part re-paired by a National Board “R” CertificateHolder, per RC-2032 provided the follow-ing documentation is provided to the “R”Certificate Holder:

1. Code of Construction, year built

2. Part identification

3. Part material specified, and

4. “VR” Certificate Holder’s unique iden-tifier as required by RA-2255(i)(1).

The completed Form R-1 shall be notedon and attached to the “VR” CertificateHolder’s document required in RA-2255(i).Similarly, NDE and heat treatment tech-niques must be covered in the qualitysystem manual. When outside services

are used for NDE and heat treatment, thequality system manual shall describe thesystem whereby the use of such servicesmeet the requirements of the applicablesection of the ASME Code.

k. Valve Testing, Setting, and Sealing The system shall include provisions that

each valve shall be tested, set and allexternal adjustments sealed according tothe requirements of the applicable ASMECode section and the National Board. Theseal shall identify the “VR” CertificateHolder making the repair. Abbreviationsor initials shall be permitted, providedsuch identification is acceptable to theNational Board.

l. Valve Repair Nameplates An effective valve stamping system shall

be established to ensure proper stampingof each valve as required by RE-1061. Themanual shall include a description of the

nameplate or a drawing.

m. Calibration

1. The manual shall describe a systemfor the calibration of examination,measuring, and test equipment usedin the performance of repairs. Docu-mentation of these calibrations shallinclude the standard used and theresults.

2. All calibration standards shall becalibrated against certified equipmenthaving known valid relationships tonationally recognized standards.

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3. All calibration standards shall becalibrated against certified equipmenthaving known valid relationships tonationally recognized standards.

n. Manual Control

The quality system shall include:

1. Measures to control the issuance ofand revisions to the quality systemmanual;

2. Provisions for a review of the sys-tem in order to maintain the manualcurrent with these rules and theapplicable sections of the ASMECode;

3. The title(s) of the individual(s) respon-sible for control, revisions, and reviewof the manual;

4. Provision of a controlled copy of thewritten quality system manual to besubmitted to the National Board.

Revisions shall be submitted for accep-tance by the National Board prior to beingimplemented.

o. Nonconformities The system shall establish measures for

the identification, documentation, evalu-ation, segregation, and disposition ofnonconformities. A nonconformity is acondition of any material, item, product,or process in which one or more charac-teristics do not conform to the establishedrequirements. These may include, but arenot limited to, data discrepancies, proce-dural and/or documentation deficiencies,

or material defects. Also, the title(s) of theindividual(s) involved in this process shall be included.

p. Exhibits Forms used in the quality system shall

be included in the manual with a writtendescription. Forms exhibited should be

marked SAMPLE and completed in amanner typical of actual valve repairprocedures.

q. Testing Equipment The system shall include a means to con-

trol the development, addition, or modifi-cation of testing equipment to ensure therequirements of RE-2010(b) are met.

r. Field Repairs (see RE-1070) If field repairs are included in the scope of

work, the system shall address any differ-ences or additions to the quality systemrequired to properly control this activity,including the following:

1. Provisions for annual audits of fieldactivities shall be included.

2. Provisions for receipt and inspectionof replacement parts, including partsreceived from the owner-user, shall beaddressed.

3. If owner-user personnel will assistwith repairs, provisions for the useof owner-user personnel shall be in-cluded.

4. Provisions for use of owner-usermeasurement and test equipment, ifapplicable, shall be addressed.

RA-2256 ASME “V”, “HV”, OR “UV”CERTIFICATE HOLDERS

A manufacturer holding a valid ASME Cer-tificate of Authorization for use of an ASME“V”, “HV”, or “UV” Code symbol stamp may

obtain the “VR” Certificate of Authorizationfor the repair of pressure relief valves covered by the ASME Certificate of Authorization andthat meet the requirements of RA-2213. Thiscan be accomplished without a review of thefacilities provided there is a written qualitysystem to cover the scope of the repairs to bemade and the repairs are carried out at the

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same location where the ASME valves aremanufactured. Unless the repaired valves aretested on the same facilities and to the sameprocedures as new valves, two (2) repairedvalves shall be selected by a National Boardrepresentative for verification tests.

The initial Certificate of Authorization shall be issued to expire concurrent with the ASMECertificate of Authorization. Subsequent cer-tificates shall be renewed upon a successfulreview and verification of implementation ofits quality system by a National Board rep-resentative. This review shall be performedconcurrently with the ASME Certificate re-newal review.

A manufacturer may also perform field re-pairs of pressure relief valves covered by theASME Certificate of Authorization providedthe provisions of RE-1070 are met.

Assemblers holding ASME Certificates ofAuthorization shall qualify for the “VR” Cer-tificate of Authorization as required elsewherein these rules.

The quality system manual shall be submittedfor review and acceptance by the National

Board.

In order for an ASME Code symbol stampholder to qualify for the National Board“VR” stamp, the following areas to thewritten quality system usually requireattention. a. Statement of Authority and Responsibility This should clearly indicate that valve

repairs are carried out in accordance withthe requirements and the rules of the

National Board and the quality systemmanual. In addition, the scope and typeof valve repairs covered by the manualshould be indicated.

b. Organization Unless the functions which affect the

quality of valve repairs are carriedout by individuals other than thoseresponsible for manufacturing orassembly, it should not be necessary to

revise the organization chart.

c. General Quality Functions Usually quality system requirements re-

garding valve repairs may be controlledin the same manner as for ASME manu-facturing or assembly provided applicableshop and/or field activities are covered. Ifthis is the case, the applicant for the “VR”stamp should include in its quality systemmanual a separate section covering valverepairs which references the applicablesection of the manual. For a more explicitexplanation see RA-2255 , Written Descrip-tion of the Quality System.

RA-2300 “NR” ACCREDITATIONREQUIREMENTS

RA-2310 SCOPE

This section provides requirements thatmust be met for an organization to obtaina National Board Certificate of Authoriza-tion to use the “NR” Symbol Stamp for theRepair/Replacement activities performed inaccordance with this Part and ASME SectionXI requirements.


Accreditation DepartmentThe National Board of Boiler and

Pressure Vessel Inspectors1055 Crupper AvenueColumbus, OH 43229-1183

Phone — 614.888.8320Fax — 614.847.1828

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The issuance of the “NR” stamp is notrestricted to organizations whose primary business is to perform repair/replacementactivities nor to manufacturers or assemblersthat hold an ASME “N” type Code symbolstamp. Owners and users of nuclear compo-

nents and other organizations that qualify inaccordance with these rules may also obtainthe “NR” stamp.

RA-2320 PREREQUISITES FOR ISSUING A NATIONAL

BOARD “NR” CERTIFICATE OF AUTHORIZATION

Before an organization can obtain a NationalBoard “NR” Certificate of Authorization, theorganization shall:

a. Have and maintain an inspection agree-ment with an accredited Nuclear Inspec-tion Agency in accordance with NB-360 ,4 NB-369 ,5 and ASME Section XI;

b. Have in the English language a writtenQuality System Program that complieswith the requirements of this section andaddresses controls for the intended scope

of activities;

c. Have a current edition and addenda of theNBIC; and

d. Have available copies of the originalcode of construction appropriate to theintended scope of work and the appli-cable edition and addenda of ASMESection XI, as required by the regulatoryauthority.6

RA-2330 PROCEDURES FOR OBTAINING OR RENEWING A NATIONAL

BOARD “NR” CERTIFICATE OF AUTHORIZATION

Prior to issuance or renewal of a NationalBoard “NR” Certificate of Authorization, theorganization and its facilities are subject to areview of its Quality System Program. Theimplementation of the Quality System Pro-gram shall be satisfactorily demonstrated bythe organization. The National Board reservesthe absolute right to cancel, refuse to issue, orrenew such authorization. The National Boardwill return fees paid for the unexpired termof the certificate.

Organizat ions desi r ing to obta in aNational Board Certificate of Authorizationshall apply to the National Board using formsobtained from the National Board. Applica-tion for renewal shall be made prior to theexpiration date of the Certificate of Autho-rization.

These procedures also apply to qualified orga-nizations that make repairs to ASME Section III“NV” pressure relief devices. An organization

that holds a valid “NR” Certificate of Autho-rization shall, for the purpose of these proce-dures, be known as an authorized nuclear repairorganization.

Authorized Nuclear Inspection Agencies andInspectors referred to in these proceduresshall meet the requirements of and have beenqualified and commissioned in accordancewith the National Board Rules for CommissionedInspectors.

4 NB-360, Criteria for Acceptance of Authorized InspectionAgencies for New Construction.

5 NB-369, Qualification and Duties for Authorized Inspec-tion Agencies (AIAs) Performing In-Service InspectionActivities and Qualification of Inspectors of Boilers andPressure Vessels.

6 Regulatory Authority. A federal government agency,such as the United States Nuclear RegulatoryCommission, empowered to issue and enforceregulations concerning the design, construction,and operation of nuclear power plants.

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Repair/replacement activities performedunder the “NR” Certificate of Authorizationmust be in accordance with the provisions ofthe NBIC, Section XI of the ASME Code andthe rules of the jurisdiction.

Each authorized nuclear repair organizationshall maintain a documented Quality SystemProgram which meets the requirements ofRA-2360. The Quality System Program shall be commensurate with the scope of the orga-nization’s activities and shall be acceptableto the jurisdiction, the Authorized NuclearInspection Agency and the National Board.

Before an “NR” Certificate of Authorizationwill be issued or renewed, the applicant musthave the Quality System Program and theimplementation of the program reviewedand found acceptable by representatives ofthe National Board, the jurisdiction, and theaccreditated Authorized Nuclear InspectionAgency. If the applicant is an ASME “N”type certificate of authorization holder, hasdemonstrated within the last 12 months theimplementation of the quality program andcan verify by documentation that the organi-zation is capable of implementing its qualityprogram as being in compliance with this part,

a further verification implementation by thesurvey team may not be necessary.

Applicants that do not hold valid ASME“N” type certificates of authorization shalldemonstrate, by documentation and ac-tual implementation, that they are capable ofperforming repair/replacement activities inaccordance with the requirements of SectionXI and the scope of their application for an“NR”Certificate of Authorization.

For National Board authorization to repairASME “NV”/”NB” stamped pressure reliefdevices, the applicant shall hold a valid “VR”Certificate of Authorization for the repair of

ASME Section III pressure relief valves andalso meet the applica ble requirements for“NR” certification and Appendix 7.

When these requirements have been met,the applicant may be issued an “NR”

Certificate of Authorization, which clearlyoutlines the scope of work for Section III pres-sure relief devices.

The jurisdiction will be the National Boardmember jurisdiction in which the applicant islocated. If the implementation of the QualitySystem Program takes place outside of the jurisdiction where the applicant’s programwas reviewed, the National Board memberin the jurisdiction where the implementationtakes place may participate in this portion ofthe survey. At the request of the jurisdiction,the National Board representative may alsoact for said jurisdiction.

Where there is no National Board member jurisdiction, the applicant’s Quality SystemProgram shall be acceptable to representativesof the National Board and the AuthorizedNuclear Inspection Agency.

The applicant shall request the Nation-

al Board to evaluate the Quality SystemProgram and implementation prior to theissuance of an “NR” Certificate of Au-thorization. The National Board, whenrequested through the appropriate form,will arrange for an evaluation of the ap-plicant’s Quality System Program. Theprogram will be evaluated on the basis ofits compliance with the National Boardrules for certification. The program shall beadequate to control the intended scope ofwork. The “NR” Certificate of Authoriza-

tion that is issued shall specify the scope andlimits of work for which the applicant iscertified.

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Revisions to the Quality System Pro-gram shall be acceptable to the Autho-rized Nuclear Inspector Supervisor of theAuthorized Nuclear Inspection Agency beforeimplementation.

The “NR” Certificate of Authorization holdershall be subject to an audit annually by theAuthorized Nuclear Inspection Agency toassure compliance with the Quality SystemProgram.

Upon notification of the survey dates fromthe National Board, it is the responsibility ofthe organization to make arrangements forthe survey.

The Survey Team, as a minimum, shallconsist of one representative each fromthe National Board, Authorized NuclearInspection Agency, and jurisdiction.

A recommendation to issue, renew or with-hold the National Board Certificate of Au-thorization for the “NR” Symbol Stampshall be included in a summary reportprepared by the survey team leader. Thecompleted summary report shall be forward-ed to the National Board.

If proper administrative fees are paidand all other requirements are met, an“NR” Certificate of Authorization will beissued evidencing authorization to use the“NR” Symbol Stamp. The Certificate shallexpire on the triennial anniversary date.

When an organization holding a NationalBoard Certificate of Authorization changesownership, name, or address, the NationalBoard shall be notified. The Certificate of

Authorization may be revised by submittingan application for National Board “NR” Cer-tificate of Authorization.

The National Board may at any time changethe rules for the issuance of the Certificate ofAuthorization and use of the “NR” SymbolStamp. These rules shall become binding onall certificate holders.

RA-2340 NATIONAL BOARD “NR” SYMBOL STAMP

All “NR” Symbol Stamps shall be obtainedfrom the National Board of Boiler and Pres-sure Vessel Inspectors. Authorization to usethe “NR” Symbol Stamp may be granted bythe National Board at its absolute discretion.

The National Board, for a nominal fee, fur-nishes the “NR” Symbol Stamp. Each orga-nization shall agree, if authorized to use the“NR” Symbol Stamp, that the “NR” SymbolStamp is at all times the property of the Na-tional Board and will be promptly returnedupon demand. If the organization discontin-ues the use of the “NR” Symbol Stamp or ifthe Certificate of Authorization has expiredand no new Certificate of Authorization has been issued, the “NR” Symbol Stamp shall bereturned to the National Board.

The organization’s Quality System Programshall provide for adequate control of the “NR”Symbol Stamp.

The organization authorized to use the “NR”Symbol Stamp may obtain more than one“NR” Symbol Stamp provided the organiza-tion’s Quality System Program describes howthe use of such stamps are controlled fromthe location shown on the “NR” Certificateof Authorization.

The organization shall not permit other or-ganizations to use the “NR” Symbol Stamploaned to it by the National Board.

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RA-2350 QUALITY SYSTEMPROGRAM

A holder of a National Board Certificate ofAuthorization shall have and maintain a writ-ten Quality System Program. The system shall

satisfactorily meet the requirements of theNBIC, jurisdictional requirements, and shall be available for review. The Quality SystemProgram may be brief or voluminous, depend-ing on the circumstances. It shall be treatedconfidentially by the National Board.

RA-2360 OUTLINE OFREQUIREMENTS FOR AQUALITY SYSTEM

PROGRAM FOR QUALIFICATION FOR THE

NATIONAL BOARD “NR”SYMBOL STAMP

These rules set forth the requirements forplanning, managing and implementing theorganization’s Quality System Programs forcontrolling the quality of activities performedduring repair/replacement activities of com-ponents and systems in nuclear power plantswithin the scope of the applicable edition and

addenda of Section XI of the ASME Code.These rules are to be the basis for evaluatingsuch programs prior to the issuance of theNational Board “NR” Certificate of Autho-rization.

a. Organization

1. The authority and responsibility ofthose in charge of the Quality SystemProgram and activities affecting qual-ity shall be clearly established and

documented. The person and orga-nization performing Quality System

functions shall have sufficient andwell-defined responsibility, authorityand organizational freedom to:

a. Identify quality problems;

b. Initiate action which results insolutions;

c. Verify implementation of solutionsto those problems;

d. Control further processing, de-livery or installation of a noncon-forming item, deficiency or unsat-isfactory condition until properdisposition has been made.

2. The person and organization respon-sible for defining and for measuringthe overall effectiveness of the QualitySystem Program shall be designatedsufficiently independent from thepressure of production, have directaccess to responsible managementat a level where appropriate actioncan be required and report regularlyon the effectiveness of the program.Assurance of quality requires man-

agement measures which providethat the individual or group assignedthe responsibility of inspection, test-ing, checking, or otherwise verifyingthat an activity has been correctlyperformed, is independent of the in-dividual or group directly responsiblefor performing the specific activity.The specific responsibilities of theQuality Assurance organization of the“NR” Certificate Holder shall includethe review of written procedures and

monitoring of all activities concernedwith the Quality System Program ascovered in these rules.

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b. Quality System Program

1. Before becoming a holder of an “NR”Certificate of Authorization, the appli-cant shall establish a Quality SystemProgram for the control of the quality

of work to be performed. The programshall define the organizational struc-ture within which the Quality SystemProgram is to be implemented andshall clearly delineate the responsibilities, levels of authority, and linesof communication for the variousindividuals involved. The programshall be documented in detail in aQuality System Manual which shall be a major basis for demonstrationof compliance with the NBIC. Theapplicant’s Quality System Programshall be documented by written poli-cies, procedures, and instructions andshall be based on the organization’sscope of work to be performed.

2. The applicant’s program need not be in the same format or sequentialarrangement as the requirements inthese rules as long as all applicableprogram requirements have been

covered. The program shall providefor the accomplishment of activitiesaffecting quality under suitablycontrolled conditions. Controlled con-ditions include the use of appropriateequipment, suitable environmentalconditions for accomplishing theactivity and assurance that prereq-uisites for the activity have beensatisfied. The program shall take intoaccount the need for special controls,processes, test equipment, tools, and

skills to attain the required qualityand need for the verification of quality by inspection and test. The programshall provide for ready detection ofnonconforming material and items

and for timely and positive correctiveactions.

3. The program shall provide for in-doctrination and training of person-nel performing activities affecting

quality as necessary to assure thatsuitable proficiency is achieved andmaintained. It shall be the responsibil-ity of the “NR” Certificate Holder toassure that all personnel performingquality functions within the scope ofthese rules, including personnel ofsubcontracted services, are qualifiedas specified in these rules. The assign-ment of qualified personnel shall be atthe discretion of the “NR” certificateholder.

4. The “NR” Certificate Holder shall beresponsible for advising his Autho-rized Nuclear Inspection Agency ofany proposed changes to the QualitySystem Manual and shall have ac-ceptance of the Authorized NuclearInspection Agency’s AuthorizedNuclear Inspector Supervisor beforeputting such changes into effect.The “NR” Certificate Holder shall

make a current copy of the QualitySystem Manual available to the Au-thorized Nuclear Inspector. The “NR”Certificate Holder shall be responsiblefor promptly notifying the AuthorizedNuclear Inspector of such acceptedchanges, including evidence of ac-ceptance by the Authorized NuclearInspection Agency.

5. The quality of all repair/replace-ment activities shall be controlled at

all points necessary to assure con-formance with the requirements ofthese rules and the “NR” CertificateHolder’s Quality System Manual.

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6. The certificate holder shall makeavailable to the Authorized NuclearInspector such drawings and processsheets as are necessary to make theQuality System Program intelligible.

c. Design Control ASME Section XI establishes that the

owner is responsible for design in connec-tion with repair/replacement activities.The “NR” Certificate Holder must ensurethat the design specification, drawings, orother specifications or instructions fur-nished by the owner satisfy the code edi-tion and addenda of the owner’s designspecification. To satisfy this requirement,the “NR” Certificate Holder shall establishrequirements that correctly incorporatethe owner’s design specification require-ments into their specification, drawings,procedures, and instructions, which may be necessary to carry out the work. The“NR” Certificate Holder’s system shallinclude provisions to assure that the ap-propriate quality standards are specifiedand included in all quality records. Theserecords shall be reviewed for compliancewith the owner’s design specificationand the requirements of Section XI of the

ASME Boiler and Pressure Vessel Code.

If the “NR” Certificate Holder’s specifica-tions, drawings, procedures and instruc-tions conflict with the owner’s designspecification, a system must be imple-mented that will resolve or eliminate thedeficiency. This system must be reconciledwith the owner and the “NR” CertificateHolder in accordance with IWA-4000 ofSection XI of the ASME Code.

d. Procurement Document Control Documents for procurement of materials,

items, and subcontracted services shallinclude requirements to the extent nec-

esary to assure their compliance with theowner’s design specifications and IWA-4000 of Section XI of the ASME Code. Tothe extent necessary, procurement docu-ments shall require suppliers to maintaina Quality System Program consistent with

the applicable requirements of the editionand addenda of the code of constructionto which the items are constructed. Mea-sures shall be established to assure thatall purchased material, items and servicesconform to these requirements.

e. Instructions, Procedures and Drawings Activities affecting quality shall be pre-

scribed by documented instructions,procedures or drawings of a type appro-priate to the circumstances and shall beaccomplished in accordance with theseinstructions, procedures, or drawings.Instructions, procedures, or drawingsshall include appropriate quantitativeand qualitative criteria for determiningthat activities affecting quality have beensatisfactorily accomplished. The “NR”Certificate Holder shall maintain a writ-ten description of procedures, instructionsor drawings used by his organizationfor control of quality and examination

requirements detailing the implementa-tion of the Quality System requirements.Copies of these procedures shall be read-ily available to the Authorized NuclearInspector.

f. Document Control The program shall include measures to

control the issuance, use, and dispositionof documents, such as specifications,instructions, procedures, and drawings,including changes thereto. These mea-

sures shall assure that the latest appli-cable documents, including changes, arereviewed for adequacy and approved forrelease by authorized personnel and dis-tributed for use at the location where theprescribed activity is performed.

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g. Control of Purchased Material, Items, andServices

Measures shall be established to assurethat all purchased material, items, andservices conform to the requirements ofthe owner’s design specifications and

applicable edition and addenda of thecode of construction and Section XI ofthe ASME Code. These measures shallinclude identification for material trace-ability. Provisions shall be identified forsource evaluation and objective evidenceshall be provided evidencing qualitystandards for material examination uponreceipt.

h. Identification and Control of Material and

Items

1. Measures shall be established for iden-tification and control of material anditems, including partially fabricatedassemblies. These measures shall as-sure that identification is maintainedand traceable, either on the material orcomponent, or on records throughoutthe repair/replacement activity. Thesemeasures shall be designed to preventthe use of incorrect or defective items

and those which have not receivedthe required examinations, tests ,orinspections.

2. Permanent or temporary unit iden-tification marks shall be applied us-ing methods and materials that arelegible and not detrimental to thecomponent or system involved. Suchidentification shall be located in areasthat will not interfere with the func-tion or quality aspects of the item.

3. Certified Material Test Reports shall be identified as required by the appli-cable material specification in SectionII of the ASME Code and shall satisfy

any additional requirements specifiedin the original code of construction.The Certified Material Test Reportor Certificate of Compliance neednot be duplicated in the checklist ordocuments. Checklist documents shall

provide a record that the CertifiedMaterial Test Report and Certificatesof Compliance have been received,reviewed, and found acceptable.When the “NR” Certificate HolderScope authorizes the organizationto perform examinations and testsin accordance with the original codeof construction, the “NR” CertificateHolder shall certify compliance eitheron a Certified Material Test Report orCertificate of Conformance that thematerial satisfies the original code ofconstruction requirements.

i. Control of Processes

1. The “NR” Certificate Holder shalloperate under a controlled systemsuch as process sheets, checklists,travelers, or equivalent procedures.Measures shall be established toassure that processes such as welding,

nondestructive examination, and heattreating are controlled in accordancewith the rules of the applicable sectionof the ASME Code and are accom-plished by qualified personnel usingqualified procedures.

2. Process sheets, checklists, travelers,or equivalent documentation shall be prepared, including the documentnumbers and revisions to whichthe process conforms, with space

provided for reporting results ofcompletion of specific operations atcheckpoints of repair/replacementactivities.

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2. Test procedures shall include provi-sions for assuring that prerequisitesfor the given test have been met, thatadequate instrumentation is availableand used, and that necessary moni-toring is performed. Prerequisites

may include calibrated instrumenta-tion, appropriate equipment, trainedpersonnel, condition of test equipmentand the item to be tested, suitableenvironmental conditions, and provi-sions for data acquisition.

3. Test results shall be documented andevaluated to assure that test require-ments have been satisfied.

l. C o n t r o l o f M e a s u r i n g a n d T e s tEquipment

Measures shall be established and doc-umented to assure that tools, gages,instruments, and other measuring andtesting equipment and devices used inactivities affecting quality are of theproper range, type, and accuracy to verifyconformance to established requirements.A procedure shall be in effect to assurethat they are calibrated and properlyadjusted at specified periods or use

intervals to maintain accuracy withinspecified limits. Calibration shall be trace-able to known national standards, wherethese standards exist, or with the devicemanufacturer’s recommendation.

m. Quality Records

1. The owner is responsible for des-ignating records to be maintained.Measures shall be established forthe “NR” Certificate Holder to

maintain these records [See m(2)]required for Quality Assuranceof repair/replacement activities.These shall include documents suchas records of materials, manufac-

j. Examinations, Tests and Inspections

1. In-process and final examinations andtests shall be established to assureconformance with specifications,drawings, instructions, and proce-

dures which incorporate or referencethe requirements and acceptancelimits contained in applicable designdocuments. Examination activities toverify the quality of work shall be per-formed by persons other than thosewho performed the activity beingexamined. Such persons shall notreport directly to the immediate su-pervisors responsible for the work being examined.

2. Process sheets, travelers, or check-lists shall be prepared, including thedocument numbers and revision towhich the examination or test is to beperformed, with space provided forrecording results.

3. Mandatory hold/inspection pointsat which witnessing is required by the “NR” Certificate Holder ’srepresentative or the Authorized

Nuclear Inspector shall be indi-cated in the controlling documents.Work shall not proceed beyondmandatory hold/inspection pointswithout the consent of the “NR”Certificate Holder’s representative orthe Authorized Nuclear Inspector, asappropriate.

k. Test Control

1. Testing shall be performed in ac-

cordance with the owner’s writtentest procedures that incorporate orreference the requirements andacceptance limits contained in appli-cable design documents.

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turing, examination, and test datataken before and during repair/replacement activity. Procedures ,specifications, and drawings usedshall be fully identified by perti-nent material or item identification

numbers, revision numbers, and issuedates. The records shall also includerelated data such as qualification ofpersonnel, procedures, equipment,and related repairs. The “NR” Cer-tificate Holder shall take such stepsas may be required to provide suitableprotection from deterioration anddamage for all records while in hiscare. Also, it is required that the “NR”Certificate Holder have a system forcorrection or amending records thatsatisfies the owner’s requirements.These records may be either the origi-nal or a reproduced, legible copy andshall be transferred to the owner athis request.

2. Records to be maintained as requiredin RA-2360(m)(1) above may includethe following:

a. An index that details the location

and who is responsible for main-taining the records;

b. Data reports, properly executed,for each replacement component,part, appurtenance, piping systemand piping assembly when re-quired by the design specificationor the owner;

c. The required as-constructed draw-ings certified as to correctness;

d. Copies of applicable CertifiedMaterial Test Reports and Certifi-cates of Compliance;

e. As-built sketch(es) includingtabulations of materials repair/replacement procedures, andinstructions to achieve compli-ance with Section XI of the ASMECode;

f. Nondestructive examination re-ports including results of exami-nations shall identify the ASNT,SNT-TC-1A, CP-189 or ACCPlevel of personnel interpreting theexamination results. The ASNTCentral Certification Program(ACCP) may be used to fulfill theexamination and demonstrationrequirement of the employer’swritten practice. Final radiographsshall be included where radiogra-phy has been performed;

g. Records of all heat treatments may be either the heat treatment chartsor a summary description of heattreatment time and temperaturedata certified by the “NR” Cer-tificate Holder. Heat treatmentsperformed by the material manu-facturer to satisfy requirements of

the material specifications may bereported on the Certified MaterialTest Report;

h. Any and all non-conformancereports shall satisfy IWA-4000 ofSection XI of the ASME Code andshall be reconciled by the ownerprior to certification of the FormNR-1 or NVR-1, as applicable.

3. After a repair/replacement activity,

all records including audit reportsrequired to verify compliance withthe applicable engineering documentsand the “NR” Certificate Holder’sQuality System Program, exceptthose required by the owner or listedin (2)(a) through (g) above, shall be

A05

A05

A05

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maintained at a place mutually agreedupon by the owner and the “NR” Cer-tificate Holder. These records shall bemaintained for a period of five yearsafter completion of the repair/replace-ment activity.

4. The original of the completed FormNR-1 or Form NVR-1 , as applicable,shall be registered with the NationalBoard and, if required, a copy for-warded to the jurisdiction where thenuclear power plant is located.

n. Examination or Test Status Measures shall be established to indicate

examination and test status of parts,items, or components during the repair/replacement activity. The system usedshall provide positive identification ofthe part, item, or component by meansof stamps, labels, routing cards, or otheracceptable methods. The system shallinclude any procedures or instructionsto achieve compliance. Also, measuresshall be provided for the identification ofacceptable and nonacceptable items. Theyshall also include procedures for controlof status indicators, including the author-

ity for application and removal of statusindicators.

o. Nonconforming Materials or Items Measures shall be established to control

materials or items that do not conformto requirements in order to prevent theirinadvertent use, including measures toidentify and control the proper installationof items and to preclude nonconformancewith the requirements of these rules.These measures shall include procedures

for identification, documentation, segre-gation, and disposition. Nonconformingitems shall be reviewed for acceptance,rejection, or repair in accordance withdocumented procedures. The responsi-

bility and authority for the dispositionof nonconforming items shall be defined.Repaired or modified items shall be re-examined in accordance with the appli-cable procedures. Measures that controlfurther processing of a nonconforming

or defective item, pending a decision onits disposition, shall be established andmaintained. Ultimate disposition of non-conforming items shall be documented.

p. Corrective Action

1. Measures shall be established toassure that conditions adverse toquality such as failures, malfunctions,deficiencies, deviations, defectivematerial and equipment, and othernonconformances are promptly iden-tified and corrected.

2. In the case of significant conditionsadverse to quality, the measures shallalso assure that the cause of these con-ditions be determined and correctedto preclude repetition. The identifica-tion of significant conditions adverseto quality, the cause, and conditionand the corrective action taken shall

be documented and reported to theappropriate levels of management.

3. The requirements shall also extend tothe performance of subcontractors’corrective action measures.

q. Audits A comprehensive system of planned and

periodic audits shall be carried out by the“NR” certificate holder’s organizationto assure compliance with the Quality

System Program and to determine its ef-fectiveness. Audits shall be performed inaccordance with written procedures orchecklists by personnel not having directresponsibilities in the areas being au-dited. Audit results shall be documented by the auditing personnel for review by

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management having responsibility inthat area. Follow-up action, includingre-audit of deficient areas, shall be takenwhere indicated. Audit results shall bemade available to the Authorized NuclearInspector.

r. Authorized Nuclear Inspector Measures shall be taken to reference the

commissioned National Board AuthorizedNuclear Inspector, qualified in accordancewith the National Board Rules for Commis-sioned Inspectors , to ensure that the latestdocuments including the Quality SystemProgram will be made available to theinspector. The Authorized Nuclear Inspec-tor shall be consulted prior to the issu-ance of a repair/replacement program inorder that he/she may select any inspec-tion or hold points in the program. TheAuthorized Nuclear Inspector shall notsign Form NR-1 or Form NVR-1 , as ap-plicable, unless he/she is satisfied that allwork carried out is in accordance with theNBIC, ASME Section XI, and any jurisdic-tional requirements.

RA-2370 INTERFACE WITH THE

OWNER’S REPAIR/ REPLACEMENT PROGRAM

Interface with the owner’s repair/replace-ment program shall meet the following:

a. The repair/replacement program shall besubject to the acceptance of the jurisdictionand the owner’s ANII.

b. Repair/replacement activities of nuclearcomponents shall meet the requirements

of Section XI of the ASME Boiler andPressure Vessel Code and the jurisdic-tion where the nuclear power plant islocated.

c. Documentation of the repair/replace-ment activities of nuclear components

shall be recorded on the National BoardReport of Nuclear Repair/Modificationor Replacement activities, Form NR-1, orForm NVR-1, as applicable. The completedforms shall be signed by a representativeof the authorized nuclear repair organiza-

tion and the Authorized Nuclear Inspectorif the repair/replacement activity meetsthe requirements of ASME Section XI. Forrepair/replacement activities that involvedesign changes as specified in RA-2360(c) , Form NR-1 , or Form NVR-1 , as applicable,shall indicate the responsible organizationsatisfying the owner’s design specificationrequirements.

d. The authorized nuclear repair organiza-tion shall provide a copy of the signedForm NR-1 or Form NVR-1 , as applicable,to the owner, if required, the jurisdiction,and the Authorized Nuclear InspectionAgency. The original Form NR-1 or FormNVR-1 , as applicable, shall be registeredwith the National Board by the authorizednuclear repair organization.

e. The authorized nuclear repair organiza-tion shall provide a nameplate/stamp-ing for repair/replacement activities for

each nuclear component unless otherwiserequired by the Owner’s Quality SystemProgram. The required information and format shall be as shown in Appendix 2.

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Inservice Inspection ofPressure-Retaining Items

Part RB

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PART RB — INSERVICE INSPECTION OF PRESSURE-RETAINING ITEMS

RB-1000 General Requirements for Inservice Inspection of Pressure-Retaining Items ...............................................................................36 RB-1010 Scope ......................................................................................................................36 RB-1020 Administration .....................................................................................................36

RB-1030 Stamping ...............................................................................................................36 RB-1040 Reference to Other Codes and Standards ........................................................37 RB-1050 Conclusions ..........................................................................................................37

RB-2000 Personnel Safety and Inspection Activities ......................................................37 RB-2010 Scope ......................................................................................................................37

RB-2100 Personnel Safety ...................................................................................................38 RB-2110 Equipment Operation .........................................................................................38 RB-2120 Vessel Entry Requirements .................................................................................38

RB-2200 Inspection Activities ............................................................................................38 RB-2210 Preparation for Internal Inspection ...................................................................38

RB-2220 Pre-inspection Activities .....................................................................................39 RB-2230 Post-inspection Activities ...................................................................................40

RB-3000 Inspection and Test Methods .............................................................................40 RB-3010 Scope ......................................................................................................................40

RB-3100 Nondestructive Examination Methods (NDE) ................................................40 RB-3110 Visual .....................................................................................................................41 RB-3120 Magnetic Particle .................................................................................................41 RB-3130 Liquid Penetrant ..................................................................................................41 RB-3140 Ultrasonic ..............................................................................................................41 RB-3150 Radiography .........................................................................................................42 RB-3160 Eddy Current ........................................................................................................42 RB-3170 Metallographic .....................................................................................................42 RB-3180 Acoustic Emission ...............................................................................................43

RB-3200 Testing ...................................................................................................................43 RB-3210 Pressure Testing ...................................................................................................43 RB-3220 Leak Testing ..........................................................................................................44

RB-3300 Material Preparation – General Guidelines .....................................................44

RB-4000 Causes of Deterioration and Failure Mechanisms ..........................................44 RB-4010 Scope ......................................................................................................................44 RB-4020 General ..................................................................................................................44

RB-4100 Corrosion ..............................................................................................................44 RB-4110 Macroscopic Corrosion Environments .............................................................44 RB-4120 Microscopic Corrosion Environments ..............................................................46

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RB-4200 Control of Corrosion ...........................................................................................46 RB-4210 Process Variables ..................................................................................................46 RB-4220 Engineering Design .............................................................................................46 RB-4230 Protection ..............................................................................................................47 RB-4240 Material Selection ................................................................................................47 RB-4250 Coatings ................................................................................................................47

RB-4300 Conclusion ............................................................................................................47

RB-4400 Failure Mechanisms ............................................................................................47 RB-4410 Fatigue ...................................................................................................................47 RB-4420 Creep .....................................................................................................................48 RB-4430 Temperature .........................................................................................................48 RB-4440 Hydrogen Embrittlement ...................................................................................48 RB-4450 Hydrogen Attack .................................................................................................49 RB-4460 Bulges and Blisters ..............................................................................................50 RB-4470 Overheating ..........................................................................................................50 RB-4480 Cracks ....................................................................................................................50

RB-4500 Specific Inspection Requirements .....................................................................51

RB-5000 Inspection of Boilers ............................................................................................51 RB-5010 Scope ......................................................................................................................51

RB-5100 General Conditions .............................................................................................51

RB-5200 Pre-Inspection Activities .....................................................................................51

RB-5300 Condition of Installation .....................................................................................51 RB-5310 General ..................................................................................................................51

RB-5400 Inspections ............................................................................................................51 RB-5410 External Inspection ..............................................................................................51 RB-5420 Internal Inspection ...............................................................................................52 RB-5430 Evidence of Leakage ............................................................................................52

RB-5500 Inspection Requirements – General ..................................................................53 RB-5510 Corrosion ..............................................................................................................53 RB-5520 Inspection of Piping, Parts, and Appurtenances .............................................54 RB-5600 Specific Inspection Requirements for Boiler Types .........................................57

RB-5700 Inservice Inspection Activities ...........................................................................64

RB-6000 Inspection of Pressure Vessels ...........................................................................64 RB-6010 Scope ......................................................................................................................64


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RB-6200 Inspections – General Requirements ................................................................64 RB-6210 Condition of Installation .....................................................................................64 RB-6220 External Inspection ..............................................................................................64 RB-6230 Internal Inspection ...............................................................................................65 RB-6240 Inspection of Parts and Appurtenances ...........................................................66 RB-6250 Gages, Safety Devices, and Controls ................................................................66

RB-6300 Records Review ....................................................................................................67

RB-6400 Inspections for Specific Types of Pressure Vessels ..........................................67 RB-6410 General ..................................................................................................................67 RB-6420 Deaerators .............................................................................................................68 RB-6430 Compressed Air Vessels ......................................................................................68 RB-6440 Expansion Tanks ..................................................................................................68 RB-6450 Liquid Ammonia Vessels ....................................................................................69 RB-6460 Inspection of Pressure Vessels with Quick-Actuating Closures ...................70 RB-6470 Graphite Pressure Equipment ...........................................................................72 RB-6480 Fiber Reinforced Vessels .....................................................................................72 RB-6490 Propane LP Gas Vessels ......................................................................................72

RB-6500 Nondestructive Examination (NDE) ................................................................72

RB-6600 Remaining Life and Inspection Intervals .........................................................72


RB-7000 Inspection of Piping Systems .............................................................................73 RB-7010 Scope ......................................................................................................................73


RB-7200 Assessment of Piping Design.............................................................................73

RB-7300 Inspection ..............................................................................................................73 RB-7310 External Inspection of Piping .............................................................................73 RB-7320 Internal Inspection of Piping .............................................................................74

RB-7330 Evidence of Leakage ............................................................................................74 RB-7340 Provisions for Expansion and Support ............................................................74 RB-7350 Gages, Safety Devices, Controls ........................................................................74


RB-8000 Inspection of Pressure Relief Devices ...............................................................75 RB-8010 Scope ......................................................................................................................75

RB-8100 Safety Considerations .........................................................................................75

RB-8200 Device Data...........................................................................................................75 RB-8210 Device Condition .................................................................................................76

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RB-8300 Installation Condition .........................................................................................76

RB-8400 Testing and Operational Inspection ..................................................................77 RB-8410 Recommended Inspection and Test Frequencies ............................................78

RB-8500 Additional Inspection Information ...................................................................80

RB-8510 Boilers ....................................................................................................................80 RB-8520 Pressure Vessels and Piping ...............................................................................81 RB-8530 Rupture Disks .......................................................................................................81

RB-8600 Requirements for Shipping and Transporting .................................................83


RB-9000 Methods to Assess Damage Mechanisms and Inspection Frequency for Pressure-Retaining Items ..................................................................................83 RB-9010 Scope ......................................................................................................................83 RB-9020 General Requirements ........................................................................................84 RB-9030 Remaining Service Life Assessment Methodology ........................................84

RB-9040 Data Requirements for Remaining Service Life Assessments .......................85 RB-9050 Determining Inspection Intervals .....................................................................86

RB-9100 Method for Estimating Inspection Intervals for Pressure-Retaining Items Subject to Erosion or Corrosion .......................................................................86 RB-9110 Method for Estimating Inspection Intervals for Exposure to Corrosion .....86 RB-9120 Method for Inspection Intervals for Pressure-Retaining Items Where

Corrosion Is Not a Factor ..............................................................................88.1RB-9200 Evaluating Inspection Intervals of Pressure-Retaining Items Exposed to Inservice Damage Mechanisms ....................................................................88.2 RB-9210 Exposure to Elevated Temperature (Creep) ..................................................88.2 RB-9220 Exposure to Brittle Fracture ............................................................................88.2 RB-9230 Evaluating Conditions That Cause Bulges/Blisters/Laminations ...........88.3 RB-2040 Evaluating Crack-Like Indications in Pressure-Retaining Item ................88.3 RB-9250 Evaluating Exposure of a Pressure-Retaining Item to Fire Damage .........88.3 RB-9260 Evaluating Exposure of Pressure-Retaining Items to Cyclic Fatigue ........88.4 RB-9270 Evaluating Pressure-Retaining Items Containing Local Thin Areas .........88.4

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RB-1000 GENERAL REQUIREMENTSFOR INSERVICE

INSPECTION OF PRESSURE-RETAINING ITEMS

RB-1010 SCOPE

Part RB provides guidelines and require-ments for conducting inservice inspectionand testing of pressure-retaining items andpressure relief devices. Appropriately, thisPart includes precautions for the safety ofinspection personnel. The safety of the In-spector is the most important aspect of anyinspection activity.

Understanding the potential damage/dete-rioration mechanisms that can affect the me-chanical integrity of a pressure-retaining itemand knowledge of the inspection methods thatcan be used to find these damage mechanismsare essential to an effective inspection. ThisPart includes a general discussion of variousdamage mechanisms and effective inspectionmethods. In addition, some specific guidanceis given on how to estimate the remaining lifeof a pressure-retaining item and determine theappropriate inspection interval.

RB-1020 ADMINISTRATION

Jurisdictional requirements describe the fre-quency, scope, type of inspection, whetherinternal, external or both, and type of docu-mentation required for the inspection. TheInspector shall have a thorough knowledgeof jurisdictional regulations where the itemis installed, as inspection requirements mayvary.

RB-1030 STAMPING

AuthorizationWhen the stamping on a pressure-retainingitem becomes indistinct or the nameplate islost, illegible, or detached , but traceability

to the original pressure-retaining item is stillpossible, the Inspector shall instruct the owneror user to have the stamped data replaced.All re-stamping shall be done in accordancewith the original code of construction, exceptas modified herein. Requests for permission

to re-stamp or replace nameplates shall bemade to the jurisdiction in which the pres-sure-retaining item is installed. Applicationmust be made on the Replacement of StampedData Form NB-136 (Appendix 5). Proof ofthe original stamping and other such data,as is available, shall be furnished with the re-quest. Permission from the jurisdiction is notrequired for the reattachment of nameplatesthat are partially attached. When traceabilitycannot be established, the jurisdiction shall be contacted.

When there is no jurisdiction, the replacementof stamped data shall be authorized and wit-nessed by a National Board CommissionedInspector and the completed Form NB-136shall be submitted to the National Board.

Replacement of Stamped DataThe restamping or replacement of data shall be witnessed by a National Board Commis-sioned Inspector and shall be identical to the

original stamping.

The restamping or replacement of a code symbol stamp shall be done only by the originalmanufacturer and witnessed by a NationalBoard Commissioned Inspector.

Replacement nameplates shall be clearlymarked “replacement.”

ReportingForm NB-136 shall be filed with the jurisdic-

tion (if required) or the National Board by theowner or user together with a facsimile of thestamping or nameplate, as applied, and shallalso bear the signature of the National BoardCommissioned Inspector who witnessed thereplacement.

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RB-1040 REFERENCE TO OTHERCODES AND STANDARDS

Other existing inspection codes, standards,and practices pertaining to the inservice in-spection of pressure-retaining items can pro-

vide useful information and references rela-tive to the inspection techniques listed in PartRB. Additionally, supplementary guidelinesfor assisting in the evaluation of inspectionresults and findings are also available. Someacceptable guidelines are as follows:

a. National Board BULLETIN – NationalBoard Classic Articles Series

b. American Society of Mechanical Engi-neers – ASME Boiler & Pressure Vessel Code Section V (Nondestructive Examination)

c. American Society of Mechanical Engi-neers – ASME Boiler & Pressure Vessel CodeSection VI (Recommended Rules for theCare and Operation of Heating Boilers)

d. American Society of Mechanical Engi-neers – ASME Boiler & Pressure Vessel Code Section VII (Recommended Guidelines forthe Care of Power Boilers Subsection C6

- Inspection)

e. American Society of Mechanical Engineers– ASME B31G (Manual for Determiningthe Remaining Strength of Corroded Pipe-lines)

f. American Petroleum Institute – API 572

Inspection of Pressure Vessels

g. American Petroleum Institute – API 574Inspection Practices for Piping System

Components

h. American Petroleum Institute – API 579Fitness-For-Service

RB-1050 CONCLUSIONS

During any inspections or tests of pressure-retaining items, the actual operating andmaintenance practices should be noted bythe Inspector and a determination made as

to their acceptability.

Defects or deficiencies in the condition, oper-ating, and maintenance practices of the boiler,pressure vessel, or piping system equipmentshould be discussed with the owner or userat the time of inspection and recommenda-tions made for correction of any such defectsor deficiencies.

RB-2000 PERSONNEL SAFETY ANDINSPECTION ACTIVITIES

Visual examination is the basic method usedwhen conducting an inservice inspection ofpressure-retaining items. Additional exami-nation and test methods may be required atthe discretion of the inspector to provide ad-ditional information to assess the condition ofthe pressure-retaining item. See RB-3000.

RB-2010 SCOPE

A proper inspection of a pressure-retainingitem requires many pre-inspection planningactivities including: safety considerations, aninspection plan that considers the potentialdamage mechanisms, selection of appropri-ate inspection methods, and awareness ofthe jurisdictional requirements. This sectiondescribes pre-inspection and post-inspectionactivities applicable to all pressure-retainingitems. Specific inspection requirements for

pressure-retaining items are identified inRB-5000 for boilers, RB-6000 for pressure ves-sels, and RB-7000 for piping.

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RB-2100 PERSONNEL SAFETY

Personnel safety is the joint responsibility ofthe owner or user and the Inspector. All appli-cable safety regulations shall be followed. Thisincludes governmental, state, regional, and/

or local rules and regulations. Owner or userprograms, safety programs of the Inspector’semployer, or similar regulations also apply. Inthe absence of such rules, prudent and gener-ally accepted engineering safety proceduressatisfactory to the Inspector shall be employed by the owner or user.

RB-2110 EQUIPMENT OPERATION

The Inspector should not operate equipment.Operation shall be conducted only by compe-tent individuals familiar with the equipmentand qualified to perform such tasks.

RB-2120 VESSEL ENTRY REQUIREMENTS

No pressure-retaining item shall be entereduntil it has been properly prepared for inspec-tion. The owner or user and inspector shall

determine that pressure-retaining items may be entered safely. This shall include:

a. Potential hazards associated with entryinto the object have been identified bythe owner or user and are brought to theattention of the Inspector, along with ac-ceptable means or methods for dealingwith each of these hazards;

b. Coordination of entry into the object by the Inspector and owner or user

representative(s) working in or near theobject;

c. If personal protective equipment is re-quired to enter an object, the necessaryequipment is available and the Inspectoris properly trained in its use;

d. An effective energy isolation program(lock out and/or tag out) is in place andin effect that will prevent the unexpectedenergizing, start up, or release of storedenergy.

The Inspector shall be satisfied that a safeatmosphere exists before entering the pres-sure-retaining item. The oxygen content ofthe breathable atmosphere shall be between19.5% and 23.5%.

The Inspector shall not be permitted to enteran area if toxic, flammable or inert gases, va-pors or dusts are present and above acceptablelimits without appropriate personal protectiveequipment. This may include, among otheritems, protective outer clothing, gloves, eyeprotection, and foot protection. The Inspectorshall have the proper training governing theselection and use of any personal protectiveclothing and equipment necessary to safelyperform each inspection. Particular attentionshall be afforded respiratory protection if thetesting of the atmosphere of the object revealsany hazards.

RB-2200 INSPECTION ACTIVITIES

RB-2210 PREPARATION FOR INTERNAL INSPECTION

The owner or user has the responsibility toprepare a pressure-retaining item for internalinspection. Requirements of occupationalsafety and health regulations (federal, state,local, or other), as well as the owner-user’sown program and the safety program of theInspector’s employer are applicable. The pres-

sure-retaining item should be prepared in thefollowing manner or as deemed necessary bythe Inspector:

a. When a vessel is connected to a commonheader with other vessels or in a systemwhere liquids or gases are present, the

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vessel shall be isolated by closing, locking,and/or tagging stop valves in accordancewith the owner’s or user’s procedures.When toxic or flammable materials areinvolved, additional safety precautionsmay require removing pipe sections or

blanking pipelines before entering thevessel. The means of isolating the vesselshall be acceptable to the Inspector and incompliance with applicable occupationalsafety and health regulations and proce-dures. For boilers or fired pressure ves-sels, the fuel supply and ignition systemshall be locked out and/or tagged out,in accordance with the owner’s or user’sprocedures.

b. The vessel shall be allowed to cool orwarm at a rate to avoid damage to thevessel. When a boiler is being preparedfor internal inspection, the water shouldnot be withdrawn until it has been suf-ficiently cooled at a rate to avoid damageto the boiler.

c. The vessel shall be drained of all liquidand shall be purged of any toxic or flam-mable gases or other contaminants thatwere contained in the vessel. Mechanical

ventilation using a fresh air blower orfan shall be started after the purging op-eration and maintained until all pocketsof “dead air,” which may contain toxic,flammable, or inert gases are reduced toacceptable limits. During air purging andventilation of vessels involved with flam-mable gases, the concentration of vapor inair may pass through the flammable range before a safe atmosphere is obtained. Allnecessary precautions shall be taken toeliminate the possibility of explosion or

fire.

d. Manhole and hand hole plates, washoutplugs, inspection plugs, and any otheritems requested by the Inspector shall beremoved;

e. The Inspector shall not enter a vessel untilall safety precautions have been taken. Thetemperature of the vessel shall be suchthat the inspecting personnel will not beexposed to excessive heat. Vessel surfacesshould be cleaned as necessary.

f. If requested by the Inspector or required by regulation or procedure, a responsibleperson (attendant) shall remain outsidethe vessel at the point of entry while the In-spector is inside and shall monitor activityinside and outside and communicate withthe Inspector as necessary. The attendantshall have a means of summoning rescueassistance, if needed, and to facilitate res-cue procedures for those inside the vesselwithout personally entering the vessel.

NOTE: If a vessel has not been properlyprepared for an internal inspection, theinspector shall decline to make the inspec-tion.

RB-2220 PRE-INSPECTION ACTIVITIES

Prior to conducting the inspection, a review

of the known history of the pressure-retainingitem and a general assessment of current con-ditions shall be performed. This shall includea review of information such as:

a. Date of last inspection;

b. Current jurisdictional inspection certifi-cate;

c. ASME Code Symbol Stamping or mark ofcode of construction;

d. National Board and/or jurisdiction regis-tration number;

e. Operating conditions and normal contentsof the vessel (discuss any unique hazardswith the owner or user);

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f. Previous inspection report, operating logsand test records;

g. Records of wall thickness checks, espe-cially where corrosion or erosion is aconsideration;

h. Review of repairs or alterations for com-pliance with applicable requirements;

i. Observation of the condition of the com-plete installation, including maintenanceand operation, to form an opinion of thecare the equipment receives;

j. Before starting the inspection, the areashould be reviewed for potential hazardssuch as exposure to falling objects andsafety of any scaffolding. When a pressuretest is to be performed, the precautions inRB-3000 should be followed.

The following activities should be performedas required to support the inspection:

a. Pressure gage should be removed for test-ing, unless there is other information toassess its accuracy.

b. Pressure relief devices should be inspectedin accordance with RB-8000.

RB-2230 POST-INSPECTION ACTIVITIES

Any defects or deficiencies in the condition,operating, and maintenance practices of thepressure-retaining item and auxiliary equip-ment should be discussed with the owner oruser and recommendations made for correc-

tion.

Documentation of inspection shall containpertinent data such as description of item,

classification, identification numbers, in-spection intervals, date inspected, type ofinspection, and test performed and anyother information required by the inspectionagency, jurisdiction, and/or owner-user. TheInspector shall sign, date, and note any defi-

ciencies, comments, or recommendations onthe inspection report. The Inspector shouldretain and distribute copies of the inspectionreport, as required.

RB-3000 INSPECTION AND TESTMETHODS

RB-3010 SCOPE

This part describes acceptable inspection andtest methods that are available to the Inspec-tor during inspection of pressure-retainingitems.

RB-3100 NONDESTRUCTIVE EXAMINATION METHODS

(NDE)

Listed below is a variety of nondestructive

examination methods that may be employedto assess the condition of pressure-retainingitems. The skill, experience, and integrity ofthe personnel performing these examinationsare essential to obtain meaningful results. TheInspector should review the methods and pro-cedures to be employed to assure compliancewith jurisdictional requirements.

Generally, some form of surface preparationwill be required prior to use of these examina-tion methods. When there is doubt as to the

extent of a defect or detrimental conditionfound in a pressure-retaining item, the Inspec-tor is cautioned to seek competent technicaladvice and supplemental NDE.

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RB-3110 VISUAL

Visual examination is an inspection methodto ascertain the surface condition of the pres-sure-retaining item. The Inspector should beaware of recognizing various surface features

and comparing these features with damagemechanisms listed in RB-4000 that could in-dicate exposure of the pressure-retaining itemto harmful corrosion or elevated temperatureservice.

In some cases the Inspector may have limitedor no access while performing an inspectionof the pressure-retaining item. Subject to ap-proval of the jurisdiction, remote camera orfiber optic devices may be considered accept-able methods to view and record the surfacecondition of the pressure-retaining item.

RB-3120 MAGNETIC PARTICLE

The magnetic particle examination methodcan be used only on ferromagnetic materialsto reveal surface discontinuities and to a lim-ited degree, those located below the surface.It uses the principle that magnetic lines offorce will attract magnetizable material. The

sensitivity of this method decreases rapidlywith depth below the surface being examinedand, therefore, it is used primarily to examinefor surface discontinuities.

In order to use this method, a magnetic fieldhas to be established within the material to be examined. This can be done directly by bringing a strong magnetic field into closeproximity of the item being examined or byinducing a magnetic field in the object by pass-ing electric current through the object.

If there is a discontinuity at or near the surface,it will deflect the magnetic lines of force outof the object, thus creating a north pole (mag-

netic lines leave the north pole of a magnet).The magnetic lines of force will re-enter thetest object on the other side of the discontinu-ity, thereby creating a south pole (magneticlines enter the south pole of a magnet). Sincea north and a south pole have been created

they will attract magnetizable objects. Ironpowder placed on the discontinuity is held inplace by the lines of force and will be visibleon the surface of the test object.

RB-3130 LIQUID PENETRANT

The liquid penetrant examination method isused to detect discontinuities that are open tothe surface of the material being examined.This method may be used on both ferrousand nonferrous materials. Liquid penetrantexamination may be used for the detection ofsurface discontinuities such as cracks, seams,laps, cold shuts, laminations, and porosity.

Liquid penetrant examination works by ap-plying a colored liquid (penetrant) to theobject to be examined. Time is allowed for theliquid to fill any voids that are open to the sur-face. Excess penetrant is then removed and a“developer” is applied in a uniform, thin coat-

ing. The developer acts as a blotter and drawsthe penetrant out of the discontinuity. Thedeveloper is usually of a contrasting color tothe penetrant. The penetrant indications willappear as colored figures on a background ofthe developer.

Liquid penetrant examination is portable, fast,and requires minimal operator training.

RB-3140 ULTRASONIC

Ultrasonic testing is used for volumetricexamination of welds and base materials(metallic and nonmetallic) for detection of

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flaws. This method depends on sound wavesof very high frequency being transmittedthrough metal and reflected at any boundary,such as a metal to air boundary at the surfaceof the metal, or metal crack boundary at adiscontinuity. High frequency sound waves

can detect small irregularities but are easilyabsorbed, particularly by coarse-grainedmaterials. Sound waves can be introducedinto a part either normal to the surface or atpredetermined angles. Factors such as mate-rial composition, surface condition, choice ofequipment, and ability of the operator affectthe results of ultrasonic inspection. Ultrasonictesting can also be used to measure materialthickness.

RB-3150 RADIOGRAPHY

Radiography is a volumetric method that candetect discontinuities throughout a material.This method is commonly used to examinefor surface and subsurface discontinuities.The use of this method may be restricted dueto the configuration of the welded joint or thelimitations of the radiographic equipment.Radiography will not give an indication ofthe depth of discontinuity unless special pro-

cedures are used.

The method uses a high energy gamma rayor x-ray source to penetrate the material to beexamined. The rays are absorbed, reflected,and refracted by the material, but some ofthe energy passes completely through. Theenergy of rays that pass completely through isdetermined by the thickness and other physi-cal properties of the material.

Radiography uses film to detect the rays that

penetrate the material. The higher the energyof the rays, the darker the film will become,similar to exposing photographic film tosunlight.

Most discontinuities (cracks, porosity, andinclusions) reduce the amount of base ma-terial available to absorb (attenuate) x-raysor gamma rays, thus allowing more energyto pass through the material. Most discon-tinuities will appear as dark shapes on the

radiographic film.

The technique used for radiography dependslargely on the equipment used and whatexperience has shown will produce the bestresults. It is not the function of the technicianto indicate the procedure to be followed,provided the procedure and films satisfy allrequirements of the applicable section of theASME Code. The radiographic film providesa permanent record of the results of the ex-amination.

RB-3160 EDDY CURRENT

Examination method that measures changesin a magnetic field caused by discontinuities.Eddy current can also detect a loss of materialon inaccessible surfaces and be used to detectchanges in hardness of a material. There arethree general types of eddy current coils: theconcentric coil which surrounds the part to

be tested (e.g., tubing); the probe coil whichis brought adjacent to the part to be tested;and the bobbin coil which is inserted into thepart to be tested (e.g., tubing).

RB-3170 METALLOGRAPHIC

Method of locally polishing, etching, andviewing the surface of a pressure-retainingitem with either acetate tape (e.g., replication)or a field microscope to determine the condi-

tion of the metal microstructure.

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RB-3180 ACOUSTIC EMISSION

Acoustic emission is a method of detectingand monitoring discontinuities in a pressure-retaining item or load-bearing structure. Thismethod utilizes wave guides, transducers,

cables, and a sophisticated data acquisitionsystem to collect transient acoustic emissionsgenerated by the rapid release of energy fromlocalized sources within the material beingtested. Signal amplitude, frequency, and loca-tion are collected for many hours of operationat various loads or pressures. Analysis of thedata can determine if any part of the systemrequires additional nondestructive examina-tion with a more sensitive test method.

RB-3200 TESTING

All testing should be performed by experi-enced personnel using written proceduresacceptable to the Inspector.

RB-3210 PRESSURE TESTING

During an inspection of a pressure-retainingitem, there may be certain instances where

inservice conditions have adversely affectedthe tightness of the component or the inspec-tion discloses unusual, hard to evaluate formsof deterioration that may affect the safety ofthe vessel. In these specific instances, a pres-sure test using air, water, or other suitable testmedium may be required at the discretion ofthe Inspector to assess leak tightness of thepressure-retaining item.

The Inspector is cautioned that a pressure testwill not provide any indication of the amount

of remaining service life or the future reliabil-ity of a pressure-retaining item. The pressuretest in this instance only serves to determineif the pressure-retaining item contains defectsthat will not allow the item to retain pressure.In certain instances, pressure tests of inser-vice components may reduce the remaining

service life of the component due to causingpermanent deformation of the item.

If an inservice pressure test is required, thefollowing precautions shall be met:

a. The test pressure should not exceed 90%of the set pressure of the lowest settingpressure relief device on the component toavoid damage to pressure relief devices.

b. Test pressure should be selected or adjusted in agreement between the Inspectorand the owner-user. When the original testpressure includes consideration of corro-sion allowance, the test pressure may befurther adjusted based upon the remain-ing corrosion allowance.

c. The metal temperature during a pressuretest should not be less than 60°F (16°C)unless the owner-user provides informa-tion on the toughness characteristics ofthe vessel material to indicate the accept-ability of a lower test temperature.

d. The metal temperature shall not be morethan 120°F (50°C) unless the owner-userspecifies the requirement for a higher test

temperature. If the owner-user specifies atest temperature higher than 120°F (50°C),then precautions shall be taken to affordthe Inspector close examination withoutrisk of injury.

e. When contamination of the vessel contents by any medium is prohibited or when apressure test is not practical, other testingmethods described below may be usedprovided the precautionary requirementsof the applicable section of the original

construction code or other standards arefollowed. In such cases, there shall beagreement as to the testing procedure be-tween the owner-user and the Inspector.

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RB-3220 LEAK TESTING

Leak testing for the purpose of detecting anyleakage may be performed when a pressuretest cannot be performed. Some methods ortechniques for leak testing may include bub-

ble test (direct pressure or vacuum), heliummass spectrometer, pressure change, or flowmeasurement. Use of leak test proceduresshall be in agreement between the owner-userand the Inspector. Use of written proceduresand experienced personnel is required whenperforming leak tests. The Inspector shallreview the written procedure to become fa-miliar with limitations, adequacy, methods,and acceptance standards identified.

RB-3300 MATERIAL PREPARATION –GENERAL GUIDELINES

Materials to be inspected shall be suitablyprepared so surface irregularities will not beconfused with or mask any defects. Materialconditioning such as cleaning, buffing, wire brushing, or grinding may be required byprocedure or, if requested, by the Inspector.Insulation or component parts may be re-quired by the Inspector to be removed.

RB-4000 CAUSES OF DETERIORATION AND

FAILURE MECHANISMS

RB-4010 SCOPE

This section describes causes of deteriorationsuch as corrosion and erosion and failuremechanisms such as cracking, fatigue, creep,

and temperature gradients that are applicableto pressure-retaining items. Further informa-tion concerning metallurgical properties ofsteels and nonferrous alloys are describedin ASME Section II, Part D, of the Boiler andPressure Vessel Code, Appendix 6, titled Met-allurgical Phenomena.

RB-4020 GENERAL

All metals and alloys are susceptible to cor-rosion. Corrosion is deterioration that occurswhen a metal reacts with its environment.Corrosion can be classified based on three

factors:

a. Nature wet – liquid or moisture present dry – high temperature gasses

b. Mechanism – electrochemical or directchemical reactions

c. Appearance – either uniform or local-ized

RB-4100 CORROSION

RB-4110 MACROSCOPIC CORROSION ENVIRONMENTS

Macroscopic corrosion types are among themost prevalent conditions found in pressure-retaining items causing deterioration. The

following corrosion types are found.

a. Uniform Corrosion (General) The most common form of corrosion is

the uniform attack over a large area of themetal surface. Safe working pressure isdirectly related to the remaining materialthickness and failures can be avoided byregular inspection.

b. Galvanic Corrosion Two dissimilar metals in contact with each

other and with an electrolyte (i.e., a filmof water containing dissolved oxygen,nitrogen, and carbon dioxide) constitute

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RB-4120 MICROSCOPIC CORROSIONENVIRONMENTS

Microscopic corrosion environments are notvisible to the naked eye. The following cor-rosion types are among the most prevalent

conditions found in pressure-retaining itemscausing deterioration.

a. Intergranular CorrosionCorrosion attack by a corrodent is usu-ally relating to the segregation of specificelements or the formation of a compoundin the grain boundary. It usually attacksthe grain boundary that has lost an ele-ment necessary for adequate corrosionresistance. In severe cases entire grainsare dislodged causing the surface to ap-pear rough to the naked eye and will feelsugary because of the loose grains. Sus-ceptibility to intergranular corrosion isusually a by-product of heat treatment.

b. Stress Corrosion Cracking The action of tensile stress and a corrodent

results in the cracking of metals. This ismost serious because periods of time (of-ten years) may pass before cracks become

visible. The cracks then propagate quiterapidly and result in unexpected failures.Stresses that cause cracking arise fromcold working, welding, thermal treatment,or may be externally applied during ser-vice. The cracks can follow intergranularor transgranular paths and often have atendency for branching.

The principal variables affecting stress cor-rosion cracking are tensile stress, servicetemperature, solution chemistry, dura-

tion of exposure, and metal properties.Modifying any one of these parameterssufficiently can reduce or eliminate thepossibility of stress corrosion cracking oc-curring in service. As an example, austen-

itic stainless steels used in water wettedservice are susceptible to stress corrosioncracking.

c. Corrosion Fatigue This is a special form of stress corrosion

cracking caused by repeated cyclic stress-ing. When fatigue is in the presence of acorrodent, the resulting failure is corro-sion fatigue. Such failures are commonto pressure-retaining items subjected tocontinued vibration.

RB-4200 CONTROL OF CORROSION

There are many ways to control and avoidcorrosion such as control of process variables,engineering design, protection, material selec-tion, and coatings.

RB-4210 PROCESS VARIABLES

Some of the more common process variablesthat influence corrosion are listed below:

• Concentration of major constituents• Impurities

• Temperature• pH• Velocity• Inhibitors• Start-up and downtime operations

RB-4220 ENGINEERING DESIGN

Crevice, galvanic, erosion, and stress corro-sion cracking are the types of corrosion mostcontrollable by proper design of equipment.

Procedures and situations such as welding,end-grain attack, and drainage are also con-trolled by proper design techniques.

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RB-4230 PROTECTION

Protective methods such as cathodic andanodic corrosion control can minimize at-tack and thereby reduce replacement costsor permit the use of less expensive or thinner

materials.

RB-4240 MATERIAL SELECTION

Chemical and physical properties of a mate-rial will enable selection of the best one for aspecific application. The final choice will often be a compromise between the desired physi-cal properties and economic factors. A check-list for material selection would include:

• Evaluating requirements to be met (prop-erties, design, appearance, mechanical,physical)

• Material selection considerations• Corrodent variables• Application of equipment• Experience of materials

RB-4250 COATINGS

Metallic and inorganic materials are typicalcoatings for controlling corrosion. Selection ofmaterials depends on the corrodent, methodof application, type of base material, and thenature of bonding between the base materialand coating. The success or failure of a coatingwill often depend on the surface preparation.Techniques for applying metallic coatingscould include:

• Hot dipping• Metal spraying

• Cladding• Cementation• Vapor deposition• Electroplating• Plating• Welding

Inorganic coatings would include:

• Porcelain, ceramic• Glass• Cement• Rubber

• Paint• Phosphates

RB-4300 CONCLUSION

By carefully selecting materials and protectionmethods, we can predict and control corrosiveattack. However, there may be unexpectedfailures as a result of one or more of the fol-lowing:

• Poor choice of materials• Operating conditions different from those

anticipated• Defective fabrication• Improper design• Inadequate maintenance• Defective material

Corrective actions will depend on which fac-tors caused the problems making it importantto diagnose the reason for failure. Early de-

tection of corrosion problems is important toprevent failures and can be achieved by per-forming regular inspections and encouragingemployees to be observant and communicatetheir observations.

RB-4400 FAILURE MECHANISMS

RB-4410 FATIGUE

Stress reversals (such as cyclic loading) inparts of equipment are common, particularlyat points of high secondary stress. If stressesare high and reversals frequent, failure of partsmay occur because of fatigue. Fatigue failuresin pressure vessels may also result from cyclic

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temperature and pressure changes. Locationswhere metals having different thermal coef-ficients of expansion are joined by weldingmay be susceptible to thermal fatigue.

RB-4420 CREEP

Creep may occur if equipment is subjectedto temperatures above those for which theequipment is designed. Since metals becomeweaker at higher temperatures, such distor-tion may result in failure, particularly atpoints of stress concentration. If excessivetemperatures are encountered, structuralproperty and chemical changes in metalsmay also take place, which may permanentlyweaken equipment. Since creep is dependenton time, temperature and stress, the actual orestimated levels of these quantities should beused in any evaluations.

RB-4430 TEMPERATURE

At subfreezing temperatures, water and somechemicals handled in pressure vessels mayfreeze and cause failure. Carbon and low alloysteels may be susceptible to brittle failure at

ambient temperatures. A number of failureshave been attributed to brittle fracture of steelsthat were exposed to temperatures below theirtransition temperature and that were exposedto pressures greater than 20% of the requiredhydrostatic test pressure. However, most brittle fractures have occurred on the firstapplication of a particular stress level (that is,the first hydrostatic test or overload). Specialattention should be given to low alloy steels because they are prone to temper embrittle-ment. Temper embrittlement is defined as a

loss of ductility and notch toughness due topostweld heat treatment or high temperatureservice, above 700°F (370°C).

RB-4440 HYDROGEN EMBRITTLEMENT

The term hydrogen embrittlement (HE) refersto a loss of ductility and toughness in steelscaused by atomic hydrogen dissolved in the

steel. Hydrogen that is dissolved in carbonand low alloy steels from steel making,welding, or from surface corrosion can causeeither intergranular or transgranular crack-ing and “brittle” fracture behavior, withoutwarning.

Hydrogen embrittlement typically occurs below 200°F (95°C) because hydrogen re-mains dissolved within the steel at or belowthis temperature. One example of hydrogenembrittlement is underbead cracking. Theunderbead cracks are caused by the absorp-tion of hydrogen during the welding processin the hard, high strength weld heat affectedzone (HAZ). Use of low hydrogen weldingpractices to minimize dissolved hydrogenand/or the use of high preheat, and/or postweld heat treatment can reduce susceptibilityto cracking from hydrogen embrittlement.The diffusivity of hydrogen is such that attemperatures above 450°F (230°C), the hydro-gen can be effectively removed eliminating

susceptibility to cracking. Thus, hydrogenembrittlement may be reversible as long as nophysical damage (e.g., cracking or fissures),has occurred in the steel.

It has been reported that hydrogen embrittle-ment is a form of stress corrosion cracking(SCC). Three basic elements are needed toinduce SCC; the first element is a susceptiblematerial, the second element is environment,and the third element is stress (applied or re-sidual). For hydrogen embrittlement to occur,

the susceptible material is normally higherstrength carbon or low alloy steels, the envi-ronment must contain atomic hydrogen, andthe stress can be either service stress and/orresidual stress from fabrication. If any of thethree elements are eliminated, HE crackingis prevented.

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In environments where processes are con-ducted at elevated temperature, the reactionof hydrogen with sulfur in carbon and low al-loy reactor vessel steels can produce hydrogensulfide stress corrosion (SSC), which is a formof hydrogen embrittlement. Susceptibility

to sulfide stress corrosion cracking dependson the strength of the steel. Higher strengthsteels are more susceptible. The strength levelat which susceptibility increases depends onthe severity of the environment. Hydrogensulfide, hydrogen cyanide, and arsenic inaqueous solutions, all increase the severity ofthe environment towards hydrogen embrittle-ment by increasing the amount of hydrogenthat can be absorbed by the steel during thecorrosion reaction. In hydrogen sulfide envi-ronments, susceptibility to cracking can bereduced by using steels with a strength level below that equivalent to a hardness of 22 onthe Rockwell C scale.

Other forms of hydrogen embrittlement arewet H2S cracking, hydrogen stress cracking,hydrogen-induced cracking (HIC), and stressoriented hydrogen induced cracking (SOHIC).In each case, three basic elements are requiredfor this damage mechanism — susceptiblematerial, hydrogen generating environments,

and stress (either residual or applied). Organicor inorganic coatings, alloy cladding or lin-ings, are often used as a barrier to mitigatewet H2S corrosion and subsequent cracking.

RB-4450 HIGH TEMPERATUREHYDROGEN ATTACK

Hydrogen attack occurs in a high tempera-ture, high pressure hydrogen environmentthat can degrade the mechanical strength of

carbon and low alloy steels. The damage iscaused by hydrogen permeating into the steeland reacting with carbon to form methane.Since carbon is an element that strengthenssteel, its removal by the high temperature re-action with hydrogen causes the steel to loosestrength. In addition, methane can become

trapped within the steel at high pressures,eventually forming bubbles, fissures (cracks),and/or blisters.

Damage caused by hydrogen attack is pre-ceded by an incubation period with no notice-

able change in properties. After the incubationperiod, decarburization and/or blistering andfissuring will occur. The length of the incuba-tion period varies with service temperature,the partial pressure of hydrogen, and alloycontent of the steel. Damage is reversibleduring the incubation period, during whichno loss of mechanical properties will have oc-curred. Once permanent degradation begins,the damage is irreversible.

Hydrogen attack is a concern primarily inrefinery and petrochemical plant equipmenthandling hydrogen and hydrogen-hydro-carbon streams at temperatures above 450°F(230°C) and pressure above 100 psi (700 kPa).A guideline for selection of steels to avoid hy-drogen attack is given in API Publication 941,“Steels for Hydrogen Service at Elevated Tempera-tures and Pressures in Petrochemical Refineriesand Petrochemical Plants.” Also widely knownas the “Nelson Curves”, API 941 shows thatthe severity of hydrogen attack depends

on temperature, hydrogen partial pressure,exposure time, and steel composition. Addi-tions of chromium and molybdenum increaseresistance to hydrogen attack.

It is important to understand that hydrogenattack is different from hydrogen embrittle-ment, which is discussed in RB-4440.

RB-4451 HYDROGEN DAMAGE

Hydrogen damage has been encountered insteam boilers that operate in the high pres-sure range (1200 psi [8MPa] or higher), withrelatively high purity boiler feed water. In boilers, the mechanism of hydrogen dam-age is initiated by underdeposit corrosion onwater-touched surfaces. During operation

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of the boiler, waterwall tubing exposed tohigh heat flux can result in a departure fromnucleate boiling (DNB) condition on the ID(waterside) surface due to small flow distur- bances. Because of the increased tube metaltemperature, low levels of contaminants inthe boiler feedwater precipitate (e.g., plateout) on the hot tube surface. The intermittentwetting from flow, over time, results in theaccumulation of deposits.

As the deposit begins to thicken, the tubemetal beneath the deposit locally increasesin temperature causing oxidation of the tubemetal. The oxidation/reduction corrosionmechanism creates atomic hydrogen whichpermeates into the tube wall at boiler pres-

sures greater than 1200 psig (8MPa).

The atomic hydrogen reacts with the carbonin the steel forming methane gas that resultsin microfissures at grain boundaries anddecarburization. The combination of decarburization and microcracks increases thesusceptibility to brittle fracture in service. Thetypical appearance of hydrogen damage in boiler tubes is a thick-lipped, “window-type” blow out of tube metal.

Hydrogen damage in copper and copper al-loys has also been observed and is sometimesknown as steam embrittlement. This type ofdamage commonly occurs when the coppercontains oxygen. Hydrogen entering themetal reacts with the oxygen to form water.At certain combinations of pressures andtemperatures steam forms and the pressuregenerated is sufficient to produce micro-cavityformation and cracking.

RB-4460 BULGES AND BLISTERS

a. A bulge may be caused by overheating ofthe entire thickness of the metal, therebylowering the strength of the metal whichis then deformed by the pressure. Bulgesmay also be caused by creep or tempera-ture gradients.

b. A blister may be caused by a defect inthe metal such as a lamination where theside exposed to the fire overheats butthe other side retains its strength due tocooling effect of water or other medium.Blisters may also be caused by a hydrogen

environment (see RB-4450).

RB-4470 OVERHEATING

Overheating is one of the most serious causesof deterioration. Deformation and possiblerupture of pressure parts may result.

Particular attention should be given to sur-faces exposed to fire. It should be observedwhether any part has become deformed dueto bulging or blistering. If a bulge or blisterreduces the integrity of the component orwhen evidence of leakage is noted comingfrom those defects, proper repairs must bemade.

RB-4480 CRACKS

Cracks may result from flaws existing in mate-rial. The design and operating conditions may

also cause cracking. Cracking can be caused by fatigue of the metal due to continual flex-ing and may be accelerated by corrosion. Firecracks are caused by the thermal differentialwhen the cooling effect of the water is notadequate to transfer the heat from the metalsurfaces exposed to the fire. Some cracks re-sult from a combination of all these causesmentioned.

Cracks noted in shell plates and fire cracksthat run from the edge of the plate into the

rivet holes of girth seams should be repaired.Thermal fatigue cracks determined by engi-neering evaluation to be self arresting may be left in place.

Areas where cracks are most likely to appearshould be examined. This includes the liga-ments between tube holes, from and betweenrivet holes, any flange where there may be

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repeated flexing of the plate during operationand around welded connections.

Lap joints are subject to cracking where theplates lap in the longitudinal seam. If thereis any evidence of leakage or other distress

at this point, the Inspector shall thoroughlyexamine the area and, if necessary, have theplate notched or slotted in order to determinewhether cracks exist in the seam. Repairs oflap joint cracks on longitudinal seams areprohibited.

Where cracks are suspected, it may be neces-sary to subject the pressure-retaining itemto nondestructive examination to determinetheir location.

RB-4500 SPECIFIC INSPECTION REQUIREMENTS

Specific inspection requirements for pressure-retaining items to determine corrosion dete-rioration and possible prevention of failuresare identified in RB-5000 for boilers, RB-6000 for pressure vessels, and RB-7000 f or piping.

RB-5000 INSPECTION OF BOILERS

RB-5010 SCOPE

This section provides guidelines for externaland internal inspection of boilers used to con-tain pressure. This pressure may be obtainedfrom an external source or by the applicationof heat from a direct or indirect source or acombination thereof.

RB-5100 GENERAL CONDITIONS

Boilers are designed for a variety of serviceconditions. The temperature and pressureat which they operate should be consideredin establishing inspection criteria. This partis provided for guidance of a general nature.

There may be occasions where more detailedprocedures will be required.

The condition of the complete installation, in-cluding maintenance and operation, can often be used by the Inspector as a guide in forming

an opinion of the care given to the boiler.

Usually the conditions to be observed by theInspector are common to both power andheating boilers, however, where appropriate,the differences are noted.

RB-5200 PRE-INSPECTION ACTIVITIES

A review of the known history of the boilershall be performed. This shall include a reviewof information contained in RB-2000 and otheritems listed below.

RB-5300 CONDITION OF INSTALLATION

RB-5310 GENERAL

The general condition of the boiler roomor boiler location should be assessed usingappropriate jurisdictional requirements andoverall engineering practice. Items that areusually considered are lighting, adequacy ofventilation for habitability, combustion air,housekeeping, personal safety, and generalsafety considerations.

RB-5400 INSPECTIONS

RB-5410 EXTERNAL INSPECTION

The external inspection of a boiler is madeto determine if it is in a condition to operatesafely. Some items to consider are:

a. The boiler fittings, valves, and pipingshould be checked for compliance with

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ASME Code or other standards or equiva-lent requirements;

b. Adequacy of structure, boiler supports,and any associated support steel;

c. Boiler casing should be free from cracks,combustion gas, or fluid leaks, excessivecorrosion or other degradation that couldinterfere with proper operation;

d. Soot blowers, valving, and actuatingmechanisms;

e. Gaskets on observation doors, accessdoors, drums, handhole and manholecovers and caps;

f. Valves and actuators, either chains, motorsand/or handwheels;

g. Leakage of fluids or combustion gases.

RB-5420 INTERNAL INSPECTION

When a boiler is to be prepared for internalinspection, the water shall not be withdrawnuntil the setting has been sufficiently cooled at

a rate to avoid damage to the boiler as well asadditional preparations identified in RB-2120 and RB-2210.

The owner or user shall prepare a boiler forinternal inspection in the following manner:

Before opening the manhole(s) and enter-ing any part of the boiler that is connectedto a common header with other boilers, therequired steam or water system stop valves(including bypass) must be closed, locked

out, and/or tagged in accordance with theowner-user’s procedures and drain valves orcocks between the two closed stop valves beopened. After draining the boiler, the blowoffvalves shall be closed, locked out, and/ortagged out in accordance with the owner-user’s procedures. Alternatively, lines may be blanked or sections of pipe removed. Blowofflines, where practicable, shall be disconnected

between pressure parts and valves. All drainsand vent lines shall be open.

The Inspector shall review all personnel safetyrequirements as outlined in RB-2000 prior toentry.

NOTE: If a boiler has not been properly pre-pared for an internal inspection, the inspectorshall decline to make the inspection.

RB-5430 EVIDENCE OF LEAKAGE

It is not normally necessary to remove in-sulating material, masonry, or fixed partsof a boiler for inspection, unless defects ordeterioration are suspected or are commonlyfound in the particular type of boiler beinginspected. Where there is evidence of leak-age showing on the covering, the Inspectorshall have the covering removed in orderthat a thorough inspection of the area may bemade. Such inspection may require removalof insulating material, masonry, or fixed partsof the boiler.

For additional information regarding a leakin a boiler or the extent of a possible defect, a

pressure test may be required.

a. To determine tightness, the test pressureneed be no greater than the maximumallowable working pressure stamped onthe pressure-retaining item.

b. During a pressure test where the test pres-sure will exceed 90% of the set pressureof a pressure relief device, the device shall be removed whenever possible. If notpossible or practical, a spindle restraint

such as a gag may be used provided thatthe valve manufacturer’s instructions andrecommendations are followed. Extremecaution should be employed to ensureonly enough force is applied to containpressure. Excessive mechanical force ap-plied to the spindle restraint may resultin damage to the seat and/or spindle andmay interfere with the proper operation

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of the valve. The spindle restraint shall be removed following the test.

The organization who performs the pres-sure test and applies a spindle restraintshall attach a metal tag that identifies the

organization and date the work was per-formed to the pressure-relieving device. Ifthe seal was broken, the organization shallreseal the adjustment housing with a sealthat identifies the responsible organiza-tion. The process shall be acceptable to the jurisdiction where the pressure-retainingitems are installed.

c. The temperature of the water used to ap-ply a pressure test should not be less than70°F (20°C) and the maximum tempera-ture during inspection should not exceed120°F (50°C). A lower water temperaturecould be used if the owner can provide in-formation on the toughness characteristicsof the material to indicate acceptability ofthe lower test temperature.

d. Hold-time for the pressure test shall be 10minutes prior to the examination by theInspector.

e. Hold-time for the examination by theInspector shall be the time necessary forthe Inspector to conduct the inspections.

f. When the introduction of water for ahydrostatic test will cause damage to a boiler or boiler component, other testingmedia or vacuum testing may be usedprovided the precautionary requirementsof the applicable section of the originalcode of construction or other standardsare followed. In such cases, there shall

be agreement as to the testing procedure between the owner and the Inspector.

RB-5500 INSPECTION REQUIREMENTS — GENERAL (See RB-4000)

RB-5510 CORROSION

Corrosion causes deterioration of the metalsurfaces. It can affect large areas or it can be localized in the form of pitting. Isolated,shallow pitting is not considered serious if

not active.

The most common causes of corrosion in boilers are the presence of free oxygen anddissolved salts in the feedwater. Where activecorrosion is found, the Inspector should advisethe owner or user to obtain competent adviceregarding proper feedwater treatment.

For the purpose of estimating the effect ofsevere corrosion over large areas on the safeworking pressure, the thickness of the remain-ing sound metal should be determined byultrasonic examination or by drilling.

Grooving is a form of metal deteriorationcaused by localized corrosion and may beaccelerated by stress concentration. This is es-pecially significant adjacent to riveted joints.

All flanged surfaces should be inspected,particularly the flanges of unstayed heads.Grooving in the knuckles of such heads is

common since there is slight movement inheads of this design which causes a stressconcentration.

Some types of boilers have ogee or reversed-flanged construction which is prone to groov-ing and may not be readily accessible forexamination. The Inspector should insert amirror through an inspection opening to ex-amine as much area as possible. Other meansof examination such as the ultrasonic methodmay be employed.

Grooving is usually progressive and when it isdetected, its effect should be carefully evalu-ated and corrective action taken.

The fireside surfaces of tubes in horizontalfiretube boilers usually deteriorate more rap-idly at the ends nearest the fire. The Inspectorshould examine the tube ends to determine if

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there has been serious reduction in thickness.The tube surfaces in some vertical tube boilersare more susceptible to deterioration at theupper ends when exposed to the heat of combustion. These tube ends should be closelyexamined to determine if there has been aserious reduction in thickness. The upper tubesheet in a vertical “dry top” boiler should beinspected for evidence of overheating.

Pitting and corrosion on the waterside sur-faces of the tubes should be examined. Invertical firetube boilers, excessive corrosionand pitting is often noted at and above thewater level.

The surfaces of tubes should be carefully ex-

amined to detect corrosion, erosion, bulges,cracks, or evidence of defective welds. Tubesmay become thinned by high velocity im-pingement of fuel and ash particles or by theimproper installation or use of soot blowers.A leak from a tube frequently causes seriouscorrosion or erosion on adjacent tubes.

In restricted fireside spaces, such as whereshort tubes or nipples are used to join drumsor headers, there is a tendency for fuel and ashto lodge at junction points. Such deposits are

likely to cause corrosion if moisture is presentand the area should be thoroughly cleanedand examined.

RB-5520 INSPECTION OF PIPING,PARTS, AND

APPURTENANCES

RB-5521 BOILER PIPING

Piping should be inspected in accordancewith RB-7000.

RB-5522 WATERSIDE DEPOSITS

All accessible surfaces of the exposed metal onthe waterside of the boiler should be inspectedfor deposits caused by water treatment, scale,

oil or other substances. Oil or scale in the tubesof watertube boilers is particularly detrimen-tal since this can cause an insulating effectresulting in overheating, weakening, and pos-sible metal fatigue by bulging or rupture.

Excessive scale or other deposits should beremoved by chemical or mechanical means.

RB-5523 STAYS AND STAYBOLTS

All stays, whether diagonal or through,should be inspected to determine whetheror not they are in even tension. Staybolt endsand the stayed plates should be examined todetermine whether cracks exist. In addition,stayed plates should be inspected for bulgingin the general area of the stay. Each stayboltend should be checked for excessive coldworking (heading) and seal welds as evidenceof a possible leakage problem. Stays or staybolts that are not in tension or adjustmentshould be repaired. Broken stays or stayboltsshall be replaced.

The Inspector should test firebox staybolts bytapping one end of each bolt with a hammerand, where practicable, a hammer or other

heavy tool should be held on the opposite endto make the test more effective. An unbroken bolt should give a ringing sound while a bro-ken bolt will give a hollow or non-responsivesound. Staybolts with telltale holes should be examined for evidence of leakage, whichwill indicate a broken or cracked bolt. Brokenstaybolts shall be replaced.

RB-5524 FLANGED OR OTHER CONNECTIONS

The manhole and reinforcing plates, as wellas nozzles or other connections flanged or bolted to the boiler, should be examined forevidence of defects both internally and exter-nally. Whenever possible, observation should be made from both sides, internally and exter-nally, to determine whether connections areproperly made to the boiler.

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All openings leading to external attachments,such as water column connections, low waterfuel cut-off devices, openings in dry pipes, andopenings to safety valves, should be examinedto ensure they are free from obstruction.

RB-5525 MISCELLANEOUS

The piping to the water column should becarefully inspected to ensure that watercannot accumulate in the steam connection.The position of the water column should be checked to determine that the column isplaced in accordance with ASME Code orother standard or equivalent requirements.

The gas side baffling should be inspected.The absence of the proper baffling or defec-tive baffling can cause high temperatures andoverheat portions of the boiler. The locationand condition of combustion arches should bechecked for evidence of flame impingement,which could result in overheating.

Any localization of heat caused by improperor defective installation or improper operationof firing equipment should be corrected beforethe boiler is returned to service.

The refractory supports and settings should be carefully examined, especially at pointswhere the boiler structure comes near thesetting walls or floor, to ensure that depositsof ash or soot will not bind the boiler and pro-duce excessive strains on the structure due tothe restriction of movement of the parts underoperating conditions.

When tubes have been rerolled or replaced,they should be inspected for proper work-

manship. Where tubes are readily accessible,they may have been over rolled. Conversely,when it is difficult to reach the tube ends theymay have been under rolled.

Drums and headers should be inspected in-ternally and externally for signs of leakage,corrosion, overheating, and erosion. Inspect blowdown piping and connections for expan-

sion and flexibility. Check header seals forgasket leakage.

Soot blower mechanical gears, chains, pul-leys, etc., should be checked for broken orworn parts. Inspect supply piping to the

soot blowers for faulty supports, leakage,and expansion and contraction provisions.Check design for proper installation to allowfor complete drainage of condensate, whichmay cause erosion.

Valves should be inspected on boiler feedwa-ter, blowdown, drain, and steam systems forgland leakage, operability, tightness, handle,or stem damage, body defects and generalcorrosion.

RB-5526 GAGES

Ensure that the water level indicated is correct by having the gage tested as follows:

a. Close the lower gage glass valve, thenopen the drain cock and blow the glassclear.

b. Close the drain cock and open the lower

gage glass valve. Water should return tothe gage glass immediately.

c. Close the upper gage glass valve, thenopen the drain cock and allow the waterto flow until it runs clean.

d. Close the drain cock and open the uppergage glass valve. Water should return tothe gage glass immediately.

If the water return is sluggish, the test should

be discontinued. A sluggish response couldindicate an obstruction in the pipe connec-tions to the boiler. Any leakage at these fit-tings should be promptly corrected to avoiddamage to the fittings or a false waterlineindication.

Each hot water boiler should be fitted with atemperature gage at or near the boiler outlet

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that will at all times indicate the water tem-perature.

Where required, all the pressure gages shall be removed, tested, and their readings com-pared to the readings of a standard test gage

or a dead weight tester.

The location of a steam pressure gage should be noted to determine whether it is exposedto high temperature from an external sourceor to internal heat due to lack of protection bya proper siphon or trap. The Inspector shouldcheck that provisions are made for blowingout the pipe leading to the steam gage.

The pressure indicated on the pressure gageshould be compared with other gages on thesame system or with a standard test gage, ifnecessary. The Inspector should observe thereading during tests; for example, the reduc-tion in pressure when testing the low waterfuel cutoff control or safety valve on steam boilers. Defective gages should be promptlyreplaced.

RB-5527 PRESSURE RELIEF DEVICES

See RB-8000 for the inspection of safety de-vices (pressure relief valves) used to preventoverpressure of boilers.

RB-5528 CONTROLS

Verify operation of low water protectiondevices by observing the blowdown of thesecontrols or the actual lowering of boiler waterlevel under carefully controlled conditionswith the burner operating. This test should

shut off the heat source to the boiler. The re-turn to normal condition such as the restartof the burner, the silencing of an alarm orstopping of a feed pump should be noted. Asluggish response could indicate an obstruc-tion in the connections to the boiler.

The operation of a submerged low water fuelcutoff mounted directly in a steam boiler shellshould be tested by lowering the boiler water

level carefully. This should be done only after being assured that the water level gage glassis indicating correctly.

On a high-temperature water boiler, it is oftennot possible to test the control by cutoff indica-

tion, but where the control is of the float type,externally mounted, the float chamber should be drained to check for the accumulation ofsediment.

In the event controls are inoperative or thecorrect water level is not indicated, the boilershould be taken out of service until the unsafecondition has been corrected.

All automatic low water fuel cut-off andwater feeding devices should be examined by the Inspector to ensure that they are prop-erly installed. The Inspector should have thefloat chamber types of control devices disas-sembled and the float linkage and connectionsexamined for wear. The float chamber should be examined to ensure that it is free of sludgeor other accumulation. Any necessary correc-tive action should be taken before the device isplaced back into service. The Inspector shouldcheck that the operating instructions for thedevices are readily available.

Check that the following controls/devicesare provided:

a. Each automatically fired steam boiler isprotected from over pressure by not lessthan two pressure operated controls, oneof which may be an operating control.

b. Each automatically fired hot water boileris protected from over-temperature bynot less than two temperature operated

controls, one of which may be an operat-ing control.

c. Each hot water boiler is fitted with a ther-mometer that will, at all times, indicate thewater temperature at or near the boileroutlet.

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RB-5529 RECORDS REVIEW

A review of the boiler log, records of main-tenance and feedwater treatment should bemade by the Inspector to ensure that regularand adequate tests have been made on the

boiler and controls.

The owner or user should be consulted re-garding repairs or alterations, if any, whichhave been made since the last inspection. Suchrepairs or alterations should be reviewed forcompliance with the jurisdictional require-ments, if applicable.

RB-5600 SPECIFIC INSPECTION REQUIREMENTS FOR

BOILER TYPES

The following details are unique to specifictype boilers and should be considered whenperforming inspections along with the generalrequirements as previously outlined.

RB-5601 WATERTUBE BOILERS

Typically constructed of drums, headers, and

tubes, boilers of this type are used to producesteam or hot water commonly in large quan-tities. They range in size and pressure fromsmall package units to extremely large fielderected boilers with pressures in excess of3000 psig (20 MPa gage). These boilers may be fired by many types of fuels such as wood,coal, gas, oil, trash, and black liquor.

There are many locations both internal andexternal where moisture and oxygen combine causing primary concern for corrosion.

The fuels burned in this type of boiler maycontain ash, which can form an abrasive gritin the flue gas stream. The abrasive action ofthe ash in high velocity flue gas can quicklyerode boiler tubes. Their size and type ofconstruction poses mechanical and thermalcyclic stresses.

Unique parts associated with this type of con-struction such as casing, expansion supports,superheater, economizer, soot blowers, drums,headers, and tubes should be inspected care-fully and thoroughly in accordance withRB-5500 , as applicable.

RB-5602 BLACK LIQUOR (KRAFT ORSULFATE) RECOVERYBOILERS

Boilers of this type are used in the pulp andpaper industry. Black liquor is a by-productof pulping processing. It contains organicand inorganic constituents and is concen-trated from about 10% solids to at least 58%solids for firing in the recovery boilers. Theorganic material that is dissolved in the pulp-ing process combusts and the spent pulpingchemicals form a molten pool in the furnace.The molten material, or “smelt,” drains fromthe furnace wall through smelt spouts intoa smelt dissolving tank for recovery of thechemicals. Ultimately, the by-product of therecovery process is steam used for processingand power. Gas or oil auxilliary burners areused to start the self-sustaining black liquorcombustion process and may be used to pro-

duce supplemental steam if sufficient liquoris not available.

The recovery combustion process requires areducing atmosphere near the furnace floorand an oxidizing atmosphere in the upperfurnace for completion of combustion. Pres-sure parts within the furnace require protec-tion from the reducing atmosphere and fromsulfidation. The rate of corrosion within thefurnace is temperature dependent. Boilersoperating up to 900 psi (6 MPa) typically have

plain carbon steel steam generating tubeswith pin studs applied to the lower furnace toretain a protective layer of refractory or “fro-zen” smelt. Above 900 psi (6 MPa) the lowerfurnace tubes will typically have a specialcorrosion protection outer layer. The mostcommon is a stainless steel clad “composite

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tube.” Other protection methods are corrosionresistant overlay welding, thermal or plasmaspray coating, and diffusion coating.

The unique hazard of these boilers is thepotential for an explosion if water should be

combined with the molten smelt. The primarysource of water is from pressure part failure,permitting water to enter the furnace. Theowner’s inspection program is carefully de-veloped and executed at appropriate intervalsto avoid pressure part failure that could admitwater to the furnace. A second source of wa-ter is the liquor fuel. Permitting black liquorof 58% or lower solids content to enter thefurnace can also result in an explosion. The black liquor firing controls include deviceswhich monitor and automatically divert theliquor from the furnace if solids content is58% or lower.

In addition to the general inspection re-quirements for all watertube-type boilers,particular awareness in the following areasis necessary:

• Furnace — the type and scope of wall,roof, and water screen tube inspection isdependent on materials of construction,

type of construction, and mode of boileroperation. In all cases, furnace wall open-ing tubes need inspection for thinning andcracking. The typical water-cooled smeltspout can admit water to the furnace if thespout fails. Common practice is to replacethese spouts in an interval shorter thanthat in which failure is known to occur.

• Water — percentage of solids contained inthe black liquor before entering the fur-nace should be closely monitored. Verify

that the black liquor firing system willautomatically divert the liquor if solidsdrop to or below 58%.

• Corrosion/erosion — the potential conse-quences of corrosion or erosion (smelt-water explosion due to pressure-retain-ing part failure) requires a well plannedand executed inspection program by the

owner. Maintenance of boiler water qual-ity is crucial to minimizing tube failureoriginating from the water side.

• Tubes — depending on type of construc-tion, inspect for damage such as loss of

corrosion protection, thinning, erosion,overheating, warping, elongation, bulg-ing, blistering, and misalignment. If floortubes may have been mechanically dam-aged or overheated, clean the floor andperform appropriate type of inspection forsuspected damage. Excursions in watertreatment may result in scale and sludgeon internal surfaces, creating conditions ofpoor heat transfer and ultimately causingcrack or rupture of tube.

• Welds — leaks frequently originate atwelds. The owner and repair agencyshould carefully plan and inspect all re-pair welds that could admit water to thefurnace. Tube butt welds that could admitwater to the furnace should be examined by a volumetric NDE method acceptableto the inspector. Tube leaks at attachmentwelds may originate from the internalstress-assisted corrosion (SAC). Minor up-sets in boiler water quality and improper

chemical cleaning may initiate SAC.

• Emergency Response to Water Entering Fur-nace — operators of Kraft recovery boilersshould have a plan to immediately termi-nate all fuel firing and drain water fromthe boiler if a tube is known or suspectedto be leaking into the furnace. This systemmay be called “Emergency Shutdown Pro-cedure” or “ESP.” The inspector shouldconfirm the ESP is tested and maintainedsuch that it will function as intended and

that operators will activate the systemwhen a leak into the furnace occurs or issuspected.

• Overheating — tube rupture due to over-heating from low water level may admitwater to the furnace. The inspector shouldverify a redundant low-water protectionscheme is provided and maintained.

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Recommended procedures for inspection of black liquor recovery boilers are identified below:

• American Forest and Paper Association “Recovery Boiler Reference Manual for Own-

ers and Operators of Kraft Recovery Boilers ,”sponsored by the Operations/Mainte-nance Subcommittee of the RecoveryBoiler Committee, Volumes I (revised June1991), II (revised June 1991), and III (firstedition October 1984.)

• The Black Liquor Recovery Boiler Adviso-ry Committee, Recommended Practices:– Emergency Shutdown Procedure

(ESP) and Procedure for Testing ESP

– Safe Firing of Black Liquor RecoveryBoilers– System for Black Liquor Boilers– Safe Firing of Black Liquor in Black

Liquor Recovery Boilers– Safe Firing of Auxilliary Fuel in Black

Liquor Recovery Boilers– Thermal Oxidation of Waste Streams

in Black Liquor Recovery Boilers– Instrumentation Checklist and Clas-

sification Guide for Instruments andControl Systems used in the Operation

of Black Liquor Recovery Boilers– Recommended Guidelines for Person-nel Safety

• Technical Association of the Pulp & PaperIndustry (TAPPI), Technical InformationPapers:– 0402-13, Guidelines for Specification and

Inspection of Electric Resistance Welded(ERW) and Seamless Boiler Tube for Criti-cal and Non-Critical Service

– 0402-15, Installation and Repair of Pin

Studs in Black Liquor Recovery Boilers; Part I: Guidelines for Accurate Tube

Thickness Testing Part II: Default Layouts for Tube Thick-

ness Surveys in Various Boiler Zones – 0402-21, Ultrasonic Technician Perfor-

mance Test for Boiler Tube Inspection– 0402-30, Inspection for Cracking of Com-

posite Tubes in Black Liquor RecoveryBoilers

– 0402-31, Guidelines for Evaluating theQuality of Boiler Tube Butt Welds withUltrasonic Testing

– 0402-33, Guideline for Obtaining HighQuality RadiographicTesting (RT) of ButtWelds in Boiler Tubes

RB 5603 THERMAL FLUID HEATERS

Design and Operating FeaturesThermal fluid heaters are pressure vessels inwhich a synthetic or organic fluid is heated orvaporized. The fluids are typically flammable,are heated above the liquid flash point, andmay be heated above the liquid boiling point.The heaters are commonly direct-fired bycombustion of a fuel or by electric resistanceelements. Heater design may be similar to anelectric resistance heated boiler, to a firetube boiler or, more commonly, to a watertube boiler. Depending on process heating require-ments, the fluid may be vaporized with anatural circulation, but more often, the fluid isheated and circulated by pumping the liquid.Use of thermal fluid heating permits heatingat a high temperature with a low system pres-sure [600°F to 700°F (315°C to 370°C) at pres-sures just above atmospheric]. To heat water

to those temperatures, a liquid would requirepressures of at least 1530 psig (10.6 MPa).

Nearly all thermal heating fluids are flam-mable. Leaks within a fired heater can resultin destruction of the heater. Leaks in externalpiping can result in fire and may result in anexplosion. Water accumulation in a thermalheating system may cause upsets and pos-sible fluid release from the system if the watercontacts heated fluid (Remember flashingwater expands 1600 times). It is essential for

safe system operation to have installed and tomaintain appropriate fluid level, temperatureand flow controls for liquid systems and level,temperature and pressure controls for vaporsystems.

A05

A05

A05

A05

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Because heat transfer fluids contract and be-come more viscous when cooled, proper con-trols and expansion tank venting are requiredto prevent low fluid level and collapse of thetank. Some commonly used fluids will solidifyas high as 54°F (12°C). Others do not become

solid until -40°F (-40°C) or even lower. Thefluids that become viscous will also becomedifficult to pump when cooled. Increasedviscosity could cause low flow rates throughthe heater. The heater manufacturer recom-mendations and the fluid manufacturer’sMaterial Safety Data Sheets (MSDS) should bereviewed for heat tracing requirements.

Industrial ApplicationsThermal fluid heaters, often called boilers, areused in a variety of industrial applicationssuch as resins, turpentines, various types ofchemicals, and drugs, plastics, corrugatingplants, and wherever high temperatures arerequired. They are also frequently found inasphalt plants for heating of oils, tars, as-phalt pitches and other viscous materials.Many chemical plants use this type of heaterin jacketed reactors or other types of heatexchangers.

Inspection

Inspection of thermal fluid heaters typically isdone in either the operating mode or the shut-down mode. Internal inspections, however,are rarely possible due to the characteristicsof the fluids and the need to drain and storethe fluid. Reliable and safe operation of aheater requires frequent analysis of the fluidto determine that its condition is satisfactoryfor continued operation. If the fluid begins to breakdown, carbon will form and collect onheat transfer surfaces within the heater. Over-heating and pressure boundary failure may

result. Review of fluid test results and controlsand safety device maintenance records are es-sential in determining satisfactory conditionsfor continued safe heater operation.

Due to the unique design and material consid-erations of thermal fluid heaters and vapor-izers, common areas of inspection are:

• Design – specific requirements outlinedin construction codes must be met. Some jurisdictions may require ASME SectionI or Section VIII construction. Code re-quirements for the particular jurisdictionshould be reviewed for specific design

criteria.

• Materials – for some thermal fluids, theuse of aluminum or zinc anywhere in thesystem is not advisable. Aluminum actsas a catalyst that will hasten decomposi-tion of the fluid. In addition, some fluidswhen hot will cause aluminum to corroderapidly or will dissolve zinc. The zinc willthen form a precipitate that can cause lo-calized corrosion or plug instrumentation,valves, or even piping in extreme cases.These fluids should not be used in sys-tems containing aluminum or galvanizedpipe. The fluid specifications will list suchrestrictions. Note: some manufacturers ofthese fluids recommend not using alumi-num paint on valves or fittings in the heattransfer system.

• Corrosion – when used in applicationsand installations recommended by fluidmanufacturer, heat transfer fluids are typi-

cally noncorrosive. However, some fluids,if used at temperatures above 150°F (65°C)in systems containing aluminum or zinccan cause rapid corrosion.

• Leakage – any sign of leakage could signifyproblems since the fluid or its vapors can be hazardous as well as flammable. Thethermal fluid manufacturer specificationswill list the potential hazards.

• Solidification of the fluid – determine that

no conditions exist, which would allowsolidification of the thermal fluid. Whenheat tracing or insulation on piping is rec-ommended by the heater manufacturer,the heat tracing and insulation should bechecked for proper operation and instal-lation.

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• Pressure relief devices – all pressure reliefdevices should be connected to a closed,vented storage tank or blowdown tankand must be the type with a closed-bon-net, no manual lift lever and solid pipeddischarge to an appropriately vented

receiver. If outdoor discharge is used, thefollowing should be considered for dis-charge piping at the point of discharge.

– Both thermal and chemical reactions(personnel hazard)

– Combustible materials (fire hazard)– Surface drains (pollution and fire

hazard)– Loop seal or rain cap on the discharge

(keep both air and water out of thesystem)

– Drip leg near device (prevent liquidcollection)

– Heat tracing for systems using highfreeze point fluids (prevent blockage)

RB-5604 WASTE HEAT BOILERS

Waste heat boilers are usually of firetube orwatertube type and obtain their heat from anexternal source or process in which a portion

of the BTU’s have been utilized. Generationof electrical energy is usually the primaryapplication of waste heat boilers. The biggestdisadvantage of this type of boiler is that it isnot fired on the basis of load demand. Sincethe boiler does not have effective controlover the amount of heat entering the boiler,there may be wide variations or fluctuationsof metal temperatures. Waste process gassesare usually in a temperature range of 400°F(205°C) to 800°F (425°C), where combustiongasses of conventional fired boilers are at

about 2000°F (1095°C). Special design con-siderations are made to compensate for lowercombustion gas temperatures such as the useof finned high-efficiency heat absorbing tubes,and by slowing the velocity of gasses throughthe boiler.

Due to the unique design and material consid-erations of waste heat boilers, the followingare common areas of inspection.

• Corrosion – chemicals in waste heat gassesmay create corrosive conditions and reactadversely when combined with normalgasses of combustion. Water or steamleakage can create localized corrosion.Extreme thermal cycling can cause cracks

and leakage at joints.

• Erosion – typically waste heat flow is verylow and erosion is not a problem, how-ever, when waste heat is supplied froman internal combustion engine, exhaustgasses can be high enough to cause ero-sion.

• Vibration – in some process applicationsand all engine waste heat applications, the boiler may be subjected to high vibrationstresses.

• Acid attack – in sulfuric acid processesrefractory supports and steel casings aresubject to acid attack. Piping, filters, heatexchangers, valves, fittings, and appur-tenances are subject to corrosive attacks because these parts are not normally madeof corrosion resistant materials.

• Dry operation – in certain applications

waste heat boilers are operated withoutwater. Care must be taken not to exposecarbon steel material to temperatures inexcess of 800°F (425°C) for prolonged pe-riods. Carbides in the steel may precipitateto graphite at elevated temperatures.

RB-5605 CAST-IRON BOILERS

Cast-iron boilers are widely used in a varietyof applications to produce low pressure steam

and hot water heat. Cast-iron boilers shouldonly be used in applications that allow fornearly 100% return of condensate or water,and are not typically used in process-typeservice. These boilers are designed to operatewith minimum scale, mud, or sludge, whichcould occur if makeup water is added to thissystem.

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Due to the unique design and material con-siderations of cast-iron boilers, the followingare common areas of inspection.

• Scale and sludge – since combustion occursat or near the bottom, accumulation of

scale or sludge close to the intense heatcan cause overheating and lead to crack-ing.

• Feedwater – makeup feedwater should notcome in contact with hot surfaces. Supplyshould be connected to a return pipe fortempering.

• Section alignment – misalignment of sec-tions can cause leakage. Leakage or cor-rosion between sections will not allownormal expansion and contraction whichmay cause cracking.

• Tie rods or draw rods – used to assemblethe boiler and pull the sections together.These rods must not carry any stress andneed to be loose allowing for sectiongrowth during heat up. Expansion wash-ers may be used and nuts should be justsnugged allowing for expansion.

• Push nipple or seal area – corrosion or leak-age is likely at the push nipple openingusually caused by the push nipple beingpushed into the seat crooked, warping dueto overheating, tie rods too tight, and pushnipple corrosion/erosion.

• Corrosion – fire sides of sections can cor-rode due to ambient moisture coupledwith acidic flue gas deposits.

• Soot – inadequate oxygen supply or im-

properly adjusted burner can allow forsoot buildup in fireside passages. A reduc-tion in efficiency and hot spots may occur.Soot, when mixed with water, can formacidic solutions harmful to the metal.

RB-5606 ELECTRIC BOILERS

This type boiler is heated by an electrical en-ergy source, either by use of electric resistantcoils or induction coils. These boilers are usedto service small or medium size loads and may

be used in either high or low pressure steamor hot water applications.

Due to the unique design and material con-siderations of electric boilers, the followingare common areas of inspection.

• Weight stress of the elements – some elec-trodes and elements can be quite heavy,especially if covered with scale deposits.These elements will scale sooner and ata faster rate than internal surfaces. Ex-cessive weight puts severe stress on theattachment fittings and welds at supportpoints.

• Thermal shock – heaters are constantlycycling on and off creating temperaturegradients.

• Leakage – any leakage noted at the openingwhere electrodes or elements are insertedis extremely dangerous due to the possible

exposure of electrical wires, contacts and breakers.

RB-5607 FIRED COIL WATER HEATERS

These heaters are used for rapid heating of po-table water or hot water service. This designutilizes a coil through which the water beingheated is passed. This type of heater has verylittle volume and may be used in conjunction

with a hot water storage vessel.

Due to the unique design and material con-siderations of fired coil water heaters, the fol-lowing are common areas of inspection.

• Erosion – size and velocity of water flowthrough the coil combines to create wearand thinning of the coils. If a tempera-

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doubt where the leakage is coming from,perform a liquid penetrant exam. Takenote of refractory locations protectingsteel that is not water-cooled. Condensa-tion of combustion gas dripping out ofthe fireside gaskets during a cold boiler

start up is expected. However, if it con-tinues after the water temperature in the boiler is at least 150°F (65°C), then furtherinvestigation to determine the source ofwater shall be conducted.

RB-5700 INSERVICE INSPECTIONACTIVITIES

Any defect or deficiency in the condition,operating, and maintenance practices of a boiler should be discussed with the owner oruser at the time of inspection and, if necessary,recommendations made for the correctionof such defect or deficiency. Follow-up in-spections should be performed as needed todetermine if deficiencies have been correctedsatisfactorily.

RB-6000 INSPECTION OF PRESSUREVESSELS

RB-6010 SCOPE

This part provides guidelines for inserviceinspection of pressure vessels used to containpressure either internal or external. This pres-sure may be obtained from an external sourceor by the application of heat from a direct orindirect source or a combination thereof.


Pressure vessels are designed for a varietyof service conditions. The media that a pres-sure vessel contains and the temperatureand pressure at which it operates should beconsidered in establishing inspection criteria.Usage, materials, and installation conditionsshould be considered in determining damage

mechanisms that will affect the mechanicalintegrity of a pressure vessel as describedin RB-4000. The general requirements forsafety, pre-inspection, and post-inspectionactivities are specified in RB-2000 and should be followed in conjunction with the specific

requirements outlined in this section whenperforming inspections of pressure vessels.There may be occasions where more detailedprocedures will be required.

RB-6200 INSPECTIONS – GENERALREQUIREMENTS

RB-6210 CONDITION OF INSTALLATION

The type of inspection given to pressurevessels should take into consideration thecondition of the vessel and the environmentin which it operates. This inspection may beeither external or internal and use a varietyof nondestructive examination methods asdescribed in RB-3000. The inspection methodmay be performed when the vessel is oper-ating on-stream or depressurized, but shallprovide the necessary information that the

essential sections of the vessel are of a condi-tion to continue to operate for the expectedtime interval. On-stream inspection, includingwhile under pressure, may be used to satisfyinspection requirements provided the accu-racy of the method can be demonstrated.

RB-6220 EXTERNAL INSPECTION

The purpose of an external inspection is toprovide information regarding the overall

condition of the pressure vessel. The followingshould be reviewed:

a. Insulation or Other Coverings If it is found that external coverings such

as insulation and corrosion-resistant lin-ings are in good condition and there isno reason to suspect any unsafe condi-tion behind them, it is not necessary to

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remove them for inspection of the vessel.However, it may be advisable to removesmall portions of the coverings in orderto investigate attachments, nozzles, andmaterial conditions.

NOTE: Precautions should be taken whenremoving insulation while vessel is underpressure.

b. Evidence of Leakage Any leakage of gas, vapor, or liquid

should be investigated. Leakage comingfrom behind insulation coverings, sup-ports or settings, or evidence of past leak-age should be thoroughly investigated byremoving any covering necessary until thesource of leakage is established.

c. Structural Attachments The pressure vessel mountings should be

checked for adequate allowance for ex-pansion and contraction, such as provided by slotted bolt holes or unobstructedsaddle mountings. Attachments of legs,saddles, skirts, or other supports should be examined for distortion or cracks atwelds.

d. Vessel Connections Manholes, reinforcing plates, nozzles, orother connections should be examined forcracks, deformation, or other defects. Boltsand nuts should be checked for corrosionor defects. Weep holes in reinforcing platesshould remain open to provide visualevidence of leakage as well as to preventpressure buildup between the vessel andthe reinforcing plate. Accessible flangefaces should be examined for distortionand to determine the condition of gasket-

seating surfaces.

e. Miscellaneous Conditions

1. Abrasives – The surfaces of the vesselshould be checked for erosion.

2. Dents – Dents in a vessel are defor-mations caused by their coming in

contact with a blunt object in such away that the thickness of metal is notmaterially impaired. Dents can createstress risers that may lead to crack-ing.

3. Distortion – If any distortion is sus-pected or observed, the overall dimen-sions of the vessel shall be checked todetermine the extent and seriousnessof the distortion.

4. Cuts or Gouges – Cuts or gouges cancause high stress concentrations anddecrease the wall thickness. Depend-ing upon the extent of the defect, itmay be necessary to repair.

5. Surface Inspection – The surfaces ofshells and heads should be examinedfor possible cracks, blisters, bulges,and other evidence of deterioration,giving particular attention to theskirt and to support attachment andknuckle regions of the heads.

6. Weld Joints – Welded joints and theadjacent heat affected zones should beexamined for cracks or other defects.

Magnetic particle or liquid penetrantexamination is a useful means for do-ing this.

7. Riveted Vessels – On riveted vessels,examine rivet head, butt strap, plate,and caulked edge conditions. If rivetshank corrosion is suspected, hammertesting for soundness or spot radiogra-phy at an angle to the shank axis may be useful.

RB-6230 INTERNAL INSPECTION

A general visual inspection in vessels is thefirst step in making an internal inspection ofpressure vessels that are susceptible to cor-rosion. Vessels should be inspected for theconditions identified in RB-4000.

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The following should be reviewed:

a. Vessel Connections Threaded connections should be inspected

to ensure that an adequate number ofthreads are engaged. All openings leading

to any external fittings or controls should be examined as thoroughly as possible toensure they are free from obstructions.

b. Vessel Closures Any special closures including those on

autoclaves, normally termed quick actu-ating (quick opening) closures (RB-6460) that are used frequently in the operationof a pressure vessel, should be checked by the Inspector for adequacy and wear.A check should also be made for cracksat areas of high stress concentration.Door safety interlock mechanisms, “maninside” alarm and associated audible andvisual alarms should be verified. The maninside alarm, is a safety cable running thelength of the internal workspace that can be pulled by the operator, thereby shuttingdown all autoclave functions and initiat-ing audible and visual alarms.

c. Vessel Internals

Where pressure vessels are equipped withremovable internals, these internals neednot be completely removed provided as-surance exists that deterioration in regionsrendered inaccessible by the internals isnot occurring to an extent that mightconstitute a hazard, or to an extent beyondthat found in more readily accessibleparts of the vessel.

If a preliminary inspection reveals un-safe conditions such as loose or corroded

internals or badly corroded internal lad-ders or platforms, steps should be takento remove or repair such parts so that adetailed inspection may be made.

d. Corrosion The type of corrosion (local pitting or uni-

form), its location and any obvious datashould be established. Data collected forvessels in similar service will aid in locat-

ing and analyzing corrosion in the vessel being inspected. The liquid level lines, the bottom, and the shell area adjacent to andopposite inlet nozzles are often locationsof most severe corrosion. Welded seamsand nozzles and areas adjacent to welds

are often subjected to accelerated corro-sion.

RB-6240 INSPECTION OF PARTS ANDAPPURTENANCES

Parts and appurtenances to be inspected de-pend upon the type of vessel and its operatingconditions. The Inspector should be familiarwith the operating conditions of the vesseland with the causes and characteristics ofpotential defects and deterioration.

RB-6250 GAGES, SAFETY DEVICES,AND CONTROLS

RB-6251 GAGES

The pressure indicated by the requiredgage should be compared with other gages

on the same system. If the pressure gage isnot mounted on the vessel itself, it shall beinstalled in such a manner that it correctlyindicates the actual pressure in the vessel.When required, the accuracy of pressuregages should be verified by comparing thereadings with a standard test gage or a deadweight tester.

The location of a pressure gage should beobserved to determine whether it is exposedto high temperature from an external source

or to internal heat due to lack of protection bya proper siphon or trap. Provisions should bemade for blowing out the pipe leading to thesteam gage

RB-6252 SAFETY DEVICES

See RB-8000 for the inspection of safety de-vices (pressure relief valves and non-closing

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devices such as rupture disks) used to preventthe overpressure of pressure vessels.

RB-6253 CONTROLS/DEVICES

Any control device attached to a vessel should be demonstrated by operation or the Inspectorshould review the procedures and records forverification of proper operation.

Temperature measuring devices shall bechecked for accuracy and general condition.

RB-6300 RECORDS REVIEW (See RB-2000)

The Inspector shall review any pressure ves-sel log, record of maintenance, corrosion raterecord, or any other examination results. TheInspector should consult with the owner oruser regarding repairs or alterations made,if any, since the last internal inspection. TheInspector shall review the records of suchrepairs or alterations for compliance withapplicable requirements.

A permanent record shall be maintained for

each pressure vessel. This record should in-clude the following:

a. An ASME Manufacturer’s Data Report or,if the vessel is not ASME Code stamped,other equivalent specifications.

b. Form NB-5 Boiler or Pressure Vessel DataReport – First Internal Inspection, may beused for this purpose. It shall show thefollowing identification numbers as ap-plicable.

National Board No.

Jurisdiction No. Manufacturer Serial No. Owner-User No.

c. Complete pressure-relieving device in-formation including safety or safety reliefvalve spring data or rupture disk data anddate of latest inspection.

d. Progressive record including, but notlimited to, the following:

1. Location and thickness of monitorsamples and other critical inspectionlocations.

2. Limiting metal temperature and loca-tion on the vessel when this is a factorin establishing the minimum allow-able thickness.

3. Computed required metal thicknessesand maximum allowable workingpressure for the design temperatureand pressure-relieving device openingpressure, static head, and other load-ings.

4. Test pressure if tested at the time ofinspection.

5. Scheduled (approximate) date of nextinspection.

6. Date of installation and date of anysignificant change in service condi-tions (pressure, temperature, characterof contents, or rate of corrosion).

7. Drawings showing sufficient details topermit calculation of the service ratingof all components on pressure vesselsused in process operations subject tocorrosive conditions. Detailed datawith sketches where necessary mayserve this purpose when drawings arenot available.

RB-6400 INSPECTIONS FOR SPECIFIC

TYPES OF PRESSURE VESSELS

RB-6410 GENERAL Inspection and examination requirementsidentified below should also include the ad-ditional requirements mentioned above.

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RB-6420 DEAERATORS

The deaerator is used to remove undesirablegases in the system and is exposed to the fol-lowing: harmful gases, fluctuation in tempera-ture and pressure, erosion, and vibration. The

air and water atmosphere in the deaerator hasa corrosive effect and may contain high con-centrations of hydrogen ions, which can causehydrogen cracking, hydrogen embrittlement,or corrosion fatigue. The water entering thedeaerator sometimes carries acids or oil thatcan cause acidic attacks on the metal.

Inspection shall consist of the following:

a. Welds – Inspect all longitudinal and cir-cumferential welds, including the HeatAffected Zone (HAZ), visually alongtheir entire length. Examine nozzle andattachment welds for erosion, corrosion,or cracking. Inspect with special attentionall exposed internal welds at or below thenormal water line.

b. Shell – Inspect exterior surfaces for corro-sion or leaks. Inspect interior for pitting,corrosion, erosion, thinning, wastage ofmetal, cracks, etc.

c. Spray Nozzles and Trays – Inspect allnozzles and spray areas for erosion, wear,wastage, and broken parts or supports.Check to see that nozzles are not pluggedand that all lines to nozzles are open. In-spect all trays for holes, erosion, wastage, broken or defective brackets, and brokensupport attachments.

d. Condenser and Vents – Examine all ventlines to see that they are open to assure

proper exiting of the gases. Inspect thecondenser unit to verify it is operable andnot plugged with scale or sludge. Checkfor corrosion, pitting, erosion, and brokenparts.

e. Supports – Inspect all support structuresfor mechanical damage, cracks, loose bolting, and bent or warped components.

Check all welds, especially attaching sup-ports to the pressure boundary.

RB-6430 COMPRESSED AIR VESSELS

Compressed air vessels include receivers,separators, filters, and coolers. Considerationsto be concerned include temperature vari-ances, pressure limitations, vibration, andcondensation. Drain connections should beverified to be free of any foreign material thatmay cause plugging.

Inspection shall consist of the following:

a. Welds – Inspect all welds for cracking orgouging, corrosion and erosion. Particularattention should be given to the welds thatattach brackets supporting the compres-sor. These welds may fail due to vibra-tion.

b. Shells/Heads – Externally, inspect the basematerial for environmental deteriora-tion and impacts from objects. Hot spotsand bulges are signs of overheating andshould be noted and evaluated for ac-ceptability. Particular attention should

be paid to the lower half of the vessel forcorrosion and leakage. For vessels withmanways or inspection openings, an in-ternal inspection shall be performed forcorrosion, erosion, pitting, excessive dirt buildup, and leakage around inspectionopenings. UT thickness testing may beused where internal inspection access islimited or to determine actual thicknesswhen corrosion is suspected.

c. Fittings and Attachments – Inspect all fit-

tings and attachments for alignment,support, deterioration, damage and leak-age around threaded joints. Any internalattachments such as supports, brackets, orrings shall be visually examined for wear,corrosion, erosion and cracks.

d. Operation – Check the nameplate to deter-mine the allowed working pressure andtemperature of the vessel. Assure the set

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c. All interior welds and highly stressedareas should be examined by the wet fluo-rescent magnetic particle-testing method(WFMT) using an A/C yoke for magne-tization. Note that weld cracks are oftentransverse in orientation. It is extremely

important to ensure that the NDE methodused will disclose cracks in any orienta-tion.

d. If cracks are discovered, a calculationmust be made to determine what depthof grinding may be carried out for crackremoval (without encroaching on theminimum thickness required by the con-struction standard or equivalent).

e. Where possible, crack removal by grind-ing is the preferred method of repair. Sincethe stresses at the crack tips are quite high,even very fine cracking should be elimi-nated.

f. Where crack depth is such that removalrequires weld repair, a weld procedureshould be employed that will minimizeHAZ hardening and residual stresses.Whenever possible, weld repairs regard-less of their size should be post-weld heat

treated.

g. Re-inspect by WFMT to ensure completecrack removal.

h. It is not intended to inhibit or limit the useof other evaluation methods. It is recog-nized that acoustic emission and fracturemechanics are acceptable techniques forassessing structural integrity of vessels.Analysis by fracture mechanics may beused to assess the structural integrity

of vessels when complete removal of allammonia stress cracks is not practical. Ifalternative methods are used, the aboverecommendation that all cracks be re-moved, even fine cracks may not apply.

Gages and Pressure-Relieving DevicesThe Inspector should note the pressure indi-cated by the gage and compare it with other

gages on the same system. If the pressure gageis not mounted on the vessel itself, it should be ascertained that the gage is on the systemand installed in such a manner that it correctlyindicates actual pressure in the vessel.

See RB-8000 for the inspection of safety de-vices (pressure relief valves) used to preventthe overpressure of liquid ammonia vessels.Pressure-relief devices in ammonia servicecannot be tested in place using system pres-sure. Bench testing is required.

RB-6460 INSPECTION OF PRESSUREVESSELS WITH QUICK-

ACTUATING CLOSURES

This part describes guidelines for inspectionof pressure vessels equipped with quick-ac-tuating closures. Due to the many differentdesigns of quick-actuating closures, potentialfailures of components that are not specificallycovered should be considered. The scope ofinspection should include areas affected byabuse or lack of maintenance and a check forinoperable or bypassed safety and warningdevices.

Temperatures above that for which the quick-actuating closure was designed can havean adverse effect on the safe operation ofthe device. If parts are found damaged andexcessive temperatures are suspected as thecause, the operating temperatures may haveexceeded those temperatures recommended by the manufacturer. Rapid fluctuations intemperatures due to rapid start-up and shut-down may lead to cracks or yielding caused by excessive warping and high thermal stress.A careful observation should be made of the

condition of the complete installation, includ-ing maintenance and operation, as a guide informing an opinion of the care the equipmentreceives. The history of the vessel should beestablished, including: year built, materialsof construction, extent of postweld heat treat-ment, previous inspection results, and repairsor alterations performed. Any leak should bethoroughly investigated and the necessarycorrective action initiated.

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Inspection of Parts and Appurtenances

a. Seating surfaces of the closure device,including but not limited to the gaskets,O-rings, or any mechanical appurtenanceto ensure proper alignment of the closure

to the seating surface, should be inspected.This inspection can be made by usingpowdered chalk or any substance that willindicate that the closure is properly strik-ing the seating surface of the vessel flange.If this method is used, a check should bemade to ensure that:

1. Material used will not contaminate thegasket or material with which it comesinto contact.

2. The substance used should be com-pletely removed after the examina-tion.

b. The closure mechanism of the deviceshould be inspected for freedom of move-ment and proper contact with the lockingelements. This inspection should indicatethat the movable portions of the lockingmechanism are striking the locking ele-ment in such a manner that full stroke can

be obtained. Inspection should be madeto ensure that the seating surface of thelocking mechanism is free of metal burrsand deep scars, which would indicate mis-alignment or improper operation. A checkshould be made for proper alignment ofthe door hinge mechanisms to ensure thatadjustment screws and locking nuts areproperly secured. When deficiencies arenoted, the following corrective actionsshould be initiated:

1. If any deterioration of the gasket,O-ring, etc., is found, the gasket,O-ring, etc., should be replaced im-mediately. Replacements should be inaccordance with the vessel manufac-turer’s specifications.

2. If any cracking or excessive wear isdiscovered on the closing mechanism,the owner or user should contact the

original manufacturer of the devicefor spare parts or repair information.If this cannot be accomplished, theowner or user should contact an orga-nization competent in quick-actuatingclosure design and construction prior

to implementing any repairs.

3. Defective safety or warning devicesshould be repaired or replaced priorto further operation of the vessel.

4. Deflections, wear, or warping of thesealing surfaces may cause out-of-roundness and misalignment. Themanufacturer of the closure should becontacted for acceptable tolerances forout-of-roundness and deflection.

The operation of the closure devicethrough its normal operating cycleshould be observed while undercontrol of the operator. This shouldindicate if the operator is followingposted procedures and if the oper-ating procedures for the vessel areadequate.

Gages, Safety Devices, and Controls

a. The required pressure gage should beinstalled so that it is visible from the op-erating area located in such a way thatthe operator can accurately determine thepressure in the vessel while it is in opera-tion. The gage dial size should be of sucha diameter that it can be easily read by theoperator. This gage should have a pressurerange of at least 1-1/2 times, but not morethan four times, the operating pressure ofthe vessel. There should be no intervening

valve between the vessel and gage.

b. The pressure gage should be of a type thatwill give accurate readings, especiallywhen there is a rapid change in pressure.It should be of rugged construction andcapable of withstanding severe serviceconditions. Where necessary, the gageshould be protected by a siphon or trap.

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c. Pressure gages intended to measure theoperating pressure in the vessel are notusually sensitive or easily read at lowpressures approaching atmospheric. Itmay be advisable to install an auxiliarygage which reads inches of water (mm

of mercury) and is intended to measurepressure from atmospheric through lowpressures. This gives assurance that thereis zero pressure in the vessel before open-ing. It would be necessary to protect theauxiliary low pressure gage from thehigher operating pressures.

d. Provisions should be made to calibratepressure gages or to have them checkedagainst a master gage as frequently asnecessary.

e. A check should be made to ensure that theclosure and its holding elements must befully engaged in their intended operatingposition before pressure can be applied tothe vessel. A device should be providedthat prevents the opening mechanismfrom operating unless the vessel is com-pletely depressurized.

f. Quick-actuating closures held in position

by manually operated locking devicesor mechanisms, and which are subject toleakage of the vessel contents prior to dis-engagement of the locking elements andrelease of the closure, shall be providedwith an audible and/or visible warningdevice to warn the operator if pressureis applied to the vessel before the closureand its holding elements are fully engagedand to warn the operator if an attempt ismade to operate the locking device beforethe pressure within the vessel is released.

Pressure tending to force the closure clearof the vessel must be released before theclosure can be opened for access.

RB-6470 GRAPHITE PRESSUREEQUIPMENT

See Appendix 8 for inspection requirements.

RB-6480 FIBER REINFORCED VESSELS

See Appendix 9 for inspection requirements.

RB-6490 PROPANE LP GAS VESSELS

See Appendix H for inspection require-ments.

RB-6500 NONDESTRUCTIVE EXAMINATION (NDE)

NDE may be employed to assess the condi-tion of the pressure vessel as described inRB-3000. These examination methods should be performed by experienced and qualifiedindividuals using procedures acceptable tothe Jurisdiction. Generally, some form of sur-face preparation will be required prior to theuse of these examination methods: magneticparticle, liquid penetrant, ultrasonic, radiog-raphy, eddy current, visual, metallographicexamination, and acoustic emission. Whenthere is doubt as to the extent of a defect ordetrimental condition found in a pressurevessel, the Inspector may require additional

NDE.

RB-6600 REMAINING LIFE ANDINSPECTION INTERVALS

New pressure vessels are placed in service tooperate under their design conditions for aperiod of time determined by the service con-ditions and the corrosion rate. If the pressurevessel is to remain in operation, the allowableconditions of service and the length of time

before the next inspection shall be based onthe conditions of the vessel as determined bythe inspection. See RB-9000 for determiningremaining life and inspection intervals.

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Any defect or deficiency in the condition,operating, and maintenance practices of thepressure vessel should be discussed with the

owner or user at the time of inspection and,if necessary, recommendations made for thecorrection of such defect or deficiency. Fol-low-up inspections should be performed asneeded to determine if deficiencies have beencorrected satisfactorily.

RB-7000 INSPECTION OF PIPINGSYSTEMS

RB-7010 SCOPE

This section provides guidelines for internaland external inspection of piping and pipingsystems.


Piping systems are designed for a variety ofservice conditions. The media that a piping

system contains, the temperature at whichit operates, and the piping corrosion historyshould be considered in establishing pipinginspection criteria. Particular attention should be given to piping systems that are subject tocorrosion, high temperatures, and hazard-ous fluid or gasses. Piping operating beyonddesign temperature limits can cause sufficientdeterioration of piping material propertiesdue to graphitization, embrittlement, andcreep to render the piping system unfit forcontinued service (RB-4000).

Any externally or internally corroded pipingshould be evaluated for integrity and repairedor replaced as necessary.

Requirements specified for inspection activi-ties and safety are identified in RB-2000 andshould be reviewed and followed as appli-cable.

RB-7200 ASSESSMENT OF PIPINGDESIGN

All pipe material and fittings should be prop-erly rated for the maximum service conditionsto which they are subjected under normal

operating conditions. The design corrosionallowance of the piping system should beconsidered when reviewing the current pipingthickness data.

If a piping system has a previous history ofultrasonic wall thickness measurements, theInspector should review this data and requestadditional wall thickness measurements ifwarranted.

RB-7300 INSPECTION

RB-7310 EXTERNAL INSPECTION OFPIPING

Piping should be externally inspected for thefollowing:

a. Evidence of leakage. (RB-7330)

b. Provision for expansion and adequatesupport. (RB-7340)

c. Proper alignment of piping joints and bolt-ed connections. Check for missing bolts orstuds, nuts, and improper or inadequate bolted connection thread engagement.Also check visible gasket and gasket align-ment condition. Threaded connectionsshould also be inspected for inadequateor excessive thread engagement.

d. Past or present evidence of excessivevibration or cyclic activity such as looseor missing piping supports or piping in-sulation. If such activity is present, pipingand piping joints should be inspected forpotential fatigue cracking.

e. Evidence of general corrosion, excessiveexternal pitting, corrosion scale buildup,exfoliation, erosion, cuts, dents, distortion,

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or other detrimental conditions such aspipe sweating, water hammer damage, orhot spots. Ultrasonic thickness measure-ments should be taken in suspect areas toensure adequate remaining piping wallthickness.

f. Evidence of corrosion under piping in-sulation (CUI) or other weather relateddamage to piping coatings.

g. Evidence of freeze damage such as bulg-ing, striations, or surface fissures.

h. Dead leg or stagnant piping internalcorrosion issues. Ultrasonic thicknessmeasurements should be taken in suspectlocations. Radiography is also useful toassess internal deposits and subsequentcorrosion in no flow piping locations.

RB-7320 INTERNAL INSPECTIONOF PIPING

Where the internal surfaces of piping, valves,and gasket surfaces are accessible to visual ex-amination, internal inspection should includean examination of all available surfaces. Non-

destructive examination for internal corrosionmay be used to supplement the inspection.Boroscope or camera inspections are also use-ful to augment piping internal inspections.

a. Internal pipe surfaces should be cleaned before inspection, if necessary.

b. The internal surfaces of piping, pipingwelds, and connections, fittings, valves,and gasket surfaces should be inspectedfor localized corrosion, pitting, erosion,

blistering, cracking, and impingementdamage.

RB-7330 EVIDENCE OF LEAKAGE

A leak should be thoroughly investigatedand corrective action initiated. Leaks beneathpiping insulation should be approached with

caution, especially when removing insulationfrom a pressurized piping system for inspec-tion.

A pressure test may be required to obtain ad-ditional information regarding the extent of

a defect or detrimental condition.

To determine tightness, the test pressureneed be no greater than the normal operatingpressure. The metal temperature should benot less than 70°F (20°C) and the maximumtemperature during inspection should notexceed 120°F (50°C). The potential corrosiveeffect of the test fluid on the piping materialshould be considered.

RB-7340 PROVISIONS FOREXPANSION AND SUPPORT

Visual inspection should include a checkfor evidence of improper piping support orsupport design. Piping supports should not be bottomed out or fully extended. Pipingsupports should keep piping in alignmentand prevent piping from colliding with otherpiping or stationary objects. The alignmentof connections between anchored equip-

ment should be observed to determine if anychange in position of the equipment due tosettling, excessive cyclic activity, steady statestresses beyond design allowances, or othercauses has placed an undue strain on the pip-ing or its connections. Inadequate supportor the lack of provision for expansion maycause broken attachment welds, cracks, orleakage at fittings. Missing, damaged, or looseinsulation materials may be an indication ofvibration or pipe movements resulting fromimproper support.

Piping support locations should be closelyinspected at the support points for externaland crevice corrosion concerns.

RB-7350 GAGES, SAFETY DEVICES,CONTROLS

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RB-7351 GAGES

Piping system pressure gages should beremoved for testing unless there is otherinformation to assess their accuracy. Faultypressure gages should be recalibrated or re-

placed as necessary.

RB-7352 SAFETY DEVICES

See RB-8000 for information on the inspectionof pressure-relieving devices used to preventthe over pressure of piping systems.

RB-7353 CONTROLS

Piping connections utilizing a quick-discon-nect coupling should be checked to ensurethat the coupling and its holding elementsare fully engaged in their intended operatingposition. Means should be provided that warnthe operator against disengaging the couplingor prevent the opening mechanism fromoperating unless the piping is completelydepressurized.


Any defect or deficiency in the condition,operating, and maintenance practices of apiping system should be discussed with theowner or user at the time of inspection and,if necessary, recommendations made for thecorrection of such defect or deficiency. Fol-low-up inspections should be performed asneeded to determine if deficiencies have beencorrected satisfactorily.

RB-8000 INSPECTION OF PRESSURERELIEF DEVICES

RB-8010 SCOPE

The most important appurtenances on anypressurized system are the pressure relief de-

vices provided for overpressure protection ofthat system. These are devices such as safetyvalves, safety relief valves, pilot valves, andrupture disks or other non-reclosing devicesthat are called upon to operate and reduce anoverpressure condition.

These devices are not designed or intendedto control the pressure in the system duringnormal operation. Instead, they are intendedto function when normal operating controlsfail or abnormal system conditions are en-countered.

Periodic inspection and maintenance of theseimportant safety devices is critical to ensuretheir continued functioning and to provideassurance that they will be available whencalled upon to operate.

Inspection areas of concern include:

a. safety considerations b. device datac. condition of the deviced. condition of the installatione. testing and operational inspection

RB-8100 SAFETY CONSIDERATIONS

Inspectors are cautioned that the operation ofthese safety devices involve the discharge ofhigh pressure and/or high temperature fluids.Extreme caution should be used when work-ing around these devices due to hazards topersonnel. Suitable hearing protection should be provided during testing because extremelyhigh noise levels, which may be encountered,can damage hearing.

RB-8200 DEVICE DATA

Nameplate marking or stamping of the de-vice should be compared to stamping on theprotected pressure-retaining item. For a singledevice, the set pressure shall be no higher thanthe maximum allowable working pressure(MAWP) marked on the protected pressure-retaining item or system.

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f. Process steam service safety relief valves:steam or air with manufacturer’s steam toair correction factor.

NOTE: Valves being tested after a repairmust be tested on steam except as permit-

ted by RE-2020.

As an alternative to a pressure test, the valvemay be checked by the owner for freedom ofoperation by activating the test or “try” lever(manual check). For high pressure boiler andprocess valves this test should be performedonly at a pressure greater than 75% of thestamped set pressure of the valve or the lift-ing device may be damaged. This test willonly indicate that the valve is free to operateand does not provide any information on theactual set pressure. All manual checks should be performed with some pressure under thevalve in order to flush out debris from the seatwhich could cause leakage.

NOTE: The manual check at 75% or higheris based on lift lever design requirements forASME Section I and VIII valves. Code designrequirements for lifting levers for Section IVvalves require that the valve be capable of being lifted without pressure.

If a valve is found to be stuck closed, thesystem should immediately be taken out ofservice until the condition can be corrected,unless special provisions have been madeto operate on a temporary basis (such as ad-ditional relief capacity provided by anothervalve).

If a pressure test indicates the valve does notopen within the requirements of the originalcode of construction, but otherwise is in ac-

ceptable condition, minor adjustments (de-fined as no more than twice the permittedset pressure tolerance) shall be made by anorganization that meets the requirementsof RA-2200 to reset the valve to the correctopening pressure. All adjustments shall beresealed with a seal identifying the respon-

sible organization and a tag shall be installedidentifying the organization and the date ofthe adjustment.

If a major adjustment is needed, this mayindicate the valve is in need of repair or hasdamaged or misapplied parts. Its conditionshould be investigated accordingly.

Systems with multiple valves will require thelower set valves to be held closed to permitthe higher set valves to be tested. A test clampor “gag” should be used for this purpose.The spring compression screw shall not betightened. It is recommended that the testclamps be applied in accordance with thevalve manufacturer’s instructions when the

valve is at or near the test temperature, and be applied hand tight only to avoid damageto the valve stem or spindle.

Upon completion of set pressure testing,all pressure relief valves gags shall be re-moved.

RB-8410 RECOMMENDED INSPECTION AND TEST

FREQUENCIES

Power Boilers

a. Pressure less than 400 psig (3 MPa): Man-ual check every 6 months; pressure testannually to verify nameplate set pressureor as determined by operating experienceas verified by testing history.

b. Pressure greater than 400 psig (3 MPa):Pressure test to verify nameplate set pres-sure every three years or as determined by

operating experience as verified by testinghistory.

Pressure tests should be performed priorto bringing the boiler down for plannedinternal inspection so needed repairs oradjustments can be made while the boileris down.

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High Temperature Hot Water BoilersPressure test annually to verify nameplateset pressure or as determined by operatingexperience as verified by testing history. Forsafety reasons, removal and testing on a steamtest bench is recommended. Such testing will

avoid damaging the safety valve by dischargeof a steam water mixture, which could occurif the valve is tested in place.

Low Pressure Steam Heating BoilersManual check quarterly; pressure test annu-ally prior to steam heating season to verifynameplate set pressure.

Hot Water Heating BoilersManual check quarterly; pressure test annu-ally prior to heating season to verify name-plate set pressure.

NOTE: The frequencies specified for thetesting of pressure relief valves on boilersis primarily based on differences betweenhigh pressure boilers that are continuouslymanned and lower pressure automaticallycontrolled boilers that are not monitored bya boiler operator at all times. When any boilerexperiences an over-pressure condition suchthat the safety or safety relief valves actuate,

the valves should be inspected for seat leakageand other damage as soon as possible and anydeficiencies corrected.

Water HeatersManual check every two months. Due to therelatively low cost of safety valves for thisservice, it is recommended that a defectivevalve be replaced with a new valve if a repairor resetting is indicated.

Pressure Vessels and Piping

Frequency of test and inspection of pressurerelief devices for pressure vessel and pipingservice is greatly dependent on the natureof the contents and operation of the systemand only general recommendations can begiven. Inspection frequency should be basedon previous inspection history. If valves are

found to be defective or damaged by systemcontents during inspection, intervals should be shortened until acceptable inspection re-sults are obtained. Where test records and/orinspection history are not available, the fol-lowing inspection and test frequencies are

suggested.

Service Inspection Frequency

Steam .......................................Annual

Air and Clean .........................Every three years Dry Gasses

Pressure relief valves.............Every five years in combination with rupture disks

Propane, Refrigerant .............Every five years

All others ................................Per inspection history

Establishment of Inspection and Test IntervalsWhere a recommended test frequency is notlisted, the valve user and Inspector must de-termine and agree on a suitable interval forinspection and test. Some items to be consid-ered in making this determination are:

a. Jurisdictional requirements;

b. Records of test data and inspections fromsimilar processes and similar devices inoperation at that facility;

c. Recommendations from the device manu-facturer. In particular, when the valveincludes a non-metallic part such as adiaphragm, periodic replacement of thoseparts may be specified;

d. Operating history of the system. Systemswith frequent upsets where a valve hasactuated require more frequent inspec-tion;

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e. Results of visual inspection of the deviceand installation conditions. Signs of valveleakage, corrosion or damaged parts allindicate more frequent operational inspec-tions;

f. Installation of a valve in a system witha common discharge header. Valves dis-charging into a common collection pipemay be affected by the discharge of othervalves by the corrosion of parts in the out-let portion of the valve or the buildup ofproducts discharged from those valves;

g. Ability to coordinate with planned systemshutdowns. The shutdown of a system forother maintenance or inspection activitiesis an ideal time for the operational inspec-tion and test of a pressure relief valve;

h. Critical nature of the system. Systemswhich are critical to plant operation orwhere the effects of the discharge of fluidsfrom the system are particularly detrimen-tal due to fire hazard, environmental dam-age, or toxicity concerns all call for morefrequent inspection intervals to ensuredevices are operating properly;

i. Where the effects of corrosion, blockage by system fluid or ability of the valve tooperate under given service conditionsare unknown (such as in a new process orinstallation), a relatively short inspectioninterval, not to exceed one year or the firstplanned shutdown, whichever is shorter,shall be established. At that time the de-vice shall be visually inspected and tested.If unacceptable test results are obtained,the inspection interval shall be reduced by50% until suitable results are obtained.

Establishment of Service IntervalsThe above intervals are guidelines for periodicinspection and testing. Typically if there areno adverse findings a pressure relief valvewould be placed back in service until the nextinspection. Any unacceptable conditions thatare found by the inspection shall be corrected

immediately by repair or replacement of thedevice. Many users will maintain spare pres-sure relief devices so the process or system isnot affected by excessive downtime.

Pressure relief valves are mechanical devices

that require periodic preventive maintenanceeven though external inspection and testresults indicate acceptable performance.There may be wear on internal parts, galling between sliding surfaces or internal corro-sion, and fouling which will not be evidentfrom an external inspection or test. Periodicre-establishment of seating surfaces and thereplacement of soft goods such as O-rings anddiaphragms are also well advised preventa-tive maintenance activities which can preventfuture problems. If the valve is serviced, acomplete disassembly, internal inspectionand repair as necessary, such that the valvescondition and performance are restored toa like new condition, should be done by anorganization meeting the requirements ofRA-2200.

Service records with test results and findingsshould be maintained for all over pressureprotection devices. A service interval of nomore than three inspection intervals or ten

years, whichever is less, is recommendedto maintain device condition. Results of theinternal inspection and maintenance findingscan then be used to establish future serviceintervals.

RB-8500 ADDITIONAL INSPECTIONINFORMATION

The following additional items should beconsidered for the specified services.

RB-8510 BOILERS

If boilers are piped together with maximumallowable working pressures differing bymore than six percent, additional protectivedevices may be required on the lower pressure

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units to protect them from overpressure fromthe higher pressure unit.

Hot-Water Heating Boilers and Water Heaters

a. These units generally do not use any wa-

ter treatment and therefore may be moreprone to problems with deposits form-ing which may impair a safety device’soperation. Particular attention should bepaid to signs of leakage through valves or buildups of deposits.

b. Hot-water boilers tend to have buildupsof corrosion products since the system isclosed with little makeup. These productscan foul or block the valve inlet.

c. Water heaters will have cleaner waterdue to continuous makeup. However,these valves usually have a thermal ele-ment that will cause the valve to openslightly when the water is heated and notremoved from the system. When this hotwater evaporates in the discharge piping,calcium deposits may tend to form in thevalve inlet and outlet.

RB-8520 PRESSURE VESSELS ANDPIPING

Standard practice for overpressure protectiondevices is to not permit any type of isola-tion valve either before or after the device.However, some pressure vessel standardspermit isolation valves under certain con-trolled conditions when shutting down of thevessel to repair a damaged or leaking valvewould be difficult. If isolation block valvesare employed, their use should be carefully

controlled by written procedures and the block valves should have provisions to beeither car-sealed or locked in an open posi-tion when not being used. For ASME SectionVIII, Div. 1 pressure vessels, see UG-135, Ap-pendix M, and jurisdictional rules for moreinformation.

RB-8530 RUPTURE DISKS

Rupture disks or other non-reclosing devicesmay be used as sole relieving devices or incombination with safety relief valves to pro-tect pressure vessels.

The selection of the correct rupture diskdevice for the intended service is critical toobtaining acceptable disk performance. Dif-ferent disk designs are intended for constantpressure, varying pressure, or pulsatingpressure. Some designs include features thatmake them suitable for back pressure and/orinternal vacuum in the pressure vessel.

The margin between the operating pressureand the burst pressure is an important fac-tor in obtaining acceptable performance andservice life of the disk. Flat and pre-bulgedsolid metal disks are typically used with anoperating pressure that is no more than 60%to 70% of the burst pressure. Other designs areavailable that increase the operating pressureto as much as 90% of the burst pressure. Disksthat have been exposed to pressures abovethe normal operating pressure for which theyare designed are subject to fatigue or creepand may fail at unexpectedly low pressures.

Disks used in cyclic service are also subject tofatigue and may require a greater operatingmargin or selection of a device suitable forsuch service.

The disk material is also critical to obtainingacceptable service life from the disk. Disksare available in a variety of materials andcoatings, and materials that are unaffected bythe process fluid should be used. Disks thatexperience corrosion may fail and open at anunexpectedly low pressure.

Disk designs must also be properly selectedfor the fluid state. Some disk types are notsuitable for use in liquid service. Some disksmay have a different flow resistance whenused in liquid service which may affect thesizing of the disk.

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Information from the rupture disk manufac-turer, including catalog data and installationinstructions, should be consulted when select-ing a disk for a particular service.

For rupture disks and other non-reclosing

devices, the following additional items should be considered during inspections.

a. The rupture disk nameplate informa-tion, including stamped burst pressureand coincident temperature, should bechecked to ensure it is compatible withthe intended service. The coincident tem-perature on the rupture disk shall be theexpected temperature of the disk when thedisk is expected to burst and will usually be related to the process temperature, notthe temperature on the pressure vesselnameplate.

b. Markings indicating direction of flowshould be carefully checked to ensure theyare correct. Some rupture disks when in-stalled in the incorrect position may burstwell above the stamped pressure.

c. The marked burst pressure for a rupturedisk installed at the inlet of a safety relief

valve shall be equal to or less than thesafety relief valve set pressure. A marked burst pressure of 90% to 100% of the safetyrelief valve set pressure is recommended.A disk with a non-fragmenting designwhich cannot affect the safety relief valveshall be used.

NOTE: If the safety relief valve set pres-sure is less than the vessel MAWP, themarked burst pressure may be higher thanthe valve set pressure, but no higher than

the MAWP.

d. Check that the space between a rupturedisk and a safety relief valve is suppliedwith a pressure gage, try cock, or telltaleindicator to indicate signs of leakagethrough the rupture disk. The safety reliefvalve shall be inspected and the leaking

disks shall be replaced if leakage throughthe disk is observed.

e. If a rupture disk is used on a valve outlet,the valve design must be of a type not in-fluenced by back pressure due to leakage

through the valve. Otherwise, for non-toxic and nonhazardous fluids, the space between the valve and the ruptured diskshall be vented or drained to prevent theaccumulation of pressure.

f. For rupture disks installed on the valveinlet, the installation should be reviewedto ensure that the combination rules of theoriginal code of construction have beenapplied. A reduction in the valve capacityup to 10% is expected when used in combination with a non-reclosing device.

g. The frequency of inspection for rupturedisks and other non-reclosing devices isgreatly dependent on the nature of thecontents and operation of the system andonly general recommendations can begiven. Inspection frequency should be based on previous inspection history. Ifdevices have been found to be leaking,defective or damaged by system contents

during inspection, intervals should beshortened until acceptable inspection re-sults are obtained. With this in mind, theinspection frequency guidelines specifiedin RB-8410(f) are suggested for similarservices.

Rupture disks are often used to isolatepressure relief valves from services wherefouling or plugging of the valve inlet oc-curs. This tendency should be consideredin establishing the inspection frequency.

Since these devices are for one time use,a visual inspection is the only inspectionthat can be performed. Rupture diskswhich are installed using a specified bolt-ing torque procedure cannot be reusedafter inspection and must be replaced.

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It is recommended that all disks be peri-odically replaced to prevent unintendedfailure while in service due to deteriora-tion of the device.

RB-8600 REQUIREMENTS FOR SHIPPING AND TRANSPORTING

The improper shipment and transport of pres-sure relief devices can have detrimental effectson device operation. Pressure relief devicesshould be treated with the same precautionsas instrumentation, with care taken to avoidrough handling or contamination prior toinstallation.

The following practices are recommended:

a. Flanged valves should be securely boltedto pallets in the vertical position to avoidside loads on guiding surfaces.

b. Threaded valves should be securely pack-aged and cushioned during transport.

c. Valve inlet and outlet connection, drainconnections, and bonnet vents should be

protected during shipment and storageto avoid internal contamination of thevalve. Ensure all covers and/or plugs areremoved prior to installation.

d. Lifting levers should be wired or securedso they cannot be moved while the valve is being shipped or stored. These wires shall be removed before the valve is placed inservice.

e. Rupture disks should be carefully checked

for damage prior to installation andhandled by the disk edges, if possible.Any damage to the surface of the disk canaffect the burst pressure.


Any defect or deficiency in the condition,operating, and maintenance practices forpressure relief devices should be discussed

with the owner or user at the time of inspec-tion and, if necessary, recommendations madefor the correction of such defect or deficiency.Follow-up inspections should be performedas needed to determine if deficiencies have been corrected satisfactorily.

RB-9000 METHODS TO ASSESSDAMAGE MECHANISMSAND INSPECTIONFREQUENCY FOR PRESSURE-RETAINING ITEMS

RB-9010 SCOPE

This section provides guidelines and alterna-tive methods to assess materials and pres-sure-retaining items subject to degradation orcontaining flaws identified during inserviceinspections/examinations. New pressure-re-taining items are placed in service to operate

within their intended design parameters fora period of time determined by service condi-tions, which can include exposure to corrosion,exposure to elevated temperature (creep), orother forms of damage. If the pressure-re-taining item is to remain safe in operation,the service conditions and the length of time before the next inspection must be identified.There are various methods that can be usedto assess the condition of a pressure-retainingitem to establish remaining service life and toultimately determine the inspection interval.

In some cases, a visual inspection of the pres-sure-retaining item will suffice. However,more comprehensive condition assessmentmethods may be required, including an engi-neering evaluation performed by a competenttechnical source (see RB-9020).

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Various assessment methods (See RB-1040)including those mentioned in this section (Anexample of guidelines for performing fitnessfor service assessments are referenced in APIrecommended practice API-579 “Fitness-for-Service”) that can be used to establish the next

inspection interval of a pressure-retainingitem and to assure safe operation. Conditionassessment methods shall be subject to reviewand approval by the Jurisdiction.

RB-9020 GENERAL REQUIREMENTS

Organizations or qualified individuals withexperience in inspection, design, construc-tion, repairs, or failure analysis of pressure-retaining items should be consulted to assistin identifying damage mechanisms, andto evaluate condition assessment results ofpressure-retaining items. Documentation andinspection data used for fitness for service as-sessment should be evaluated for compliance,with codes, industry standards/experienceor good engineering practices, and shall beacceptable to the Jurisdiction. Understand-ing the operation of equipment or systemsand interaction with their internal or externalservice environment is necessary to correctly

identify damage mechanisms.

There are various condition assessment andfitness for service methods that can be usedto determine inspection intervals, based oncalculating the remaining service life of thepressure-retaining item. For items subject tocorrosion or erosion, the method to determineor adjust inspection intervals is identified inRB-9100. Methods for assessing other types ofinservice damage that affect remaining servicelife of pressure-retaining items are identified

in RB-9200.

RB-9021 RESPONSIBILITIES

a. Owner-User The owner-user of the pressure-retain-

ing item is responsible for the selection

and application of a suitable fitness forservice or condition assessment method-ology described in this section, subject toreview and approval by the Jurisdictionif required.

b. Inspector The Inspector shall review the condition

assessment methodology and assure in-spection data and documentation are inaccordance with RB-9000.

RB-9030 REMAINING SERVICELIFE ASSESSMENTMETHODOLOGY

An evaluation of inservice damage using oneor more condition assessment methods is notintended to provide a precise determinationof the actual time to failure for a pressure-re-taining item. Instead, the extent of inservicedamage should be estimated based on thequality of available information, establishedengineering assessment guidelines or meth-odology and appropriate assumptions usedfor safety, operation, and inspection.

If inspection and engineering assessment

results indicate that a pressure-retainingitem is safe for continued operation, futuremonitoring and inspection intervals should bedetermined and submitted to the Jurisdictionfor review and approval. If an engineeringassessment indicates that a pressure-retainingitem is not suitable for service under currentoperating conditions, new operating condi-tions could be established (i.e., derate), orthe item could be repaired subject to revisedinspection intervals, or the item could bereplaced.

Determination of the extent of inservice dam-age life requires the following:

• Understanding applicable damage andfailure mechanisms

• Developing inspection plans that canmonitor the extent of inservice damage

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• Performing an assessment of the damageincluding estimation of remaining life

• Considerations needed to minimize riskof failure

• Determination of root cause

RB-9040 DATA REQUIREMENTS FORREMAINING SERVICE LIFEASSESSMENTS

Evaluating the extent of inservice damageto a pressure-retaining item requires an un-derstanding of known and potential damagemechanisms. Information that can be usedto evaluate service life can be divided intothree categories: inspection history, operat-ing, and maintenance history, and equipmentinformation. Examples of types of data arelisted below:

a. Inspection History

• Summary/records of repairs/altera-tions

• Test Records including pressure tests• Results of prior inservice examina-

tions (NDE methods, thickness mea-surements, and corrosion rate)

• Physical measurements or inspec-tions

b. Operating History/Conditions

• Operating logs to include pressure,temperature, startups/shutdowns,cycles

• Consult with operating personnel todetermine operating history

• Date of installation• Identify internal and external environ-

mental conditions to include pressure,temperature, age, design, chemicaland mechanical environment, load-ings, processes, etc.

• List damage mechanisms identifiedin the past and that may be present based on materials, contaminants, andoperating conditions

• Identify the damage mechanismspresently active or which may becomeactive

• Identify the failure modes associatedwith the identified damage mecha-nisms, i.e., leaks, cracks, bursts

c. Equipment Information

• Manufacturer’s Data Reports• Material Test Reports• Drawings• Original design calculations/specifi-

cations

RB-9041 IDENTIFICATION OFDAMAGE MECHANISMS

There are a variety of damage mechanismsthat may affect the remaining service life of apressure-retaining item. Damage mechanismswill cause either micro or macro changes tothe material affecting its conditions or proper-ties. Damage mechanisms may be difficult toassess, therefore, detailed methods of evalu-ation for each damage mechanism should beperformed in accordance with establishedindustry practices or other acceptable stan-

dards should be followed (See RB-1040).These results should be evaluated and theinspection interval reviewed for possible adjustment. Various failure modes are describedin RB-4000.

Common forms of damage and damagemechanisms that affect remaining service lifeevaluations are listed below:

• Bulging• Sagging

• Stress corrosion cracking• Corrosion (local or general)• Creep• Thermal or mechanical fatigue• Hydrogen damage• Metallurgical changes• Erosion

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a. Any suitable nondestructive examinationmethod may be used to obtain thicknessmeasurements provided the instrumentsemployed are calibrated in accordancewith the manufacturer’s specification oran acceptable national standard.

1. If suitably located existing openingsare available; measurements may betaken through the openings.

2. When it is impossible to determinethickness by nondestructive means, ahole may be drilled through the metalwall and thickness gage measure-ments taken.

b. For new pressure-retaining items or PRI’sfor which service conditions are beingchanged, one of the following methodsshall be employed to determine the prob-able rate of corrosion from which theremaining wall thickness, at the time ofthe next inspection, can be estimated:

1. The corrosion rate as established bydata for pressure-retaining items inthe same or similar service;

2. If the probable corrosion rate cannot bedetermined by the above method, on-stream thickness determinations shall be made after approximately 1,000hours of service. Subsequent sets ofthickness measurements shall be takenafter additional similar intervals untilthe corrosion rate is established.

c. Corrosion Resistant Lining When part or all of the pressure-retain-

ing item has a corrosion resistant lining,

the interval between inspections of thosesections so protected may be based onrecorded experience with the same typeof lining in similar service, but shall notexceed ten years, unless sufficient datahas been provided to establish an alter-native inspection interval as describedin RB-9050. If there is no experience on

which to base the interval between inspec-tions, performance of the liner shall bemonitored by a suitable means, such asthe use of removable corrosion probes ofthe same material as the lining, ultrasonicexamination, or radiography. To check

the effectiveness of an internal insulationliner, metal temperatures may be obtained by surveying the pressure-retaining itemwith temperature measuring or indicatingdevices.

d. Two or More Zones When a pressure-retaining item has two

or more zones and the required thickness,corrosion allowance, or corrosion rate dif-fer so much that the foregoing provisionsgive significant differences in maximumperiods between inspections for the re-spective zones (e.g., the upper and lowerportions of some fractionating towers),the period between inspections may beestablished individually for each zoneon the basis of the condition applicablethereto, instead of being established forthe entire vessel on the basis of the zonerequiring the more frequent inspection.

e. Above-Ground Pressure Vessels

All pressure vessels above ground shall be given an external examination afteroperating the lesser of five years, or onequarter of remaining life, preferably whilein operation. Alternative intervals result-ing in longer periods may be assigned pro-vided the requirements of RB-9050 have been followed. Inspection shall includedetermining the condition of the exteriorinsulation, the supports, and the generalalignment of the vessel on its supports.Pressure vessels that are known to have a

remaining life of over ten years or that areprevented from being exposed to externalcorrosion (such as being installed in a cold box in which the atmosphere is purgedwith an inert gas, or by the temperature being maintained sufficiently low or suf-ficiently high to preclude the presenceof water), need not have the insulation

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removed for the external inspection.However, the condition of the insulatingsystem and/or the outer jacketing, suchas the cold box shell, shall be observedperiodically and repaired if necessary.

f. Interrupted Service The periods for inspection referred to

above assume that the pressure-retainingitem is in continuous operation, interrupt-ed only by normal shutdown intervals. Ifa pressure-retaining item is out of servicefor an extended interval, the effect of theenvironmental conditions during such aninterval shall be considered.

If the pressure-retaining item was im-properly stored, exposed to a detrimentalenvironment or the condition is suspect, itshall be given an inspection before beingplaced into service.

The date of next inspection, which was es-tablished at the previous inspection, shall be revised if damage occurred during theperiod of interrupted service.

g. Circumferential Stresses An area affected by a general corrosion in

which the circumferential stresses governthe MAWP, the least thicknesses along themost critical plane of such area may beaveraged over a length not exceeding:

1. The lesser of one-half the pressurevessel diameter, or 20 in. (500 mm) forvessels with inside diameters of 60 in.(1.5 m) or less, or

2. The lesser of one-third the pressurevessel diameter, or 40 in. (1 m), for

vessels with inside diameters greaterthan 60 in. (1.5 m), except that if thearea contains an opening, the distancewithin which thicknesses may be av-eraged on either side of such openingshall not extend beyond the limits ofreinforcement as defined in the ap-plicable section of the ASME Code for

ASME Stamped vessels and for othervessels in their applicable Codes ofConstruction.

h. Longitudinal Stresses If because of wind loads or other factors

the longitudinal stresses would be of im-portance, the least thicknesses in a lengthof arc in the most critical plane perpen-dicular to the axis of the pressure vesselmay be averaged for computation of thelongitudinal stresses. The thicknessesused for determining corrosion rates atthe respective locations shall be the mostcritical value of average thickness.

i. Local Metal LossCorrosion pitting shall be evaluated in ac-cordance with RB-9270. Widely scatteredcorrosion pits may be left in the pressure-retaining item in accordance with the fol-lowing requirements:

1. Their depth is not more than one-halfthe required thickness of the pres-sure-retaining item wall (exclusive ofcorrosion allowance);

2. the total area of the pits does not ex-

ceed 7 sq. in. (4500 sq mm) within any50 sq. inches (32000 sq mm); and

3. the sum of their dimensions (depthand width) along any straight linewithin this area does not exceed 2 in.(50 mm).

j. Weld Joint Efficiency Factor When the surface at a weld having a joint

efficiency factor of other than one is cor-roded as well as surfaces remote from the

weld, an independent calculation usingthe appropriate weld joint efficiency factormust be made to determine if the thick-ness at the weld or remote from the weldgoverns the maximum allowable workingpressure. For the purpose of this calcula-tion, the surface at a weld includes 1 in.(25 mm) on either side of the weld, or two

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times the minimum thickness on eitherside of the weld, whichever is greater.

k. Ellipsoidal and Torispherical Heads

1. When measuring the corroded thick-

ness of ellipsoidal and torisphericalheads, the governing thickness may be:

i. that of the knuckle region withthe head rating calculated by theappropriate head formula; or

ii. that of the central portion of thedished region, in which case thedished region may be consideredas a spherical segment whose al-lowable pressure is calculated bythe formula for spherical shells inthe ASME Code or other code ofconstruction.

2. The spherical segment of ellipsoi-dal and torispherical heads shall beconsidered to be that area located en-tirely within a circle whose diameteris equal to 80% of the shell diameter.The radius of the dish of a torispheri-

cal head is to be used as the radius ofthe segment (equal to the diameter ofthe shell for standard heads, thoughother radii have been permitted). Theradius of the spherical segment of el-lipsoidal heads shall be considered to be the equivalent spherical radius K

0

(as defined in the ASME Code).

l. Adjustments in Corrosion Rate If, upon measuring the wall thickness at

any inspection, it is found that an inaccu-

rate rate of corrosion has been assumed,the corrosion rate to be used for deter-mining the inspection frequency shall beadjusted to conform with the actual ratefound.

m. Riveted Construction For a pressure-retaining item with riveted

joints, in which the strength of one or moreof the joints is a governing factor in estab-lishing the maximum allowable workingpressure, consideration shall be given asto whether and to what extent corrosionwill change the possible modes of failure

through such joints. Also, even though noadditional thickness may have originally been provided for corrosion allowance atsuch joints, credit may be taken for thecorrosion allowance inherent in the jointdesign.

RB-9120 ESTIMATING INSPECTIONINTERVALS FOR PRESSURE-RETAINING ITEMS WHERECORROSION IS NOT AFACTOR

When the corrosion rate of a pressure-retain-ing item is not measurable, the item need not be inspected internally provided all of thefollowing conditions are met and completeexternal inspections, including thicknessmeasurements, are made periodically on thevessel, see RB-9050:

a. The non-corrosive character of the content,

including the effect of trace elements, has been established by at least five yearscomparable service experience with thefluid being handled.

b. No questionable condition is disclosed byexternal inspection.

c. The operating temperature of the pres-sure-retaining item does not exceed thelower limits for the creep range of thevessel metal. Refer to Table RB-9210.

d. The pressure-retaining item is protectedagainst inadvertent contamination.

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RB-9200 EVALUATING INSPECTIONINTERVALS OF PRESSURE-RETAINING ITEMS EXPOSEDTO INSERVICE DAMAGEMECHANISMS

RB-9210 EXPOSURE TO ELEVATEDTEMPERATURE (CREEP)

The owner-user of the pressure-retaining itemand the Inspector are cautioned to seek com-petent technical advice to determine whichof the condition assessment methods can beused to assure safe operation and determi-nation of the next inspection interval for thepressure-retaining item when elevated servicetemperature is a consideration.

When creep damage is suspected in a pressure-retaining item, an assessment of remainingservice life should be discussed with the ow-ner-user of the pressure-retaining item. Thisassessment may include, but is not limited to,the following methods:

a. Dimensional measurements of the item tocheck for creep.

b. Measurement of oxide scale and wallthickness for use in engineering analysisto determine remaining service life. Creeplife can be predicted through an empiricalapproach which uses available data forthe pressure-retaining component; total

number of operating hours to the presentis needed. Oxide scale thickness (steamside) can be measured directly from mate-rial samples or be measured in situ usingultrasonic techniques.

c. Metallographic examination to determinethe extent of exposure to creep damage.

d. Removal of a material sample for creeprupture testing. A test matrix is selected toyield the most meaningful results from thematerial sample. Test specimens are ma-chined from the sample and tested underrepresentative loads and temperatures (asselected in the test matrix). Creep strain vs.time and temperature vs. time to rupturedata are recorded.

RB-9220 EXPOSURE TO BRITTLEFRACTURE

Determining susceptibility to brittle fractureshould be required as part of the overall as-sessment for evaluating remaining service lifeor to avoid failure of the pressure-retainingitem during a hydrotest. In order to carry out brittle fracture assessment, mechanical design

information and materials of constructionshall be known. This information is requiredfor pressure-retaining components in orderto identify the most limiting componentmaterial that governs brittle fracture. Designinformation, maintenance/operating history,and information relating to environmentalexposure shall be evaluated to determine ifthere is a risk of brittle fracture.

When brittle fracture is a concern, methodsto prevent this failure shall be taken. These

methods could include changes to operatingconditions and further engineering evalua-tions to be performed by a qualified engineer(metallurgical/corrosion/mechanical). Engi-neering evaluation methods to prevent brittlefracture shall be reviewed and approved bythe owner-user, Inspector, and Jurisdiction.

TABLE RB-9210 — Temperatures AboveWhich Creep Becomes a Consideration

Material Temperature

Carbon Steel andC-1/2 Mo and FerriticStainless Steels

750°F (400°C)

Low Alloy Steels(Cr-Mo)

850°F (455°C)

Austenitic StainlessSteels

950°F (510°C)

Aluminum Alloys 200°F (95°C)

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RB-9230 EVALUATING CONDITIONSTHAT CAUSE BULGES/

BLISTERS/LAMINATIONS

Blistering in pressure-retaining items can re-sult from laminations, inclusions in the metal,

or damage mechanisms that occur in service.Procedures for evaluating bulges/blisters/laminations are referenced in applicable stan-dards (see RB-1040).

An engineering evaluation shall be performedto ensure continued safe operation when bulges/blisters/laminations are identified.If a bulge/blister/lamination is within thespecified corrosion allowance, further assess-ment should be performed to evaluate anycrack-like indications in surrounding basematerial.

Note: Proximity of crack-like indications inwelds and HAZ is important. Cracks and blisters should be evaluated separately.

RB-9240 EVALUATING CRACK-LIKEINDICATIONS IN PRESSURE-RETAINING ITEMS

Crack-like indications in pressure-retainingitems are planar flaws characterized by lengthand depth with a sharp root radius. Cracksmay occur within material or on the surfaceand may be individual or multiple in nature.In some cases, a conservative approach is totreat aligned porosity, inclusions, undercuts,and overlaps as crack-like indications. It isimportant that the cause of cracking is iden-tified prior to any further determination ofinspection intervals.

If crack-like indications are on the surfaceand within the specified corrosion allow-ance, removal by blend grinding or air arcgouging can be performed. Measurementsshall be taken to assure minimum thicknessis met and effective monitoring techniquesshould be established. If a crack-like flaw is

not completely removed and repaired, thenan engineering fracture mechanics or otherassessment must be performed to verify con-tinued safe operation.

There are various methods or approaches

for assessing crack-like indication, some ofwhich are referenced in applicable standards(see RB-1040).

RB-9250 EVALUATING EXPOSURE OFA PRESSURE-RETAININGITEM TO FIRE DAMAGE

The extreme heat of a fire can produce visualstructural damage and less apparent degra-dation of mechanical properties (decrease inyield strength or fracture toughness). Poten-tial damage includes changes in mechanicalproperties, decrease in corrosion resistance,distortion, and cracking of pressure bound-ary components. Distortion of equipmentextremities such as ladders and platformsdoes not necessarily mean that the pressureequipment is no longer suitable for continuedservice. Process fluid inside the vessel mayserve as a cooling medium, thus preservingmechanical properties of the equipment.

Instrumentation and wiring are commonlydamaged during a fire.

Data requirements and history informationshould be obtained as identified in RB-9040.

Recommended measurements and collectionof data for assessment of fire damage shallinclude but are not limited to:

• Concentrated areas of fire damage versusoverall fire damage as it relates to normal

operation• Determination of cause and origin of fire• Temperature extremes• Nature of the fuel• Source of ignition• Time at temperature• Cooling rate

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• Photographs taken• Plant personnel interviewed• Actual strength and toughness properties

of the material

Note: It is important that evidence be main-

tained in order to perform a proper evaluationand assessment.

Components subjected to fire damage canexhibit altered mechanical properties, andshould be evaluated to determine if the ma-terial has retained necessary strength andtoughness as specified in the original code ofconstruction. Heating above the lower criticaltemperature results in a phase transformationthat upon rapid cooling can dramatically af-fect material properties. Evaluation methodsmay consist of:

• Portable hardness testing• Field metallography or replication• Hydrostatic pressure testing• Magnetic particle testing• Liquid penetrant testing• Visual examination• Dimensional verification checks

If visual distortion or changes in the micro-

structure or mechanical properties are noted,consideration of replacing the component ora detailed engineering analysis shall be per-formed to verify continued safe operation.

Techniques for assessing fire damage are refer-enced in applicable standards (see RB-1040).

RB-9260 EVALUATING EXPOSUREOF PRESSURE-RETAININGITEMS TO CYCLIC FATIGUE

A fatigue evaluation should be performed ifa component is subject to cyclic operation.The allowable number of cycles (mechanicalor thermal) at a given level of stress should be adequate for the specified duration ofservice to determine suitability for continuedoperation.


Techniques for assessing fatigue are ref erencesin applicable standards (see RB-1040).

RB-9270 EVALUATING PRESSURE- RETAINING ITEMS

CONTAINING LOCAL THINAREAS

Local thin areas can result from corrosion/erosion, mechanical damage, or blend/grindtechniques during fabrication or repair, andmay occur internally or externally. Types oflocal thin areas are grooves, gouges, and pit-ting. When evaluating these types of flaws,the following should be considered:

• Original design and current operatingconditions

• Component is not operating in the creeprange

• Material has sufficient toughness• Not operating in cyclic service• Does not contain crack-like indications• Flaws are not located in knuckle regions

of heads or conical transitions

• Applied loads• The range of temperature fluctuation

Where appropriate crack-like indicationsshould be removed by blend/grinding, andevaluated as a local thin area.


Required measurements for assessment oflocal thin areas shall include:

• Thickness profiles within the local re-gion

• Flaw dimensions• Flaw to major structural discontinuity

spacing• Vessel geometry• Material properties

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Required measurements for assessment ofpitting corrosion shall include:

• Depth of the pit• Diameter of the pit• Shape of the pit

• Uniformity

If metal loss is less than specified corrosion/erosion allowance and adequate thickness isavailable for future corrosion, then monitor-ing techniques should be established. If metalloss is greater than specified corrosion/ero-sion allowance, a detailed engineering evalu-ation shall be performed to ensure continuedsafe operation.

Techniques for assessing local thin areas andpitting are referenced in applicable standards(see RB-1040).

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Repairs and Alterationsof Pressure-Retaining Items

Part RC

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PART RC — REPAIRS AND ALTERATIONS OF PRESSURE-RETAINING ITEMS

TABLE OF CONTENTS

RC-1000 General Requirements ....................................................................................... 91 RC-1010 Scope ..................................................................................................................... 91

RC-1020 Construction Standards ..................................................................................... 91 RC-1030 Accreditation ....................................................................................................... 91 RC-1040 Materials .............................................................................................................. 91 RC-1050 Replacement Parts .............................................................................................. 91 RC-1060 Authorization ...................................................................................................... 92 RC-1070 Inspector ............................................................................................................... 92 RC-1090 Welding ................................................................................................................ 93

RC-1100 Heat Treatment .................................................................................................... 94 RC-1110 Nondestructive Examination ............................................................................ 94 RC-1120 Pressure Gages, Measurement, Examination, and Test Equipment ............ 95 RC-1130 Acceptance Inspection ....................................................................................... 95 RC-1140 Stamping .............................................................................................................. 95 RC-1150 Registration of “R” Forms ................................................................................. 95

RC-2000 Additional Requirements for Repairs .............................................................. 96 RC-2010 Scope ..................................................................................................................... 96 RC-2020 Defect Repairs ..................................................................................................... 96 RC-2030 Authorization ...................................................................................................... 96 RC-2050 Examination and Test ......................................................................................... 97 RC-2060 Stamping .............................................................................................................. 98 RC-2070 Documentation .................................................................................................... 98 RC-2080 Repair of ASME Code Section VIII, Division 2 or 3 , Pressure Vessels ........ 99

RC-3000 Additional Requirements for Alterations ..................................................... 100

RC-3010 Scope ................................................................................................................... 100 RC-3020 Design ................................................................................................................. 100 RC-3030 Examination and Test ....................................................................................... 101 RC-3040 Stamping ............................................................................................................ 103 RC-3050 Documentation .................................................................................................. 103

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RC-1000 GENERAL REQUIREMENTS

RC-1010 SCOPE

This part provides general requirementsthat apply to repairs and alterations to pres-

sure-retaining items and shall be used inconjunction with RC-2000 and RC-3000.

RC-1020 CONSTRUCTION

STANDARDS

When the s ta nd a rd governi ng theoriginal construction is the ASME Code,repairs and alterations shall conform,insofar as possible, to the section andedition of the ASME Code most applicable tothe work planned.

When the s ta nd a rd governi ng theoriginal construction is not the ASMECode, repairs or alterations shall con-form, insofar as possible, to the editionof the construction standard or specifica-tion most applicable to the work. Wherethis is not possible or practicable, it ispermissible to use other codes, standards,or specifications, including the ASME Code

,provided the “R” Certificate Holder has theconcurrence of the Inspector and the juris-diction where the pressure-retaining item isinstalled.

RC-1030 ACCREDITATION

Organizations performing repairs or altera-tions shall be accredited as described in Part RA , as appropriate for the scope of work to be performed.

RC-1040 MATERIALS

The materials used in making repairs oralterations shall conform to the originalcode of construction including the material

specification requirements. Carbon or alloysteel having a carbon content of more than0.35% shall not be welded unless permitted by the original code of construction. The “R”Certificate Holder is responsible for verify-ing identification of existing materials from

original data, drawings or pressure-retainingitem records and identification of the mate-rials to be installed. Consideration shall begiven to the condition of the existing material,especially in the weld preparation area.

For corrugating rolls manufactured per therequirements of paragraph UF-7 of SectionVIII, Div. 1, restoration of worn corrugatingroll surfaces by weld overlay is permitted forall classes of SA-649 forging material and anexception to the 0.35% carbon limit is per-mitted. The requirements to qualify weldingprocedures and welder performance shall be those in ASME Section IX for hard facing(water resistance) and corrosion resistanceoverlays.

RC-1050 REPLACEMENT PARTS

Replacement parts to be used in repairs oralterations shall meet the following applicable

requirements:

a. Replacement parts that will be subjectto internal or external pressure thatconsist of new materials which should be formed to the required shape bycasting, spinning, forging, die forming,and on which no fabrication welding isperformed shall be supplied as mate-rial. Such parts shall be marked withthe material and part identificationand the name or trademark of the parts

manufacturer. In lieu of full identificationmarking on the material or part, the partmanufacturer may use a coded markingsystem traceable to the original marking.Such markings shall be considered as theparts manufacturer’s certification that thepart complies with the original code of

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construction. Examples include seamlessor welded tubes or pipe, forged nozzles,heads or tubesheets, or subassemblies at-tached together mechanically.

b. Replacement parts that will be subject to

internal or external pressure that are pre-assembled by attachment welds shall havethe welding performed in accordance withthe original code of construction. The sup-plier or manufacturer shall certify that thematerial and fabrication are in accordancewith the original code of construction.This certification shall be supplied in theform of bills of material and drawingswith statement of certification. Examplesinclude boiler furnace wall or floor panelassemblies, prefabricated openings in boiler furnace walls, such as burner open-ings, air ports, inspection openings, orsootblower openings.

c. When ASME is the original code ofconstruction, replacement parts subject tointernal or external pressure fabricated by welding, which require shop inspec-tion by an Authorized Inspector shall befabricated by an organization having anappropriate ASME Certificate of Autho-

rization. The item shall be inspected andstamped as required by the applicablesection of the ASME Code. A completedASME Manufacturer’s Partial Data Reportshall be supplied by the manufacturer.

d. When the original code of constructionis other than ASME, replacement partssubject to internal or external pressure,fabricated by welding shall be manu-factured by an organization certifiedas required by the original code of con-

struction. The item shall be inspectedand stamped as required by the originalcode of construction. Certification to theoriginal code of construction as required by the original code of construction or

equivalent shall be supplied with the item.When this is not possible or practicable,the organization fabricating the partmay have a National Board Certificate ofAuthorization; replacement parts shall be documented on Form R-3 and the “R”

symbol stamp applied as described inAppendix 2.

RC-1060 AUTHORIZATION

The Inspector’s authorization to perform arepair or alteration shall be obtained prior toinitiation of a repair or alteration to a pres-sure-retaining item.

RC-1070 INSPECTOR

Inspection and certification shall be made by an Inspector employed by one of thefollowing:

a. A Jurisdictional Authorized InspectionAgency,

b. The Authorized Inspection Agency of the“R” Certificate Holder making the repair

or alteration,

c. The Authorized Inspection Agency thatinsures the pressure-retaining item, or

d. The Owner-User Inspect ion Organi-zation. An Inspector employed by anOwner-User Inspection Organizationmay authorize and accept work only onpressure-retaining items owned-used bythe company. The company’s organizationand inspection procedures shall have the

specific approval of the Jurisdiction orin the absence of a Jurisdiction, by theNational Board.

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RC-1090 WELDING

Welding shall be performed in accordancewith the requirements of the original code ofconstruction used for the pressure-retainingitem.

RC-1091 WELDING PROCEDURE

SPECIFICATIONS

Welding shall be performed in accordancewith Welding Procedure Specifications (WPS)qualified in accordance with the original codeof construction. When this is not possibleor practicable, the WPS may be qualified inaccordance with Section IX of the ASMECode.

RC-1092 STANDARD WELDING

PROCEDURE

SPECIFICATIONS

An “R” Certificate Holder may use one ormore applicable Standard Welding ProcedureSpecifications shown in Appendix A withoutsupporting procedure qualification records(PQRs) since SWPs are prequalified and the

PQR will not be supplied.

RC-1093 PERFORMANCE

QUALIFICATION

Welders or welding operators shall bequalified for the welding processes that areused. Such qualification shall be in accordancewith the requirements of the original code ofconstruction or Section IX of the ASME Code.Use of Standard Welding Procedure Specifi-

cation shown in Appendix A is permitted forperformance qualification testing.

RC-1094 WELDING RECORDS

The “R” Certificate Holder shall maintaina record of the results obtained in weldingprocedure qualifications, except for thosequalifications for which the provisions of

RC-1092 are used and of the results obtainedin welding performance qualifications. Theserecords shall be certified by the “R” CertificateHolder and shall be available to the inspector.

RC-1095 WELDERS’

IDENTIFICATION

The “R” Certificate Holder shall establisha system for the assignment of a uniqueidentification mark to each welder/weld-ing operator qualified in accordance withthe requirements of the NBIC. The “R” Cer-tificate Holder shall also establish a writtenprocedure whereby all welded joints can beidentified as to the welder or welding opera-tor who made them. This procedure shall useone or more of the following methods and beacceptable to the Inspector. The welder’s orwelding operator’s identification mark may be stamped (low stress stamp) adjacent to allwelded joints made by the individual or, in

lieu of stamping, the “R” Certificate Holdermay keep a record of welded joints andthe welders or welding operators used inmaking the joints.

RC-1096 WELDERS’ CONTINUITY

The performance qualification of a welder orwelding operator shall be affected when oneof the following conditions occur:

a. When the welder or welding operatorhas not welded using a specific processduring a period of six months or more,their qualifications for that process shallexpire.

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b. When there is specific reason to questiontheir ability to make welds that meet thespecification, the qualification which sup-ports the welding that is being performedshall be revoked. All other qualificationsnot questioned remain in effect.

RC-1100 HEAT TREATMENT

RC-1101 PREHEATING

Preheating may be employed during weld-ing to assist in completion of the welded joint (Appendix B). The need for and thetemperature of preheat are dependent on anumber of factors such as chemical analysis,degree of restraint of the items being joined,material thickness, and mechanical proper-ties. The welding procedure specification forthe material being welded shall specify thepreheat temperature requirements.

RC-1102 POSTWELD HEAT

TREATMENT

Postweld heat treatment shall be per-

formed as required by the original code ofconstruction in accordance with a writtenprocedure. The procedure shall contain theparameters for postweld heat treatment. Lo-cal PWHT that is not specified by the originalcode of construction may be performed inaccordance with an Alternative PostweldHeat Treatment Method described in RD-1100 with acceptance by the Inspector and, whenrequired, by the Jurisdiction.

RC-1103 ALTERNATIVE POSTWELDHEAT TREATMENT

METHODS

Under certain conditions, postweld heattreatment in accordance with the originalcode of construction may be inadvisable or

impractical. In such instances, alternativemethods of postweld heat treatment orspecial welding methods acceptable to theInspector may be used. Methods which may be used as alternatives to postweld heat treat-ment are described in Part RD.

RC-1110 NONDESTRUCTIVE

EXAMINATION

The nondestructive examination (NDE)requirements, including technique, extent ofcoverage, procedures, personnel qualification,and acceptance criteria, shall be in accordancewith the original code of construction used forconstruction of the pressure-retaining item.Weld repairs and alterations shall be subjectedto the same nondestructive examination re-quirements as the original welds. Where thisis not possible or practicable, alternative NDEmethods acceptable to the Inspector and the jurisdiction where the pressure-retaining itemis installed, where required, may be used.

NDE personnel shall be qualified and certi-fied in accordance with the requirements ofthe original code of construction. When thisis not possible or practicable, NDE personnel

may be qualified and certified in accordancewith their employer’s written practice. ASNTSNT-TC-1A, Recommended Practice for Non-destructive Testing Personnel Qualification andCertification (2001 edition), or ASNTCP-189,Standard for Qualification and Certification ofNondestructive Testing Personnel (2001 edition),shall be used as a guideline for employers toestablish their written practice. The ASNTCentral Certification Program (ACCP, Rev. 3,Nov. 1997) may be used to fulfill the examina-tion and demonstration requirements of SNT-

TC-1A and the employer’s written practice.Provisions for qualification and certification ofNDE personnel shall be described in the “R”Certificate Holder’s written quality system.

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RC-1120 PRESSURE GAGES,

MEASUREMENT,

EXAMINATION, AND TEST

EQUIPMENT

The calibration of pressure gages, measure-

ment, examination, and test equipment, anddocumentation of calibration shall be per-formed as required by the applicable standardused for construction.

RC-1130 ACCEPTANCE INSPECTION

The Inspector making the acceptance inspec-tion shall be the same inspector who autho-rized the repair or alteration. Where this is notpossible or practicable, another Inspector mayperform the acceptance inspection; however,in all cases, the Inspector who performs theacceptance inspection shall be an employee ofthe same organization as the Inspector whoauthorized the repair or alteration.

Before signing the appropriate NBIC ReportForm, the Inspector shall review the drawings,assure the repair or alteration was performedin accordance with the acceptable code ofconstruction or standard, witness any pres-

sure test or any acceptable alternative testmethod applied, assure that the requirednondestructive examinations have beenperformed satisfactorily, and that the otherfunctions necessary to assure compliancewith the requirements of this Code have beenperformed.

RC-1140 STAMPING

The stamping of or attaching of a nameplate

to, a pressure-retaining item shall indicatethat the work was performed in accordancewith the requirements of this Code. Suchstamping or attaching of a nameplate shall be done only wi th the know ledge andauthorization of the Inspector. The “R”Certificate Holder responsible for the repair

or the construction portion of the alterationshall apply the stamping. For a re-ratingwhere no physical changes are made to thepressure-retaining item, the “R” CertificateHolder responsible for design shall apply thestamping. Required stamping and nameplate

information is shown in Appendix 2.

RC-1141 REMOVAL OF ORIGINAL

STAMPING OR NAMEPLATE

If it becomes necessary to remove theoriginal stamping, the Inspector shall, subjectto the approval of the Jurisdiction, witnessthe making of a facsimile of the stamping,the obliteration of the old stamping, and thetransfer of the stamping to the new item.When the stamping is on a nameplate, theInspector shall witness the transfer of thenameplate to the new location. Anyrelocation shall be described on the applicableNBIC “R” Form. ASME Code items shall not be restamped with the ASME Code Symbol.

RC-1150 REGISTRATION OF “R”

FORMS

Organizations performing repairs oralterations under an “R” stamp program mayregister such repairs or alterations with theNational Board.

It should be noted that some jurisdictions mayrequire registration of repairs and alterationswith the National Board.

For those “R” Forms not registered with theNational Board, the organization performingrepairs or alterations shall retain a copy of

the “R” Form on file for a minimum periodof five years.

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RC-1151 FORM R LOG

The “R” Certificate Holder shall maintain asingle, sequential log of “R” Form num bersassigned for NBIC Report Forms (i.e. , R-1 , R-2 , and R-3) that are registered with the National

Board.

RC-2000 ADDITIONAL

REQUIREMENTS FOR

REPAIRS

RC-2010 SCOPE

This section provides additional require-ments for repairs to pressure-retainingitems and shall be used in conjunction withRC-1000.

RC-2020 DEFECT REPAIRS

Before a repair is made to a defect in a welded joint or base metal, care should be taken to in-vestigate its cause and to determine its extentand likelihood of recurrance.

RC-2021 DRAWINGS

As appropriate, drawings shall be preparedto describe the repair. Drawings shall in-clude sufficient information to satisfactorilyperform the repair.

RC-2030 AUTHORIZATION

Repairs to pressure-retaining items shall not

be initiated without the authorization of theInspector, who shall determine that the repairmethods are acceptable.

Subject to acceptance of the Jurisdiction, theInspector may give prior approval for routine

repairs provided the Inspector assures thatthe “R” Certificate Holder has acceptableprocedures covering the repairs.

RC-2031 ROUTINE REPAIRS

Prior to performing routine repairs, the “R”Certificate Holder should determine thatroutine repairs are acceptable to the jurisdiction where the pressure-retaining itemis installed.

a. The four categories of routine repairsare:

1. Welded repairs or replacements oftubes or pipes NPS 5 (DN 125) andsmaller, or sections thereof, whereneither postweld heat treatment norNDE other than visual examinationis required by the original code ofconstruction.

2. The addition or repair of non-load bearing attachments to pressure-re-taining items where postweld heattreatment is not required.

3. Weld buildup of wasted areas in shellsand heads not exceeding 100 sq. in.(65,000 sq. mm) or 25% of nominalwall thickness or 1/2 in. (13 mm),whichever is less.

4. Corrosion resistance weld overlay notexceeding 100 sq. in. (65,000 sq.mm).

b. Routine repairs shall be performed un-der the “R” Certificate Holder’s qualitysystem program; however, the require-

ment for in-process involvement of theInspector and stamping may be waived.See RC-2060.

c. The process of identifying, controlling,and implementing routine repairs shall

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be documented in the “R” Certif icateHolder’s quality system program.

d. Routine repairs shall be documented ona Form R-1 with a statement on line 10,Remarks: “Routine Repair”.

RC-2032 WELD REPAIRS TO

PRESSURE RELIEF VALVE

PARTS

Prior to performing weld repairs to pressurerelief valve (PRV) parts, the “R” CertificateHolder shall receive repair information re-quired by RA-2255(j) from the “VR” Certifi-cate Holder responsible for the pressure reliefvalve repair.

a. PRV part weld repairs shall be performedunder the “R” Certificate Holder’s qual-ity system; however, the requirements forin-process involvement of the Inspector(RC-1130) may be waived. The require-ment for stamping is waived.

b. The process of identifying and controllingrepairs shall be documented in the “R”Certificate Holder’s quality system.

c. PRV part repairs shall be documented on aForm R-1 with a statement under Remarks“PRV Part Repair.” The owner’s name andlocation of installation shall be that of the“VR” Certificate Holder. The informationreceived from the “VR” Certificate Holder(RA-2255(j)) shall be noted under Descrip-tion of Work.

d. Upon completion of the repair, the re-paired part and completed Form R-1

shall be returned to the “VR” CertificateHolder responsible for completing thePRV repair.

RC-2050 EXAMINATION AND TEST

The following requirements shall apply to allrepairs to pressure-retaining items:

a. The integrity of repairs and replacement

parts used in repairs shall be verified byexamination or test.

b. The “R” Certificate Holder is responsiblefor all activities relating to examinationand test of repairs.

c. Examinations and tests to be used shall be subject to acceptance of the Inspectorand where required, acceptance of the jurisdiction.

RC-2051 METHODS

Based on the nature and scope of the repairactivity, one or a combination of the follow-ing examination and test methods shall beapplied to repairs and replacement parts usedin repairs.

a. Liquid Pressure Test Pressure testing of repairs shall meet the

following requirements:

1. Pressure tests shall be conducted us-ing water or other liquid medium. Thetest pressure shall be the minimumrequired to verify the leak tightnessintegrity of the repair, but not morethan 150% of the maximum allowableworking pressure (MAWP) stampedon the pressure-retaining items, as adjusted for temperature. When originaltest pressure included consideration

of corrosion allowance, the test pres-sure may be further adjusted based onthe remaining corrosion allowance.

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2. During a pressure test where thetest pressure will exceed 90% of theset pressure of the pressure reliefdevice, the device shall be removedwhenever possible. If not possible, atest gag may be used following the

valve manufacturer’s instructions andrecommendations. Extreme cautionshould be employed to ensure onlyenough force is applied to containpressure. Excessive mechanical forceapplied to the test gag may result indamage to the seat and/or spindle andmay interfere with the proper opera-tion of the valve. The test gag shall beremoved following the test.

The organization who performs thepressure test and applies a spindlerestraint shall attach a metal tag thatidentifies the organization and datethe work was performed to the pres-sure relieving device. If the seal was broken, the organization shall resealthe adjustment housing with a sealthat identifies the responsible organi-zation. The process shall be acceptableto the jurisdiction where the pressure-retaining items are installed.

3. The metal temperature for the pres-sure test shall be in accordance withthe original code of construction, butnot less than 60°F (16°C) unless theowner provides information on thetoughness characteristics of the mate-rial to indicate the acceptability of alower test temperature. During closeexamination the metal temperatureshall not exceed 120°F (50°C) unlessthe owner specified requirements for

a higher test temperature, and it isacceptable to the Inspector.

4. Hold-time for the pressure test shall be a minimum of 10 minutes prior toexamination by the Inspector. Wherethe test pressure exceeds the MAWPof the item, the test pressure shall be reduced to the MAWP for close

examination by the Inspector. Hold-time for close examination shall be asnecessary for the Inspector to conductthe examination.

b. Pneumatic Test

A pneumatic test may be conducted. Con-currence of the owner shall be obtained inaddition to that of the Inspector and juris-diction where required. The test pressureshall be the minimum required to verifyleak tightness integrity of the repair, butshall not exceed the maximum pneumatictest pressure of the original code of con-struction. Precautionary requirements ofthe original code of construction shall befollowed.

c. Initial Service Leak Test When an initial service leak test is

permitted by the original code of con-struction, such testing may also be usedto verify the leak tightness integrity ofrepairs.

d. Vacuum Test A vacuum test may be conducted. Vacuum

test methods used shall be suitable toverify the leak tightness integrity of the

repair.

e. Nondestructive Examination Nondestructive examination (NDE) may

be conducted. NDE methods used shall besuitable for providing meaningful resultsto verify the integrity of the repair.

RC-2060 STAMPING

Pressure-retaining items repaired in accor-

dance with the NBIC shall be stamped asrequired by Appendix 2.

Subject to the acceptance of the jurisdictionand the concurrence of the Inspector, name-plates and stamping may not be required forroutine repairs (RC-2031). In all cases, thetype and extent of repairs necessary shall beconsidered prior to waiving the requirement.

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RC-2070 DOCUMENTATION

Repairs that have been performed in accor-dance with the NBIC shall be documentedon Form R-1, Report of Repair , as shown inAppendix 5. Form R-4, Report Supplementary

Sheet shall be used to record additional datawhen space is insufficient on Form R-1.

RC-2071 PREPARATION OF

FORM R-1

Preparation of Form R-1 shall be theresponsibility of the “R” Certificate Holderperforming the repair.

An Inspector shall indicate acceptance bysigning the Form R-1.

The Form R-3 and the manufacturer’s datareports described in RC-1050 shall be a partof the completed Form R-1 and shall be at-tached thereto.

RC-2072 DISTRIBUTION

Legible copies of the completed Form

R-1 , together with attachments, shall bedistributed to the owner or user, the Inspec-tor, the jurisdiction, if required, and the Au-thorized Inspection Agency responsible forinservice inspection.

Distribution of Form R-1 and attachmentsshall be the responsibility of the organizationperforming the repair.

RC-2073 REGISTRATION

Form R-1 may be registered with the NationalBoard as noted in RC-1150.

RC-2080 REPAIR OF ASME CODE

SECTION VIII, DIVISION 2

OR 3, PRESSURE VESSELS

RC-2081 SCOPE

The following requirements shall apply for therepair of pressure vessels constructed to therequirements of Section VIII, Division 2 or 3,of the ASME Code.

RC-2082 REPAIR PLAN

The user shall prepare or cause to haveprepared a detailed plan covering the scopeof the repair.

a. Professional Engineer ReviewThe repair plan shall be reviewed andcertified by a Professional Engineer who isregistered in one or more of the states of theUnited States of America or the provincesof Canada, is experienced in pressure ves-sel design, and is knowledgeable in ASMESection VIII, Div. 2 or 3, as applicable. Thereview and certification shall be such as toensure the work involved in the repair is

compatible with the user’s designspecification and the manufacturer’sdesign report.

b. Authorized Inspection Agency AcceptanceFollowing review and certification,the repair plan shall be submitted foracceptance to the Authorized InspectionAgency/Owner-User Inspection Orga-nization whose Inspector will make theacceptance inspection and sign the FormR-1.

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RC-3000 ADDITIONAL

REQUIREMENTS FOR

ALTERATIONS

RC-3010 SCOPE

This section provides additional requirementsfor alterations to pressure-retaining items andshall be used in conjunction with RC-1000.

RC-3020 DESIGN

The “R” Certificate Holder performingalterations shall establish controls to en-sure that all required design information,applicable drawings, design calculations,specifications, and instructions are prepared,obtained, controlled, and interpreted toprovide the basis for an alteration inaccordance with the original code of con-struction. When a Manufacturer’s Data Re-port is required by the original constructionstandard, a copy of the original Data Reportshall be obtained for use in the design of thealteration. When the original Manufacturer’sData Report cannot be obtained, agreementson the method of establishing design basis

for the alteration shall be obtained from theInspector and the jurisdiction.

RC-3021 CALCULATIONS

A set of calculations shall be completed priorto the start of any physical work. All designwork shall be completed by an organizationexperienced in the design portion of thestandard used for construction of the item.All calculations shall be made available for

review by the Inspector accepting the design.

RC-3022 RE-RATING7

Re-rating of a pressure-retaining item byincreasing the maximum allowable workingpressure (internal or external) or tempera-ture or decreasing the minimum tempera-

ture shall be done only after the followingrequirements have been met to thesatisfaction of the jurisdiction at the locationof the installation:

a. Revised calculations verifying the newservice conditions shall be prepared in ac-cordance with the “R” Certificate Holder’sQuality Control System. Establishing ahigher joint efficiency to re-rate a pres-sure-retaining item is not permitted.

b. All re-ratings shall be established inaccordance with the requirements ofthe construction standard to which thepressure-retaining item was built.

c. Current inspection records verify that thepressure-retaining item is satisfactory forthe proposed service conditions.

d. The pressure-retaining item has beenpressure tested, as required, for the new

service conditions.

RC-3023 DRAWINGS

As appropriate, drawings shall be preparedto describe the alteration. Drawings shallinclude sufficient information to satisfactorilyperform the alteration.

7 Re-rating: Except as provided for Yankee Dryers inAppendix K, this code does not provide rules forderating boilers or pressure vessels; however, whenthe MAWP and/or allowable temperature of a

boiler or pressure vessel is reduced, the jurisdictionwherein the object is installed should be contactedto determine if specific procedures should be fol-lowed.

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RC-3024 ALLOWABLE STRESSES

For re-rating or re-calculating a new minimumwall thickness for a pressure-retaining itemusing a later edition/addenda of the originalcode of construction that permits use of higher

allowable material stress values than wereused in the original construction, the addi-tional requirements of RD-3000 shall apply.

RC-3025 ALTERATION OF ASME

CODE SECTION VIII,

DIVISION 2 OR 3 PRESSURE

VESSELS

RC-3026 SCOPE

The following shall apply for the alteration ofpressure vessels constructed to the require-ments of Section VIII, Division 2 or 3 of theASME Code.

RC-3027 ALTERATION PLAN

Professional Engineer ReviewThe alteration plan shall be reviewed and

certified by a Professional Engineer who isregistered in one or more of the states of theUnited States of America or the provincesof Canada, is experienced in pressure vesseldesign, and is knowledgeable in ASME Sec-tion VIII, Div. 2 or 3, as applicable. The reviewand certification shall be such as to ensurethe work involved in alteration is compatiblewith the user’s design specification and themanufacturer’s design report.

User’s Design Specification

If the alteration is such that the work is notcompatible with or changes one or morerequirement(s) of the original user’s designspecification, the user’s design specificationshall be revised by the user with the newparameters or changes. The revisions shall

be certified by a Professional Engineer whois registered in one or more of the states ofthe United States of America or the provincesof Canada, is experienced in pressure vesseldesign, and is knowledgeable in ASME Sec-tion VIII, Div. 2 or 3, as applicable.

Manufacturer’s Design ReportThe “R” Certificate Holder shall prepare orcause to have prepared a supplement to themanufacturer’s design report to reconcile thenew parameters or changes with the user’sdesign specification.

The supplement to the manufacturer’s designreport shall be certified by a ProfessionalEngineer who is registered in one or more ofthe states of the United States of America orthe provinces of Canada, is experienced inpressure vessel design, and is knowledge-able in ASME Section VIII, Div. 2 or 3, asapplicable.

Authorized Inspection Agency AcceptanceFollowing review and certification, the altera-tion plan shall be submitted for acceptance tothe Authorized Inspection Agency/Owner-User Inspection Organization whose inspectorwill make the acceptance inspection and sign

the Form R-2.

RC-3030 EXAMINATION AND TEST

The following requirements shall apply to allalterations to pressure-retaining items:

a. The integrity of alterations and replace-ment parts used in alterations shall beverified by examination or test.

b. The “R” Certificate Holder is responsiblefor all activities relating to examinationand test of alterations.

c. Examinations and tests to be used shall be subject to acceptance of the Inspector,and where required, acceptance of the Jurisdiction.

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RC-3031 METHODS

Based on the nature and scope of thealterations activity, one or a combination ofthe following examination and test meth-ods shall be applied to alterations and

replacement parts used in alterations.

a. Liquid Pressure Test Pressure testing of alterations shall meet

the following requirements:

1. A pressure test as required by theoriginal code of construction shall be conducted. The test pressure shallnot exceed 150% of the maximum al-lowable working pressure (MAWP)stamped on the pressure-retain-ing item, as adjusted for tempera-ture. When the original test pressureincluded consideration of corrosionallowance, the test pressure may be further adjusted based on theremaining corrosion allowance. Thepressure test for replacement partsmay be performed at the point ofmanufacture or point of installation.

2. As an alternative to pressure testing

connecting welds in accordance withthe original code of construction,connecting welds may be tested orexamined in accordance with the rulesfor repairs (see RC-2051). Connectingwelds are defined as welds attachingthe replacement part to the pressure-retaining item.

3. During a pressure test where thetest pressure will exceed 90% of theset pressure of the pressure relief

device, the device shall be removedwhenever possible. If not possible,a test gag may be used following thevalve manufacturer’s instructions andrecommendations. Extreme cautionshould be employed to ensure onlyenough force is applied to contain

pressure. Excessive mechanical forceapplied to the test gag may result indamage to the seat and/or spindle andmay interfere with the proper opera-tion of the valve. The test gag shall beremoved following the test.

The organization who performs thepressure test and applies a spindlerestraint shall attach a metal tag thatidentifies the organization and datethe work was performed to the pres-sure relieving device. If the seal was broken, the organization shall resealthe adjustment housing with a sealthat identifies the responsible organi-zation. The process shall be acceptableto the jurisdiction where the pressure-retaining items are installed.

4. The metal temperature for the pres-sure test shall be in accordance withthe original code of construction, but not less than 60°F (16°C) unlessthe owner provides information onthe toughness characteristics of thematerial to indicate the acceptability ofa lower test temperature. During closeexamination the metal temperature

shall not exceed 120°F (50°C) unlessthe owner specifies requirements fora higher test temperature and it is ac-ceptable to the Inspector.

5. Hold-time for the pressure test shall be a minimum of 10 minutes priorto examination by the Inspector. Thetest pressure shall be reduced to theMAWP for close examination by theInspector. Hold-time for close exami-nation shall be as necessary for the In-

spector to conduct the examination.

b. Pneumatic Test A pneumatic test may be conducted when

contamination of the pressure-retainingitem by liquids is possible or when liq-uid pressure testing is not practicable.

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Concurrence of the owner shall be ob-tained in addition to the Inspector and jurisdiction where required. Pneumatictest requirements and precautions shall be in accordance with the original codeof construction.

c. Nondestructive Examination Nondestructive examination (NDE) may

be conducted when contamination of thepressure-retaining item by liquids is pos-sible or when pressure testing is not prac-ticable. Concurrence of the owner shall beobtained in addition to the Inspector and jurisdiction where required. NDE meth-ods used shall be suitable for providingmeaningful results to verify the integrityof the alteration.

RC-3040 STAMPING

Pressure-retaining items altered in accor-dance with this code shall have a nameplateor stamping applied adjacent to the originalmanufacturer’s stamping or nameplate in ac-cordance with Appendix 2. For an alterationwhere physical changes are made to the pres-sure-retaining item, the “R” Certificate Holder

responsible for the construction portion ofthe alteration shall apply the stamping ornameplate. For an alteration where no physi-cal changes are made to the pressure-retain-ing item (e.g., a re-rating) the “R” CertificateHolder, assuming responsiblity for the design,shall apply the stamping or nameplate.

RC-3050 DOCUMENTATION

Alterations performed in accordance with the

NBIC shall be documented on Form R-2 , Reportof Alteration, as shown in Appendix 5. FormR-4, Report Supplementary Sheet shall be usedto record additional data when space isinsufficient on Form R-2.

RC-3051 PREPARATION

Initial preparation of Form R-2 shall be theresponsibility of the “R” Certificate Holderresponsible for the design portion of thealteration. The design organization shall

complete and sign the “Design Certificate”section of the Form R-2. An inspector shallindicate acceptance of the design by signingthe “Certificate of Design Change Review”section of the Form R-2.

Final preparation of Form R-2 , including thegathering and attaching of supporting reports,shall be the responsibility of the “R” Certifi-cate Holder that performed the constructionportion of the alteration. The constructionorganization shall complete the Form R-2 provided by the design organization, includ-ing the Construction Certificate section. Aninspector shall indicate that the work complieswith the applicable requirements of this code by completing and signing the Certificate ofInspection section of the form. When no con-struction work is performed (e.g., a re-ratingwith no physical changes), the “R” CertificateHolder responsible for the design shall pre-pare the Form R-2 , including the gatheringand attaching of supporting reports.

The following shall be attached to and becomea part of the completed Form R-2:

a. For ASME boilers and pressure vessels, acopy of the original Manufacturer’s DataReport, when available;

b. Form R-3 , Report of Parts Fabricated byWelding or Manufacturer’s Partial Data Re- ports , and;

c. For other than ASME, the manufacturer’sreports (i.e., reports required by theoriginal code of construction), when avail-able.

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RC-3052 DISTRIBUTION

Distribution of the completed Form R-2 shall be the responsibility of the “R” CertificateHolder that performed the construction por-tion of the alteration. When no construction

work is performed, (e.g., a re-rating with nophysical changes), the “R” Certificate Holderresponsible for the design shall distribute theform.

Legible copies of the completed Form R-2 , to-gether with attachments, shall be distributedto the inspector, the authorized inspectionagency responsible for the inservice inspec-tion of the pressure-retaining item, the owner-user, the “R” Certificate Holder responsiblefor design and the jurisdiction if required.

RC-3053 REGISTRATION

If the pressure-retaining item is registeredwith the National Board, an original Form R-2together with attachments shall be registeredwith the National Board.

If the item is not registered with the NationalBoard, one original Form R-2 together with

attachments may be registered with theNational Board or retained as required byRC-1150.A05

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Repair/Alteration Methods

Part RD

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PART RD — REPAIR/ALTERATION METHODS

TABLE OF CONTENTS

RD-1000 Alternatives to Postweld Heat Treatment ..................................................... 107 RD-1010 Scope ................................................................................................................... 107

RD-1020 Nondestructive Examination of Welds .......................................................... 107 RD-1030 Welding Method 1 ............................................................................................ 107 RD-1040 Welding Method 2 ............................................................................................ 108 RD-1050 Welding Method 3 ........................................................................................... 110 RD-1060 Welding Method 4 ........................................................................................... 111 RD-1070 Welding Method 5 .............................................................................................113

RD-1100 Alternative Local Postweld Heat Treatment Method ...................................115

RD-2000 Repair Methods ................................................................................................. 115 RD-2010 Scope ................................................................................................................... 115 RD-2020 Defect Repairs ................................................................................................... 116 RD-2030 Wasted Areas ..................................................................................................... 117 RD-2040 Seal Welding ...................................................................................................... 117 RD-2050 Re-Ending or Piecing Pipes or Tubes ............................................................. 117 RD-2060 Patches ................................................................................................................ 117 RD-2070 Stays .................................................................................................................... 123

RD-3000 Alterations Based on Allowable Stress Values ..............................................123RD-3010 Re-rating ..............................................................................................................123

RD-3020 Minimum Wall Thickness .................................................................................124

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c. The welding shall be limited to theshielded metal-arc welding (SMAW), gasmetal-arc welding (GMAW), fluxcored arcwelding (FCAW), and gas tungsten-arcwelding (GTAW) processes.

d. The welders and welding procedures(WPS) shall be qualified in accordancewith the applicable rules of the originalcode of construction, except that the post-weld heat treatment of the test couponused to qualify the weld procedure shall be omitted.

e. The weld area shall be preheated andmaintained at a minimum temperature of300˚F (150˚C) during welding. The 300˚F(150˚C) temperature should be checkedto assure that 4 in. (100 mm) of the mate-rial or four times the material thickness(whichever is greater) on each side ofthe groove (or full thickness of joint for agroove weld) is maintained at the mini-mum temperature during welding. Themaximum interpass temperature shall notexceed 450˚F (230˚C). When the weld doesnot penetrate through the full thickness ofthe material, the minimum preheat andmaximum interpass temperatures need

only be maintained at a distance of 4 in.(100 mm) or four times the depth of therepair weld, whichever is greater on eachside of the joint.

RD-1040 WELDING METHOD 2

When using this method the following isrequired:

a. This method shall be used when the

applicable rules of the original code of con-struction required notch toughness testingor shall be used when the applicable rulesof the original code of construction did notrequire notch toughness testing providedthe adequacy of the notch toughness of the

weld, including the heat-affected zone, inthe as-welded condition at operating andpressure test conditions is verified.

b. The materials shall be limited to carbonand low alloy steels permitted for welded

construction by the applicable rules ofthe original code of construction, includ-ing those materials conforming to any ofthe following ASME P-No. designations:P-No. 1, Group 1, 2, and 3, P-No. 3, Group1, 2, and 3, P-No. 4, P-No. 5A, P-No. 9A,P-No. 10A, P-No. 10B, P-No. 10C, P-No.11A or P-No. 11B.

c. The welding shall be limited to theshielded metal-arc welding (SMAW), gasmetal-arc welding (GMAW), fluxcored arcwelding (FCAW), and gas tungsten-arcwelding (GTAW) processes.

d. The welders and welding procedures(WPS) shall be qualified in accordancewith the applicable rules of the originalcode of construction, except that the post-weld heat treatment of the test couponused to qualify the weld procedure shall be omitted. The WPS shall be qualified forthis repair method using the requirements

in RD-1040(i). The qualification thicknessfor the test plates and repair grooves shall be in accordance with Table RD-1040-1.

e. As shown in Table RD-1040-1 , the depthof the repair groove (or full thickness ofa joint for a groove weld) in base metalor in weld metal is not limited providedthe test material thickness for the weld-ing procedure qualification is at least fivetimes the depth of the repair, but neednot exceed the thickness of the material

to be repaired, provided the required testspecimens can be removed. When thethickness of the base metal to be repairedis greater than 2 in. (50 mm), the proce-dure qualification test material need notexceed 2 in. (50 mm); however, the depth

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of the groove in the test material shall bethe greater of 1 in. (25 mm) or the depthof the groove to be repaired.

f. The test material for the welding proce-dure qualification shall be of the same

material specification (including specifi-cation type, grade, class, and conditionof heat treatment) as the original materialspecification for the repair. In the eventthat the notch toughness of the materialto be repaired is unknown, evidence fromtests of that material or from another ac-ceptable source (see RD-1010) may beused for the base metal notch toughnesswhen qualifying the WPS as required in(g). In the event that the original materialspecification is obsolete, the test materialused should conform as close as possibleto the original material used for construc-tion, but in no case shall the material belower in strength.

g. The organization making the repair shallinclude, when qualifying its WPS, suffi-cient tests to determine that the toughnessof the weld metal and the heat-affectedzone of the base metal in the as-weldedcondition is adequate at the minimum

operating and pressure test temperatures(including start-up and shutdown). Whenthese conditions are met, any originalcode of construction credit for PWHT may be continued. If for reasons of corrosionresistance, special hardness limits arenecessary, such limits shall be includedwhen qualifying the WPS.

h. Notch toughness shall be determinedand evaluated by Charpy impact tests inaccordance with the provisions of the

original code of construction.

i. The WPS shall include the followingadditional requirements:

1. The supplementary essential variableof ASME Code, Section IX, paragraphQW-250, shall apply;

2. The maximum weld heat input foreach layer shall not exceed that usedin the procedure qualification test;

3. The minimum preheat temperaturefor welding shall not be less than that

used in the procedure qualificationtest;

4. The maximum interpass temperaturefor welding shall not be greater thanthat used in the procedure qualifica-tion test;

5. The preheat temperature shall bechecked to assure that 4 in. (100mm) of the material or four timesthe material thickness (whichever isgreater) on each side of the weld jointwill be maintained at the minimumtemperature during welding. Whenthe weld does not penetrate throughthe full thickness of the material, theminimum preheat temperature needonly be maintained at a distance of 4in. (100 mm) or four times the depth ofthe repair weld, whichever is greateron each side of the joint;

6. For the welding process in (c) above,use only filler metals which are clas-sified by the filler metal specificationwith an optional supplemental dif-fusible-hydrogen designator of H8or lower. When shielding gases areused with a process, the gas shallexhibit a dew point that is below-60°F (-50°C). Surfaces on whichwelding will be done shall be main-tained in a dry condition duringwelding and be free of rust, mill

scale, and hydrogen producing con-taminents such as oil, grease, andother organic materials;

7. The welding technique shall be acontrolled-deposition temper beador half bead technique. The specifictechnique or specific combinations of

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techniques shall be that used in theprocedure qualification test;

8. After completion of welding andwithout allowing the weldment tocool below the minimum preheat

temperature, the temperature of theweldment shall be raised to a mini-mum temperature of 450°F (230°C) fora minimal period of two hours. Thishydrogen bake-out treatment may beomitted provided the electrode usedis classified by the filler metal specifi-cation with an optional supplementaldiffusible-hydrogen designator of H4(e.g., E7018-H4); and

9. After the finished repair weld hascooled to ambient temperature, thefinal temper bead reinforcement layershall be removed substantially flushwith the surface of the base material.



a. This method may be used when theapplicable rules of the original code ofconstruction did not require notch tough-ness testing.

b. The materials shall be limited to anyP-No. 1 or P-No. 3 material as permittedfor welded construction by the applicablerules of the original code of construc-tion.

c. The welding shall be limited to the

shielded metal-arc welding (SMAW) andgas tungsten-arc welding (GTAW) pro-cesses.

d. The welders and welding procedures(WPS) shall be qualified in accordancewith the applicable rules of the originalcode of construction, except that the post-weld heat treatment of the test couponused to qualify the weld procedure shall

be omitted. The WPS shall be qualifiedfor this repair method using the require-ments in RD-1050(h). The qualificationthicknesses for the test plates and repair grooves shall be in accordance with Table RD-1040-1.

e. As shown in Table RD-1040-1 , the depthof the repair groove (or full thickness ofa joint for a groove weld) in base metalor in weld metal is not limited providedthe test material thickness for the weld-ing procedure qualification is at least fivetimes the depth of the repair, but neednot exceed the thickness of the materialto be repaired, provided the required testspecimens can be removed. When thethickness of the base metal to be repairedis greater than 2 in. (50 mm), the proce-dure qualification test material need notexceed 2 in. (50 mm); however, the depthof the groove in the test material shall bethe greater of 1 in. (25 mm) or the depth

of the groove to be repaired.

f. The test material for the welding proce-dure qualification shall be of the sameP-No. and Group No. as the originalmaterial specification for the repair. In theevent that the original material specifica-tion is obsolete, the test material usedshould conform to the nominal composi-tion and carbon equivalent (IIW formula)as the original material used for construc-tion, but in no case shall the material be

lower in strength.

g. If for reasons of corrosion resistance,special hardness limits are necessary, suchlimits shall be included when qualifyingthe WPS.

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h. The WPS shall include the followingadditional requirements:

1. The maximum weld heat input foreach layer shall not exceed that usedin the procedure qualification test;

2. The minimum preheat temperature forwelding shall be 350°F (175°C) and themaximum interpass temperature shall be 450°F (230°C);

3. For the welding process in (c) above,use only filler metals that are classified by the filler metal specification withan optional supplemental diffusible-hydrogen designator of H8 or lower.When shielding gases are used witha process, the gas shall exhibit a dewpoint that is below -60°F (-50°C). Sur-faces on which welding will be doneshall be maintained in a dry conditionduring welding and be free of rust,mill scale, and hydrogen producingcontaminents such as oil, grease, andother organic materials;

4. The welding technique shall be acontrolled-deposition temper bead

or half bead technique. The specifictechnique or specific combinations oftechniques shall be that used in theprocedure qualification test;

5. For SMAW the electrode size shallnot exceed 1/8 in. (3 mm) and forGTAW the electrode size and the fillermetal size shall not exceed 3/32 in. (2.5mm);

6. For welds made by SMAW, after

completion of welding and withoutallowing the weldment to cool belowthe minimum preheat temperature,the temperature of the weldment shall be raised to a temperature of 450°F(230°C) minimum for a minimum

period of two hours. This hydrogen bake-out treatment may be omittedprovided the electrodes used are clas-sified by the filler metal specificationwith an optional supplemental diffus-ible-hydrogen designator of H4 (e.g.,

E7018-H4); and

7. After the finished repair weld hascooled to ambient temperature, thefinal temper bead reinforcement layershall be removed substantially flushwith the surface of the base material.



a. This method is limited to boilers for whichthe applicable rules of the original code ofconstruction did not require notch tough-ness testing.

b. The materials shall be limited to P-No. 4,Groups 1 and 2 and P-No. 5A steels aspermitted for welded construction bythe applicable rules of the original code

of construction.

c. The welding shall be limited to theshielded metal-arc welding (SMAW),fluxcored-arc welding (FCAW), and gastungsten-arc welding (GTAW) processesusing low-hydrogen filler metals classified by the filler metal specification with an op-tional supplemental diffusable-hydrogendesignator of H8 or lower, and suitablycontrolled by maintenance proceduresto avoid contamination by hydrogen

producing sources. The surface of themetal prepared for welding shall be freeof contaminants.

d. The welders and welding procedures(WPS) shall be qualified in accordance

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with the applicable rules of the originalcode of construction, except that the post-weld heat treatment of the test couponused to qualify the weld procedure shall be omitted. The WPS shall be qualified forthis repair method using the requirements

in RD-1060 (h). The qualification thicknessfor the test plates and repair grooves shall be in accordance with Table RD-1040-1.

e. As shown in Table RD-1040-1 , the depthof the repair groove (or full thickness of a joint for a groove weld) in the base metalor in weld metal is not limited providedthe test material thickness for the weld-ing procedure qualification is at least fivetimes the depth of the repair, but neednot exceed the thickness of the materialto be repaired, provided the required testspecimens can be removed. When thethickness of the base metal to be repairedis greater than 2 in. (50 mm), the proce-dure qualification test material need notexceed 2 in. (50 mm); however, the depthof the groove in the test material shall bethe greater of 1 in. (25 mm) or the depthof the groove to be repaired.

f. The test material for the welding proce-

dure qualification shall be of the sameP-No. and Group No. as the original ma-terial specification for the repair. In theevent that the original material specifica-tion is obsolete, the test material used shallconform to the nominal composition andcarbon equivalent (IIW formula) as theoriginal material used for construction,and in no case shall the material be lowerin strength.

g. If for reasons of corrosion resistance, spe-

cial hardness limits are necessary, suchlimits shall be included when qualifyingthe WPS.

h. The WPS shall include the following ad-ditional requirements:

1. The minimum preheat temperaturefor welding shall be 300°F (150°C) forP-No. 4 material and 400°F (205°C)

for P-No. 5A material. The preheattemperature shall be checked to as-sure that 4 in. (100 mm) of the materialor four times the material thickness(whichever is greater) on each side ofthe groove (or full thickness of jointfor a groove weld) is maintained atthe minimum temperature duringwelding. The maximum interpasstemperature shall not exceed 800°F(425°C). When the weld does not pen-etrate through the full thickness of thematerial, the minimum preheat andmaximum interpass temperature needonly be maintained for 4 in. (100 mm)or four times the depth of the repairweld (whichever is greater) on eachside of the joint.

2. The welding technique shall be acontrolled-deposition temper beadtechnique and shall include a butter-ing layer deposited over the entire

groove faces (or fillet leg faces) usinga 3/32 in. (2.5 mm) diameter electrode.The buttering layer shall be depositedusing stringer beads with an overlapof approximately 50%. The second andremaining layers shall be depositedover the buttering layer using a 3/32in. (2.5 mm) or 1/8 in. (3 mm) diameterelectrode for SMAW, 0.045 in. (1.1 mm)for FCAW, or 1/16 in. (1.5 mm) or 3/32in. (2.5 mm) for GTAW filler metal. Thesecond and remaining layers shall not

contact the base material and shall bedeposited using stringer beads. Afterthe groove is filled (or fillet size isachieved), a 3/32 in. (2.5 mm) or 1/8in. (3 mm) thick reinforcement layer

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TABLE RD-1040-1 —Welding Methods as Alternatives to Postweld Heat Treatment Qualification Thicknessesfor Test Plates and Repair Grooves

BASE METALTHICKNESS

REPAIRGROOVEDEPTH

PQR TEST MATERIALTHICKNESS

PQR GROOVEDEPTHNote (2)

THICKNESSQUALIFIEDNote (1)

< 2" (50 mm) < 1" (25 mm) 5 times the repair cavitydepth, but need notexceed the thicknessof the base metal to berepaired.

< 1" (25 mm) See PQR test materialthickness column and≤ PQR groove depth.

≤ 2" (50 mm) > 1" (25 mm) Thickness of the basemetal to be repaired.

> 1" (25 mm) ≤ PQR test materialthickness and ≤ PQRgroove depth.

> 2" (50 mm) 1" (25 mm) 2" (50 mm) 1" (25 mm) All base metal thick-ness and ≤ 1" (25 mm)repair groove depth.

> 2" (50 mm) > 1" (25 mm) 2" (50 mm) > 1" (25 mm) All base metal thick-ness and ≤ PQR groovedepth.

Note 1. Repair groove depth is limited to the maximum depth qualified.

Note 2. The depth of the groove used for procedure qualification must be deep enough toremove test specimens.

shall be deposited to temper the priorweld layer. This temper layer shall bedeposited to within 1/8 in. (3 mm)of the toe of the weld, but shall notcontact the base metal.

3. After completion of welding andwithout allowing the weldment tocool below the minimum preheattemperature, the temperature of theweldment shall be raised to a mini-mum temperature of 450°F (230°C) for

a minimal period of two hours. Thishydrogen bake-out treatment may beomitted provided the filler metal usedis classified by the filler metal specifi-cation with an optional supplementaldiffusable-hydrogen designator of H4(e.g., E7018-H4).

4. After the finished repair weld hascooled to ambient temperature, thefinal temper bead reinforcement layershall be removed substantially flushwith the surface of the base metal (andfor a fillet weld to the required sizeand suitable contour of the toes).


When using this method the following is

required:

a. This method may be used when the appli-cable rules of the original code of construc-tion for which postweld heat treatment forone material joined to another materialmay be inadvisable, such as carbon or A05

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low-alloy steel joined to austenitic stain-less steel or to nickel or nickel-based al-loys.

b. The materials shall be limited to those ma-terials conforming to any of the following

ASME designations: P-No. 1, Groups 1, 2,and 3, P-No. 3, Groups 1, 2, and 3, P-No.4, P-No. 5A, P-No. 9A, P-No. 10A, P-No.10B, P-No. 10C, P-No. 11A, or P-No. 11B joined to either P-No. 8, P-No. 41, P-No.42, P-No. 43, P-No. 44, P-No. 45, P-No.46, or P-No. 47, as permitted for weldedconstruction by the applicable rules of theoriginal code of construction.

c. The welding shall be limited to theshielded metal-arc welding (SMAW), flux-cored-arc welding (FCAW), gas metal-arcwelding (GMAW), and gas tungsten-arcwelding (GTAW) processes. The surfaceof the metal prepared for welding shall be free of contaminants. It is cautionedto determine if the dissimilar metal jointwill be exposed to elevated temperatureservice since significant differences incoefficient of thermal expansion of dis-similar metal-welded joints may result inexcessive differences in relative deforma-

tion and thermal fatigue at the joint. Theelectrodes/filler metals for dissimilarmetal welded joint shall be either of thoseconforming to the ASME designationsA-No. 8 or F-No. 43, as applicable. It iscautioned that using austenitic stainlesssteel electrodes/filler metals for joiningP-No. 8 materials to carbon or low-alloysteels for weld joints exposed to servicetemperatures greater than 800°F (425°C)will exhibit reduced creep life along thefusion zone of the ferritic material due to

carbon diffusion.

d. The welders and welding procedures(WPS) shall be qualified in accordance

with the applicable rules of the originalcode of construction, except that thepostweld heat treatment of the test cou-pon used to qualify the weld procedureshall be omitted in accordance with thefollowing paragraphs (e) through (h), as

applicable.

e. Qualifica tion of welding procedures(WPS) for joining P-No. 1, Groups 1, 2,and 3, P-No. 3, Groups 1, 2 (excluding Mn-Mo steels in Group 2) ferritic materials toeither P-No. 8, P-No. 41, P-No. 42, P-No.43, P-No. 44, P-No. 45, P-No. 46, or P-No.47 materials shall be in accordance withRD-1030 Welding Method 1 if the originalcode of construction did not require notchtoughness testing.

f. Qualifica tion of welding procedures(WPS) for joining ASME P-No. 1, Groups1, 2, and 3, P-No. 3 Groups 1, 2, and 3, P-No. 4, P-No. 5A, P-No. 9A, P-No. 10A, P-No. 10B, P-No. 10C, P-No. 11A, P-No. 11Bferritic materials to either P-No. 8, P-No.41, P-No. 42, P-No. 43, P-No. 44, P-No. 45,P-No. 46, or P-No. 47 materials shall be inaccordance with RD-1040 Welding Meth-od 2 if the original code of construction

required notch toughness testing or whenthe original code of construction did notrequire notch toughness testing providedthe adequacy of the heat affected zoneof the ferritic material in the as-weldedcondition at operating and pressure testconditions has been verified.

g. Qualifica tion of welding procedures(WPS) for joining any P-No. 1 or P-No. 3materials to P-No. 8, P-No. 41, P-No. 42,P-No. 43, P-No. 44, P-No. 45, P-No. 46, or

P-No. 47 materials shall be in accordancewith RD-1050 Welding Method 3 if theoriginal code of construction did notrequire notch toughness testing and the

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welding is limited to the shielded metal-arc welding (SMAW) and the gas-tung-sten-arc welding (GTAW) processes.

h. Qualification of welding procedures(WPS) for joining P-No. 4 and P-No. 5A

materials to either P-No. 8, P-No. 41, P-No.42, P-No. 43, P-No. 44, P-No. 45, P-No.46, or P-No. 47 materials shall be in ac-cordance with RD-1060 Welding Method4 if the original code of construction didnot require notch toughness testing.

i. The requirements of RD-1040(i)(6) and(i)(8) , RD-1050 (h)(3) , and RD-1060(c) and(h)(3) for low hydrogen electrodes/fillermetals and for a hydrogen bake-out treat-ment may be omitted.

RD-1100 ALTERNATIVE LOCALPOSTWELD HEATTREATMENT METHOD

When it is impractical or detrimental to post-weld heat treat the entire item or an entire band around the item, the following local (e.g., bulls eye) postweld heat treatment methodmay be performed on spherical or cylindri-

cal pressure-retaining items using the timeand temperature parameters in the originalcode of construction and in accordance witha written procedure.

a. Heat a local area around the nozzle,welded attachment, or repair area in sucha manner that the area is brought up uni-formly to the required temperature. Theapplication of local postweld heat treat-ment should be performed with controlledheating methods such as induction or

electric resistance heaters with thermo-couples. The soak band, which is the bandrequired to be heated to the minimumPWHT temperature, shall be a circle (e.g.,

bulls eye method) that extends beyond theentire nozzle, attachment weld and repairarea in all directions by a minimum ofthe thickness of the shell, t or 2" (50 mm),whichever is less.

b. The temperature gradient extendingoutside the bulls eye postweld heat treat-ment band applied to repair welds orattachment welds shall be kept as low aspossible in all directions to avoid harmfultemperature gradients adjacent to nozzlesor geometric discontinuities.

c. For bulls eye postweld heat treatment ofnozzle welds, repair welds, and externalattachment welds on smooth sphericalshells, heads, and cylindrical shells, thethermal gradients outside the circumfer-ential heat band should not exceed 250°F(120°C) per foot (0.3 m).

d. The term t, or definition of thickness forcalculating the holding time, for localpostweld heat treatment shall be the nomi-nal thickness of either a full penetrationweld, the groove weld depth of a partialpenetration repair weld, or if a fillet weldis used in combination with a groove

weld, the nominal thickness is the depthof the groove or the throat dimensions,whichever is greater.

RD-2000 REPAIR METHODS

RD-2010 SCOPE

A repair of a defect, such as a crack in a welded joint or base material, shall not be made un-

til the defect has been removed. A suitablenondestructive examination method such asmagnetic particle (MT) or liquid penetrant(PT) may be necessary to assure complete

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removal of the defect. If the defect penetratesthe full thickness of the material, the repairshall be made with a complete penetrationweld such as a double butt weld or a single butt weld with or without backing. Where cir-cumstances indicate that the defect is likely to

recur, consideration should be given to remov-ing the defective area and installing a flushpatch or taking other acceptable, correctivemeasures. A repair of a bulge or blister shall bemade if a bulge or blister will affect the pres-sure-retaining capability of the plate or tubeor when evidence of leakage is noted.

RD-2020 DEFECT REPAIRS

Unstayed Boiler Furnace CracksCracks at the knuckle or at the turn of theflange of the furnace opening require immedi-ate replacement of the affected area or specificapproval of repairs by the jurisdiction. SeeFigure RD-2020-a.

Rivet or Staybolt Hole CracksCracks radiating from rivet or staybolt holesmay be repaired if the plate is not seriouslydamaged. If the plate is seriously damaged,it shall be replaced. For suggested methods

of repair. See Figure RD-2020-b.

Minor DefectsMinor cracks, isolated pits, and small plateimperfections should be examined to deter-mine the extent of the defect and whetherrepair by welding is required. Prior to repair by welding, the defects shall be removed tosound metal. Liquid penetrant or magneticparticle examination may be used before orafter welding.

Defective BoltingDefective bolting material shall not be re-paired but shall be replaced with suitablematerial that meets the specifications of theoriginal code of construction.

BulgesA bulge on a water tube shall be investigatedto determine the cause and extent of dam-age to the tube prior to repair. If the bulgehas resulted in metallurgical changes to theoriginal tube material, as determined by field

metallography, installation of a new length oftubing or tube patch (RD-2060) is required. Ifthe bulge has cracks as determined by NDE,installation of a new length of tubing or atube patch is required. If the bulge does notexhibit cracks and has not resulted in metal-lurgical changes to the original tube mate-rial, a mechanical repair may be consideredsubject to the concurrence of the inspector or jurisdiction.

A bulge on a plate shall be investigated to de-termine the cause and extent of damage to theplate prior to repair. If the bulge has resultedin metallurgical changes to the original platematerial, as determined by field metallogra-phy, installation of a flush patch (RD-2060) isrequired. If the plate has cracks as determined by NDE, installation of a flush patch is re-quired. If the bulge does not exhibit cracks andhas not resulted in metallurgical changes tothe original plate material, a mechanical repairmay be considered, subject to the concurrence

of the inspector or jurisdiction.

BlistersA blister may be caused by a defect in themetal such as lamination where one side ex-posed to the fire overheats but the other sideretains its strength due to the cooling effectof the water. After the blistered material has been removed, the remaining wall thicknessshall be determined by ultrasonic thicknesstesting. A surface examination using liquidpenetrant testing or magnetic particle testing

shall be made to assure the remaining mate-rial contains no defects. If the remaining wallthickness is adequate, in the judgement of theinspector, the area may be repaired by weld-ing as covered in RD-2030 , Wasted Areas. Ifthe remaining wall thickness is not adequate,

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a plate will require a flush patch (RD-2060) and a tube will require a new length of tubeor tube patch (RD-2060).

RD-2030 WASTED AREAS

Shells, Drums, HeadersWasted areas in stayed and unstayed shells,drums, and headers may be built up bywelding provided that in the judgementof the Inspector the strength of the struc-ture has not been impaired. Where ex-tensive weld buildup is employed, theInspector may require an appropriate methodof NDE for the completed surface of the repair.For suggested methods of building up wastedareas by welding. See Figure RD-2030-a.

Access OpeningWasted areas around access openings may be built up by welding or they may be repairedas described in Figure RD-2030-b.

FlangesWasted flange faces may be cleaned thorough-ly and built up with weld metal. They should be machined in place if possible to a thicknessnot less than that of the original flange or that

required by calculations in accordance withthe provisions of the original code of construc-tion. Wasted flanges may also be remachinedin place without building up with weld metal,provided that metal removed in the processdoes not reduce the thickness of the flange toa measurement below that calculated above.Flanges that leak because of warpage or dis-tortion and which cannot be remachined shall be replaced with new flanges that have at leastthe dimensions conforming to the originalcode of construction.

TubesWasted areas on tubes may be repaired bywelding provided that in the judgement of theInspector the strength of the tube has not been

impaired. Where deemed necessary, compe-tent technical advice should be obtained fromthe manufacturer or from another qualifiedsource. This may be necessary when consider-ing such items as size limitations of repairedareas, minimum tube thickness to be repaired,

tube environment, location of the tube in the boiler, and other similar conditions.

RD-2040 SEAL WELDING

Seal Welding of TubesTubes may be seal welded provided the endsof the tubes have sufficient wall thickness toprevent burn-through and the requirements ofthe original code of construction are satisfied.See Figure RD-2040-a.

Seal Welding of Riveted JointsEdges of buttstraps, plate laps, and noz-zles, or of connections attached by riv-e t i ng m a y be res tored to or i g i na ldimensions by welding. Seal welding of riv-eted joints, buttstraps, or rivets shall requirethe approval of the jurisdiction. If seal weldingis approved, suggested methods and precau-tions are shown in Figure RD-2040-b.

RD-2050 RE-ENDING OR PIECINGPIPES OR TUBES

Re-ending or piecing pipes or tubes is per-mitted provided the thickness of the remain-ing pipe or tube is not less than 90% of thatrequired by the original code of construction.See Figure RD-2050.

RD-2060 PATCHES

Flush PatchesThe weld around a flush patch shall bea full penetration weld and the accessiblesurfaces shall be ground flush where required

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Fire Cracks at Door Openings

FIGURE RD-2020-a — Unstayed Boiler FurnacesCracks at the knuckle or at the turn of the flange of the furnace opening require immediate replacement of theaffected area. If repairs are attempted, specific approval of the jurisdiction is required.

Fire Cracks at Girth SeamsCircumferential Cracks at Girth Seams

Cracks in Stayed Plates

FIGURE RD-2020-b — Rivet and Staybolt Hole CracksCracks radiating from rivet or staybolt holes should be repaired if the plate is not seriously damaged. If theplate is seriously damaged, it shall be replaced. A suggested repair method is described below:

a. Prior to welding, the rivets or staybolts from which the cracks extend and the adjacent rivets (or staybolts if appropriate) should be removed.

b. In riveted joints, tack bolts should be placed in alternate holes to hold the plate laps firmly.

c. The cracks should then be prepared for welding by chipping, grinding, or gouging.

d. In riveted joints, cracks which extend past the inner edge of the plate lap should be welded from both sides.

e. Rivet holes should be reamed before new rivets are driven.

f. Threaded staybolt holes should be retapped and new staybolts properly driven and headed.

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FIGURE RD-2030-a — Weld Buildup of Wasted AreaRivet and Stayboltsa. Prior to welding, the rivets or staybolts in the wasted area should be removed.

b. Threaded staybolt holes should be retapped after welding.

c. Rivet holes should be reamed after welding.

d. Welding should not cover rivet or staybolt heads.

Tubesheet

Rivet and Staybolt

Tubesheeta. Prior to welding, the tubes in the wasted area should be removed.

b. After welding, the tube holes may be reamed before new tubes are installed.

Wasted areas in stayed and unstayed surfaces may be repaired by weld build-up, provided that in the judgment of the Inspector the strength of the structure will not be impaired. Where extensive weld buildup isemployed, the Inspector may require an appropriate method of NDE for the complete surface of the repair.

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FIGURE RD-2030-b — Repairs for Access OpeningsA badly wasted manhole flange may be removed and replaced with a ring-type frame as shown at right.The requirements for flush patches shall be met. A full penetration weld is required. May be either double orwelded from one side with or without a backing ring.

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FIGURE RD-2040-a — Typical Examples of Seal Welding TubesTubes may be seal welded provided the ends of the tubes have sufficient wall thickness to prevent burn-through. Seal welding shall be applied in strict accordance with the original code of construction for therequirements of tube projection, welding, and tube expanding. Seal welding shall not be considered a strengthweld.

In watertube boilers, tubes may be seal welded on the inside or outside of the tubesheet.

A badly wasted area around a handhole opening may be repaired by adding a ring, as shown at right, on theinside of the object.

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FIGURE RD-2060-a — Flush PatchesBefore installing a flush patch, the defective material should be removed until sound material is reached. Thepatch should be rolled or pressed to the proper shape or curvature. The edges should align without overlap.

In stayed areas, the weld seams should come between staybolt rows or riveted seams. Patches should be madefrom a material that is at least equal in quality and thickness to the original material.

Patches may be of any shape or size. If the patch is rectangular, an adequate radius should be provided at thecorners. Square corners should be avoided.

Typical Rivet Joint Showing Seal Weld

Re-ending or Piercing of Pipes or Tubes

Flush Patches

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FIGURE RD-2040-b — Seal Wdling of Riveted JointsSeal welding of riveted joints requires the approval of the jurisdiction. Seal welding shall not be considered astrength weld. Prior to welding, the area should be examined by an appropriate method of NDE to assure thatthere are no cracks radiating from the rivet holes. If necessary, the rivets should be removed to assure completeexamination of the area. Seal welding should not be performed if cracks are present in riveted areas.

FIGURE RD-2050 — Re-Ending or Piecing of Pipes or TubesThickness of remaining pipe or tube not less than 90% required by original Code of Construction.

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FIGURE RD-2060-b — Tube Window Patching MethodIt may be necessary to weld a flush patch on a tube since, in some situations, accessibility around the completecircumference of the tube is restricted. Listed below are the suggested methods for making window patches:

a. The patch should be made from tube material of the same type, diameter, and thickness as the one being repaired.

b. Fit-up of the patch is important to weld integrity. The root opening should be uniform around the patch.

c. The gas tungsten-arc welding process should be used for the initial pass on the inside of the tube and for the initial pass joining the patch to the tube.

d. The balance of the weld may be completed by any appropriate welding process.

Front and Side View of Tube

Side View Showing Patch Fit and Welding

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by the applicable original code of construc-tion. Examples of flush welded patches areshown in Figure RD-2060-a. The welds shall be subjected to the nondestructive exami-nation method used in the original code ofconstruction or an alternative acceptable to

the Inspector.

Tube PatchesIn some situations it is necessary to welda flush patch on a tube, such as whenreplacing tube sections and accessibil-ity around the complete circumferenceof the tube is restricted, or when it isnecessary to repair a small bulge. This isreferred to as a window patch. Suggestedmethods for window patches are shown inFigure RD-2060-b.

RD-2070 STAYS

Threaded stays may be replaced by welded-instays provided that, in the judgement of theInspector, the material adjacent to the staybolthas not been materially weakened by deterio-ration or wasting away. All requirements ofthe original code of construction governingwelded-in stays shall be met.

RD-3000 ALTERATIONS BASED ONALLOWABLE STRESS

VALUES

RD-3010 RE-RATING

The following requirements shall apply forre-rating a pressure-retaining item by using alater edition/addendum of the original code

of construction, which permits higher allow-able stress values for the material than wasused in the original construction.

a. The “R” Certificate Holder shall verify, bycalculations and other means, that the re-rated item can be satisfactorily operated atthe new service condition (e.g., stiffness, buckling, external mechanical loadings,etc.).

b. The pressure-retaining item shall not beused in lethal service.

c. The pressure-retaining item shall not beused in high-cycle operation or fatigueservice (i.e., loadings other than primarymembrane stress are controlling designconsiderations).

d. The pressure-retaining item shall have been constructed to the 1968 Edition orlater edition/addenda of the original codeof construction.

e. The pressure-reta ining item shall beshown to comply with all relevant require-ments of the edition/addenda of the codeof construction, which permits the higherallowable stress values (e.g., reinforce-ment, toughness, examination, pressuretesting, etc.).

f. The pressure-retaining item shall havea satisfactory operating history and cur-rent inspection of the pressure-retainingitem shall verify the item exhibits no un-repaired damage (e.g., cracks, corrosion,erosion, etc.).

g. The re-rating shall be acceptable to theInspector and, where required, the juris-diction.

h. All other requirements of Part RC shall be

met.

i. Use of this paragraph shall be documentedin the Remarks Section of Form R-2.

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RD-3020 MINIMUM WALL THICKNESS

The following requirements shall apply forrecalculating a new minimum wall thicknessfor a pressure-retaining item by using a later

edition/addendum of the original code ofconstruction, which permits higher allowablestress values for the material than was usedin the original construction.

a. The “R” Certificate Holder shall verify, by calculations and other means, that theaffected portions of the pressure-retainingitem can be satisfactorily operated (e.g.,stiffness, buckling, external mechanicalloadings, etc.).

b. The pressure-retaining item shall not beused in lethal service.

c. The pressure-retaining item shall not beused in high-cycle operation or fatigueservice (i.e., loadings other than primarymembrane stress are controlling designconsiderations).

d. The pressure-retaining item shall have been constructed to the 1968 Edition or

later edition/addenda of the original codeof construction.

e. The pressure-retaining item shall beshown to comply with all relevant require-ments of the edition/addenda of the codeof construction, which permits the higherallowable stress values (e.g., reinforce-ment, toughness, examination, pressuretesting, etc.).

f. The pressure-retaining item shall have asatisfactory operating history and currentinspection of the pressure-retaining itemshall verify the item exhibits no unre-paired damage (e.g., cracks, etc.). Areasof corrosion or erosion may be left in place

provided the remaining wall thicknessis greater than the new minimum thick-ness.

g. The design shall be acceptable to the In-spector and, where required the jurisdic-tion.

h. All other requirements of Part RC shall bemet.

i. Use of this paragraph shall be documentedin the Remarks Section of Form R-2.

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Repairs of Pressure Relief Valves

Part RE

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PART RE — REPAIRS OF PRESSURE RELIEF VALVES

TABLE OF CONTENTS

RE-1000 General Requirements ..................................................................................... 127

RE-1010 Scope ................................................................................................................... 127 RE-1020 Definition of Repair .......................................................................................... 127 RE-1030 Accreditation ......................................................................................................128 RE-1040 Materials .............................................................................................................128 RE-1050 Replacement Parts .............................................................................................128 RE-1060 Nameplates .........................................................................................................128 RE-1070 Field Repair ........................................................................................................130

RE-1100 Welding for Pressure Relief Valves ................................................................ 131 RE-1110 Welding Procedure Specifications .................................................................. 131 RE-1120 Standard Welding Procedure Specifications ..................................................131 RE-1130 Performance Qualification ...............................................................................131 RE-1140 Welding Records ................................................................................................131

RE-1150 Welders’ Identification ......................................................................................131 RE-1160 Welders’ Continuity ..........................................................................................132

RE-1200 Heat Treatment ...................................................................................................132 RE-1210 Preheating .......................................................................................................... 132 RE-1220 Postweld Heat Treatment .................................................................................132

RE-2000 Performance Testing and Testing Equipment ................................................132 RE-2010 Test Medium and Testing Equipment .............................................................132 RE-2020 Owner-User Section VIII Steam Testing .........................................................133 RE-2030 Lift Assist Testing ...............................................................................................133 RE-2040 Pressure Test of Parts ........................................................................................134

RE-3000 Training and Qualification of Personnel ........................................................134 RE-3010 General ................................................................................................................134 RE-3020 Contents of Training Program .........................................................................134 RE-3030 Qualification of Personnel ................................................................................134 RE-3040 Annual Review of Qualification ......................................................................134

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RE-1000 GENERAL REQUIREMENTS

RE-1010 SCOPE

This part provides general requirements thatapply to repairs to pressure relief valves.Repairs may be required because of defectsfound during periodic inspections becausetesting has identified that valve performancedoes not meet the original Code of Construc-tion requirements, failure during operation, orfor routine preventative maintenance.

RE-1020 DEFINITION OF REPAIR

Repair of a pressure relief valve is consideredto be the disassembly, replacement, remachin-ing, or cleaning of any critical part, lappingof a seat and disc, reassembly, adjustment,testing, or any other operation that may af-fect the flow passage, capacity, function, orpressure-retaining integrity.

Conversions, changes, or adjustments affect-ing critical parts are also considered repairs.The scope of conversions may include changesin service fluid and changes such as bellows,

soft seats, and other changes that may affecttype/model number provided such changesare recorded on the document required byRA-2255(i) and the repair nameplate. SeeRE-1060.

The scope of repair activities shall not includechanges in ASME Code status.

When a repair is being performed under theadministrative requirements of Part RA-2200 , a repair shall consist of the following opera-

tions as a minimum:

a. Complete disassembly, cleaning and in-spection of all parts, repair or replacementof parts found to be defective, reassembly,

testing as required by RE-2000 , sealingand application of a repair nameplate.When completed, the valve’s conditionand performance shall be equivalent tothe standards for new valves.

b. The administrative requirements of RA-2200 apply only to valves that are stampedwith an ASME “V”, “UV”, or “NV” Codesymbol, or marked with an ASME “HV”symbol and have been capacity certifiedon the applicable fluid by the NationalBoard.

RE-1021 CONSTRUCTION

STANDARDS

The applicable standard for new valves to beused for reference during repairs is the ASMECode. ASME Code Cases shall be used forrepairs when they were used in the originalconstruction of the valve. ASME Code Casesmay be used when they have been acceptedfor use by revision or interpretation by theNBIC Committee.

The Code Case number shall be noted on the repair document specified in RA-2255(i)(1) ,

and when required by the Code Case, stampedon the repair nameplate. The applicable juris-diction shall be consulted for any uniquerequirements it may have established.

RE-1022 INITIAL ADJUSTMENTS TO

PRESSURE RELIEF VALVES

The initial installation testing and adjustmentsof a new pressure relief valve on a boiler orpressure vessel are not considered a repair if

made by the manufacturer or assembler ofthe valve.

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RE-1050 REPLACEMENT PARTS

All critical parts shall be fabricated by thevalve manufacturer or to his specifications.Critical parts are those that may affect thevalve flow passage, capacity, function, or

pressure-retaining integrity.

All critical parts not fabricated by the valvemanufacturer shall be received with mate-rial test certification for the material used tofabricate the part.

Parts fabricated by the valve manufacturer donot require material test certification if theyhave the manufacturer’s identification on thepart or are accompanied by the manufactur-er’s identification label or tag.

Material for bolting shall meet the manufac-turer’s specification, but does not require ma-terial test certification if marked as required by the material specification.

RE-1060 NAMEPLATES

Proper marking and identification of tested orrepaired valves is critical to ensuring accep-

tance during subsequent inspections, and alsoprovide for traceability and identification ofany changes made to the valve. All operationswhich require the valve’s seals to be replacedshall be identified by a nameplate as describedin RE-1061 or RE-1063.

RE-1061 REPAIR NAMEPLATE

When a pressure relief valve is repaired, ametal repair nameplate stamped with the

information required below shall be securelyattached to the valve. If not mounted directlyon the valve, the nameplate shall be securelyattached so as not to interfere with valveoperation and sealed in accordance with RA-2255(k).

RE-1023 JURISDICTIONAL

AUTHORIZATION TO

ADJUST PRESSURE RELIEF

VALVES

The jurisdiction may authorize properly

trained and qualified employees of boiler orpressure vessel owners-users or their desig-nees to restore required set pressure and/orperformance of pressure relief valves. Allexternal adjustments shall be resealed with aseal identifying the responsible organizationand a metal tag that identifies the organiza-tion and the date of the adjustment shall beinstalled (See RE-1063 for marking require-ments and Appendix J).

RE-1024 DEFINITIONS

Unless otherwise specified in these rulesand procedures, the definitions relating topressure relief devices in Section 2 of ANSI/ASME PTC-25-2001 shall apply.

RE-1030 ACCREDITATION

Organizations performing repairs shall be

accredited as described in Part RA-2200, asappropriate for the scope of work to be per-formed.

RE-1040 MATERIALS

The materials used in making repairs shallconform to the requirements of the originalcode of construction. The “VR” CertificateHolder is responsible for verifying identifica-tion of existing materials from original data,

drawings, or unit records and identificationof the materials to be installed.

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Prior to attachment of the repair nameplate,the previous repair nameplate, if applicable,shall be removed from the repaired valve. As a minimum, the information on the valverepair nameplate (see Appendix 2 , Figure 2-

1000-e) shall include:

a. The name of the repair organization pre-ceded by the words “repaired by”;

b. The “VR” repair symbol stamp and the“VR” Certificate Number;

c. Unique identifier (e.g., repair serial number, shop order number, etc.);

d. Date of repair;

e. Set pressure;

f. Capacity and capacity units (if changedfrom original nameplate due to set pres-sure or service fluid change); and

g. Type/model number (if changed fromoriginal nameplate by a conversion, seeRE-1020).

h. When an adjustment is made to correctfor service conditions of superimposed back pressure and/or temperature or thedifferential between popping pressure between steam and air (see RE-2020) , theinformation on the valve repair nameplateshall include the:

1. Cold Differential Test Pressure (CDTP),and

2. Superimposed Back Pressure (BP)

(only when applicable).

RE-1062 CHANGES TO ORIGINAL

PRESSURE RELIEF VALVE

NAMEPLATE INFORMATION

If the set pressure is changed, the set pressure,capacity and blowdown, if applicable, on

the original nameplate or stamping shall bemarked out but left legible. The new capacityshall be based on that for which the valve wasoriginally certified.

If the service fluid is changed, the capacity,

including units, on the original nameplate orstamping shall be marked out but left legible.The new capacity shall be based on that forwhich the valve was originally certified, or ifa conversion has been made, as described inRE-1020 on the capacity certification for thevalve as converted.

If the type/model number is changed, thetype/model number on the original name-plate shall be marked out but left legible.

If the blowdown is changed, the blowdownon the original nameplate or stamping shall be marked out but left legible. The new blow-down may be based on the current ASMECode requirements.

Incorrect information on the original manu-facturer’s nameplate shall be marked out butleft legible. Corrected information shall beindicated on the repair nameplate and notedon the document referred to in RA-2255(i).

RE-1063 TEST ONLY NAMEPLATE

Where a valve has been tested and adjustedas permitted by RE-1023 but not otherwiserepaired, a “Test Only” nameplate shall beapplied which contains the following infor-mation:

a. Name of responsible organization,

b. Date of test,

c. Set Pressure,

d. An identification such as “Test Only.”

A “test only” nameplate is also recommendedwhen periodic testing has been performed,even when no adjustments have been made,

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for the purpose of identifying the date thevalve was tested.

The existing repair nameplace, if applicable,should not be removed during such testing.

RE-1064 ILLEGIBLE OR

REPLACEMENT OF MISSING

NAMEPLATES

Illegible NameplatesWhen the information on the original manu-facturer’s or assembler’s nameplate or stamp-ing is illegible, the nameplate or stamping will be augmented or replaced by a nameplatefurnished by the “VR” stamp holder stamped“duplicate”. It shall contain all informationthat originally appeared on the nameplate orvalve, as required by the applicable sectionof the ASME Code, except the “V”, “HV”, or“UV” symbol and the National Board mark.The repair organization’s nameplate, with the“VR” stamp and other required data specifiedin RE-1061 , will make the repairer respon-sible to the owner and the jurisdiction thatthe information on the duplicate nameplateis correct.

Missing NameplatesWhen the original valve nameplate is missing,the repair organization is not authorized toperform repairs to the valve under the “VR”program, unless positive identification can bemade to that specific valve and verificationthat the valve was originally stamped with anASME “V” or “UV” symbol or marked withan ASME “HV” symbol. Valves that can bepositively identified will be equipped with aduplicate nameplate, as described in RE-1064 , in addition to the repairer’s “VR” stamped

nameplate. The repairer’s responsibilities foraccurate data, as defined in RE-1064 (IllegibleNameplates), shall apply.

Marking of Original Code StampWhen a duplicate nameplate is affixed toa valve, as required by RE-1064 , it shall bemarked “Sec. I”, “Sec. IV”, or “Sec. VIII”,

as applicable, to indicate the original ASMECode stamping.

RE-1070 FIELD REPAIR

Repair organizations may obtain a “VR” Cer-tificate of Authorization for field repair, eitheras an extension to their in-shop/plant scope,or as a field-only scope, provided that:

a. Qualified technicians in the employ of thecertificate holder perform such repairs;

b. An acceptable quality system coveringfield repairs, including field audits, ismaintained;

c. All functions affecting the quality of therepaired valves are supervised from theaddress of record where the “VR” certifi-cation is issued.

RE-1071 AUDIT REQUIREMENTS

Upon issuance of a certificate of authorization,provided field repairs are performed, annualaudits of the work carried out in the field shall

be performed to ensure that the requirementsof the certificate holder’s quality system aremet. The audit shall include, but not be limitedto, performance testing, in accordance withRE-2000 , of valve(s) that were repaired in thefield. The audits shall be documented.

RE-1072 USE OF OWNER-USER

PERSONNEL

For the repair of pressure relief valves at an

owner-user’s facility for the owner-user’sown use, the “VR” Certificate Holder mayutilize owner-user personnel to assist certifi-cate holder technician(s) in the performanceof repairs provided:

a. The use of such personnel is addressedin the “VR” Certificate Holder’s qualitysystem;

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b. The owner-user personnel are trained andqualified in accordance with RE-3000;

c. Owner-user personnel work under di-rect supervision and control of the “VR”Certificate Holder’s technician(s) during

any stage of the repair when they are uti-lized;

d. The “VR” Certificate Holder shall havethe authority to assign and remove owner-user personnel at its own discretion;

e. The names of the owner-user personnelutilized are recorded on the documentrequired by RA-2255(i).

RE-1100 WELDING FOR PRESSURE

RELIEF VALVES

Welding shall be performed in accordancewith the requirements of the original codeof construction used for the pressure reliefvalve.

Cast iron and carbon or alloy steel having acarbon content of more than 0.35%, shall not be welded.

Defects in pressure relief valve parts such ascracks, pits, or corrosion that will be repaired by welding shall be completely removed be-fore the weld repair of the part is performed.Removal of the defect shall be verified bysuitable NDE as required.

Consideration shall be given to the conditionof the existing material, especially in the weldpreparation area.

RE-1110 WELDING PROCEDURE

SPECIFICATIONS

Welding shall be performed in accordancewith Welding Procedure Specifications (WPS)

qualified in accordance with the original codeof construction. When this is not possible orpracticable, the WPS may be qualified in ac-cordance with Section IX of the ASME Code.

RE-1120 STANDARD WELDINGPROCEDURE

SPECIFICATIONS

A “VR” Certificate Holder may use one ormore applicable Standard Welding ProcedureSpecifications shown in Appendix A.

RE-1130 PERFORMANCE

QUALIFICATION

Welders or welding operators shall be quali-fied for the welding processes that are used.Such qualification shall be in accordance withthe requirements of the original code of con-struction or Section IX of the ASME Code.

RE-1140 WELDING RECORDS

The “VR” Certificate Holder shall maintaina record of the results obtained in welding

procedure qualifications, except for thosequalifications for which the provisions ofRE-1120 are used, and of the results obtainedin welding performance qualifications. Theserecords shall be certified by the “VR” Cer-tificate Holder and shall be available to theNational Board.

RE-1150 WELDERS’ IDENTIFICATION

The “VR” Certificate Holder shall establish a

system for the assignment of a unique identifi-cation mark to each welder/welding operatorqualified in accordance with the requirementsof the NBIC. The “VR” Certificate Holder shallalso establish a written procedure wherebyall welded joints can be identified as to the

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welder or welding operator who made them.This procedure shall use one or more of thefollowing methods and shall be described inthe quality control system written description.The welder’s or welding operator’s identi-fication mark may be stamped (low stress

stamp) adjacent to all welded joints made by the individual or, in lieu of stamping, the“VR” Certificate Holder may keep a recordof welded joints and the welders or weldingoperators used in making the joints.

RE-1160 WELDERS’ CONTINUITY

The performance qualification of a welder orwelding operator shall be affected when oneof the following conditions occur:

a. When the welder or welding operatorhas not welded using a specific processduring a period of six months or more,their qualifications for that process shallexpire.

b. When there is specific reason to questiontheir ability to make welds that meet thespecification, the qualification which sup-ports the welding that is being performed

shall be revoked. All other qualificationsnot questioned remain in effect.

RE-1200 HEAT TREATMENT

RE-1210 PREHEATING

Preheating may be employed during weldingto assist in completion of the welded joint (Ap-pendix B). The need for and the temperatureof preheat are dependent on a number of

factors, such as chemical analysis, degree ofrestraint of the items being joined, materialthickness, and mechanical properties. Thewelding procedure specification for the ma-terial being welded shall specify the preheattemperature requirements.

RE-1220 POSTWELD HEAT

TREATMENT

Postweld heat treatment shall be performedas required by the original code of construc-tion in accordance with a written procedure.

The procedure shall contain the parametersfor postweld heat treatment.

RE-2000 PERFORMANCE TESTING

AND TESTING EQUIPMENT

Each pressure relief valve to which the “VR”repair symbol stamp is to be applied shall besubjected to the following tests by the repaircertificate holder.

RE-2010 TEST MEDIUM AND

TESTING EQUIPMENT

Valves marked for steam service, or havingspecial internal parts for steam service, shall be tested on steam. Valves marked for air,gas, or vapor service shall be tested with airor gas. Valves marked for liquid service shall be tested with water or other suitable liquid.Section IV hot water valves shall be tested on

water, steam, or air.

a. Each valve shall be tested to demonstratethe following:

1. Set pressure (as defined by thevalve manufacturer and as listed inNB-18);

2. Response to blowdown, when re-quired by the original Code of Con-struction;

3. Seat tightness;

4. For valve designed to discharge to aclosed system, the tightness of the sec-ondary pressure zone shall be testedas required by the original Code ofConstruction.

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b. The equipment used for the performancetesting prescribed by RE-2010 shall meetthe following requirements:

1. The performance testing equipmentshall include a pressure vessel of ad-

equate volume and pressure sourcecapacity to ensure compliance withRE-2010(a)(1).

2. Prior to use, all performance testingequipment shall be qualified by thecertificate holder to ensure that theequipment and testing procedureswill provide accurate results whenused within the ranges establishedfor that equipment. This qualificationmay be accomplished by bench marktesting, comparisons to equipmentused for verification testing (RA-2225) ,or comparisons to field performance.This qualification shall be docu-mented and provisions made to retainsuch documentation for a period of atleast five years after the testing equip-ment is retired. Documentation of thisqualification shall include but not belimited to:

a. Schematic of the performance testequipment;

b. Size and pressure ranges of valvesto be tested;

c. Dimensions of test vessels;

d. Accuracy of pressure measuringequipment;

e. Size and design type of valves

used to control flow; and

f. Method of qualifying.

3. Prior to the implementation of anyaddition or modification to the test-ing equipment that would alter the

contents of the document required inRE-2010(b)(2) , the certificate holdershall requalify the performance testequipment in accordance with RE-2010(b)(2). If the equipment changedwas used to satisfy the requirements

of verification testing, the certificateholder shall notify the National Boardand additional verification testing,in accordance with RA-2225 , may berequired.

RE-2020 OWNER-USER SECTION VIII

STEAM TESTING

When ASME Section VIII valves are repaired by the owner for the owner’s own use, valvesfor steam service may be tested on air for setpressure and, if possible, blowdown adjust-ment provided manufacturer’s corrections fordifferential in set pressure between steam andair are applied to the set pressure.

RE-2030 LIFT ASSIST TESTING

A device may be used to apply an auxiliarylifting load on the spring of a repaired valve

to establish the set pressure in lieu of the testsrequired in RE-2010(a)(1) when such testingat full pressure:

a. may cause damage to the valve beingtested; or

b. is impractical when system design con-siderations preclude testing at full pres-sure.

While actual valve blowdown and valve per-

formance characteristics cannot be verified,valve set pressure may be determined to an ac-ceptable degree of accuracy using this testingtechnique provided, as a minimum, that:

a. Equipment utilized is calibrated as re-quired in RA-2255(m);

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b. The device and test procedures whichhave proved to give accurate results areused and followed;

c. A static inlet pressure is applied with thetest medium specified in RE-2010;

d. Adjustments are made in accordancewith the valve manufacturer’s recom-mendations as to ensure proper lift and blowdown.

RE-2040 PRESSURE TEST OF PARTS

Parts used in repaired valves shall be pressuretested and documentation provided accordingto the following catagories:

a. Replacement Parts The “VR” Certificate Holder is responsible

for documentation that the appropriatepressure test has been completed as re-quired by the original code of construc-tion.

b. Parts Repaired by Welding These parts shall be subjected to a pres-

sure test required by the original code of

construction. The “VR” Certificate Holdershall be responsible for documentation ofsuch test.

c. Parts repaired by re-machining withinpart specifications, lapping, or polishingdo not require a pressure test.

RE-3000 TRAINING AND

QUALIFICATION OF

PERSONNEL

RE-3010 GENERAL

It is essential that valve repair organizationsensure that their personnel engaged in repairsto pressure relief valves are knowledgeableand qualified within the scope of the repairsto be conducted.

The National Board offers coordinated train-ing courses for valve repair organization per-sonnel to further their skills and knowledge inthe repair of pressure relief valves. Many reliefvalve manufacturers also sponsor trainingcourses on the repair and maintenance of their

respective valve types and series. Pressure re-lief valve repair organizations are encouragedto have their personnel participate in thesecourses. It is also recommended that valverepair organizations cooperate and establishworking relationships with valve manufac-turers to help ensure the proper repair of themanufacturer’s specific valves.

RE-3020 CONTENTS OF TRAINING

PROGRAM

The repair organization shall establish adocumented in-house training program. Thisprogram shall establish training objectivesand provide a method of evaluating trainingeffectiveness. As a minimum, training objec-tives for knowledge level shall include:

a. Applicable ASME Code and NBIC re-quirements;

b. Responsibilities within the organization’squality system; and

c. Knowledge of the technical aspects andmechanical skills for the applicable posi-tion held.

RE-3030 QUALIFICATION OF

PERSONNEL

Each repair organization shall establish

minimum qualification requirements for thosepositions within the organization as theydirectly relate to pressure relief valve repair.Each repair organization shall document theevaluation and acceptance of an individual’squalification for the applicable position.

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RE-3040 ANNUAL REVIEW OF

QUALIFICATION

The repair organization shall annually reviewthe qualifications of repair personnel to verifyproficiency as well as compliance with the cer-

tificate holder’s quality system. This reviewshall include training records, documentedevidence of work performed and, when neces-sary, monitoring job performance. The reviewshall be documented.

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134.2

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Preparation of Technical Inquiries to theNational Board Inspection Code Committee

Appendix 1

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APPENDIX 1 — PREPARATION OF TECHNICAL INQUIRIES TO THE

NATIONAL BOARD INSPECTION CODE COMMITTEE

1-1000 INTRODUCTION

The NBIC Committee meets regularly toconsider written requests for interpretationsand revisions to the Code rules and to de-velop new rules, as dictated by technologicaldevelopment. The Committee’s activities inthis regard are limited strictly to interpreta-tions of the rules or to the consideration ofrevisions to the present rules on the basisof new data or technology. As a matter ofpublished policy, the National Board doesnot approve, certify or endorse any item,construction, proprietary device, or activity

and, accordingly, inquiries requiring suchconsideration will be returned. Moreover, theNational Board does not act as a consultant onspecific engineering problems or on thegeneral application or understanding ofthe Code rules. If, based on the inqui-ry information submitted, it is the opin-ion of the Committee that the inquirershould seek assistance, the inquiry will bereturned with the recommendation that suchassistance be obtained.

All inquiries that do not provide theinformation needed for the Committee’s fullunderstanding will be returned.

1-2000 INQUIRY FORMAT

Inquiries shall be limited strictly to interpre-tations of the rules or to the consideration ofrevision to the present rules on the basis ofnew data or technology. Inquiries shall besubmitted in the following format:

a. Scope Involve a single rule or closely relat-

ed rules. An inquiry letter concerningunrelated subjects will be returned.

b. Background State the purpose of the inquiry, which

would be either to obtain an interpretation of code rules or to propose considerationof a revision to the present rules. Provideconcisely the information needed forthe committee’s understanding of theinquiry, being sure to include referenceto the applicable code edition, addenda,paragraphs, and figures. If sketches areprovided, they shall be limited to thescope of the inquiry.

c. Inquiry Structure

Prepare statements in a condensedand precise question format, omittingsuperfluous background information,and, where appropriate, composed insuch a way that “yes” or “no” (perhapswith provisos) would be an acceptablereply. This inquiry statement should betechnically and editorially correct.

d. Proposed Reply State what it is believed the Code requires.

If, in the inquirer’s opinion, a revision to

the Code is needed, recommended word-ing shall be provided.

1-3000 SUBMITTAL

Inquiries shall preferably be submittedin typewritten form; however, legible hand-written inquiries will also be considered.They shall include the name, email address,and mailing address of the inquirer and bemailed to the following address:

Secretary, NBIC Committee1055 Crupper AvenueColumbus, OH 43229

614.847.1828 — Fax614.888.8320 ext. 228 — Phone

[email protected] — EmailA05

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Stamping and Nameplate Information

Appendix 2

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APPENDIX 2 — STAMPING AND NAMEPLATE INFORMATION

2-1000 SCOPE

When a pressure-retaining item is repaired

or altered, the Certificate Holder shall attacha nameplate or stamp the item, except whenotherwise permitted by these rules. Similarly,when pressure relief devices are repaired, theattachment of a nameplate is required. Thespecific requirements for nameplates/stamp-ing are described in this Appendix. See Fig-ures 2-1000-a thru 2-1000-g.

2-2000 GENERAL REQUIREMENTS

FOR STAMPING AND

NAMEPLATES

Required data shall be in characters at least5/32 in. (4 mm) high, except that characters forpressure relief valve repair nameplates may besmaller. Markings may be produced by cast-ing, etching, embossing, debossing, stamp-ing or engraving. The selected method shallnot result in any harmful contamination ofor sharp discontinuities to the pressure-retain-ing item.

The National Board code symbols (“R”,“VR”, and “NR”) are to be stamped; do notemboss.

Stamping direct ly on i tems, whenused, shall be done with blunt-nose continu-ous or blunt-nose interrupted dot die stamps.If direct stamping would be detrimental tothe item, required markings may appear ona nameplate affixed to the item.

The Certificate Holder shall use its full nameas shown on the Certificate of Authorizationor an abbreviation acceptable to the NationalBoard.

Stamping or nameplate shall be applied adjacent to the original manufacturer’s stamp-

ing or nameplate. A single repair nameplateor stamping may be used for more than onerepair to a pressure-retaining item provided it

is carried out by the same Certificate Holder.The date of each repair, corresponding withthe date on the associated Form R-1 , shall bestamped on the nameplate.

The letters “RP” shall be stamped below the“R” symbol stamp to indicate organizationsaccredited for performing repairs or altera-tions to Fiber Reinforced Plastic items.

The letter “G” shall be stamped below the“R” symbol stamp to indicate organizationsaccredited for performing repairs or altera-tions to Graphite Pressure vessels.

2-2100 ADDITIONAL STAMPING

REQUIREMENTS FOR

REPAIRS

Stamping or nameplate shall be applied adjacent to the original manufacturer’s stamp-ing or nameplate. A single repair nameplate

or stamping may be used for more than onerepair to a pressure-retaining item provided itis carried out by the same Certificate Holder.The date of each repair, corresponding withthe date on the associated Form R-1 , shall bestamped on the namepate.


REQUIREMENTS FOR

ALTERATIONS AND

RE-RATINGS

Stamping or nameplate shall be applied adja-cent to the original manufacturer’s stampingor nameplate.

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APPENDIX 2 — STAMPING AND NAMEPLATE INFORMATION


REQUIREMENTS FOR PARTS

Stamping or nameplate shall be applied in aconspicuous location on the part.


REQUIREMENTS FOR


Pressure relief valve repair stamping or name-plate shall be applied adjacent to the originalmanufacturer’s stamping or nameplate.

Note(2): To be indicated only whenchanged.

�

�

� ��

Figure 2-1000-a — Required Markings forRepairs, with use of National Board Form R-1

��

�

�

Figure 2-1000-b — Required Markings for Altera-tions, with use of National Board Form R-2

��

�

�

Figure 2-1000-c — Required Markings for Re-rat-ings, with use of National Board Form R-2

��

�

Figure 2-1000-d — Required Markings for PartsFabricated by Welding, with use of NationalBoard Form R-3

�

�

�

Figure 2-1000-e — Required Markings for Repairof ASME/National Board “V”, “UV”, and “HV”Stamped Pressure Relief Valves

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�

�

�

(TYPE/MODEL NUMBER)

Figure 2-1000-f — Required Markings for NuclearRepairs or Replacements

Figure 2-1000-g — Required Markings for Repairor Replacement of Nuclear Pressure Relief Valves

�

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Steam Locomotive Firetube BoilerInspection, Repair, and Storage

Appendix 3

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�

�

�

�

FIGURE 3-1010-a — Locomotive Boiler General Arrangement

CombustionChamber

SideSheet

RoofSheet

Throat Sheet

Inside Throat Sheet

Dome Course

Crown Sheet

FIGURE 3-1010-b — Arrangement of Firebox Sheets (Staybolts Deleted for Clarity)

APPENDIX 3 — STEAM LOCOMOTIVE FIRETUBE BOILERINSPECTION, REPAIR, AND STORAGE


3-1010 SCOPE

This appendix is provided as a guide for in-spection, repairs and alterations, and storage

of steam locomotive firetube boilers. Theserules for the repair and alteration of steamlocomotive boilers shall be used in conjunc-tion with the applicable rules of this code. Seegeneral figures 3-1010-a and 3-1010-b.

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APPENDIX 3 — STEAM LOCOMOTIVE FIRETUBE BOILER INSPECTION, REPAIR, AND STORAGE

3-1100 SPECIAL JURISDICTIONALREQUIREMENTS

Many jurisdictions have special requirementsfor locomotive boilers. Such requirementsshall be considered in addition to those in

this appendix.

3-1200 FEDERAL RAILROADADMINISTRATION (FRA)

The FRA rules for steam locomotive boil-ers are published in the Code of FederalRegulations (CFR) 49CFR Part 230 DatedNovember 17,1999.8 All locomotives underFRA jurisdiction are documented on FRAForm 4 as defined in 49CFR Part 230. Thisdocument is the formal documentation of thesteam locomotive boiler and is required to becompleted prior to the boiler being placed inservice. This document shall be used as theData Report for the boiler, applicable to allrepairs and alterations performed. NationalBoard “R” Certificate Holders shall documenttheir repairs and/or alterations on NationalBoard Forms R-1 or R-2. These reports shall be distributed to the owner/user of the boiler,who is required to incorporate them into a

FRA Form 19, which becomes an attachmentto the FRA Form 4. The design margin for allsuch repairs or alterations shall not be lessthan four based on ultimate tensile strengthof the material.

3-1300 REQUIREMENTS FORWELDING ACTIVITIES

Before performing any welding activities,consideration shall be given to ensure the

weldability of locomotive boiler materials.

Special jurisdictional approval may be re-quired prior to starting welding activity onlocomotive boilers.

3-1400 FORMULA ANDCALCULATIONS FOR STEAMLOCOMOTIVE BOILERS

Most steam locomotive boilers were manu-factured in the first half of the 20th century

or before. The calculations, formula, and shoppractices used are now distant history andquite difficult to obtain. The rules for rivetedconstruction were last published by ASME in Section I Code, 1971 Edition. Appendix C , herein, provides a copy of the 1971 rivetingrules from Parts PR and PFT.

Appendix 3, herein, is based in part on theASME Code, Section III, 1952 Edition ,9 whichwas the last published edition of the SteamLocomotive Code. The railroad industry hasattempted to collect the old formula and someshop practices. These have been published by The Engineering Standards Committee forSteam Locomotives, Inc. (ESC) as Compendi-um, Volume 1, Compilation of Calculations.10

3-2000 LOCOMOTIVE FIRETUBEBOILER INSPECTION

3-2010 INSPECTION METHODS

Plate thickness and depth of corrosion may bedetermined by use of the ultrasonic thicknesstesting process.

Where access is possible, the depth of pittingmay be determined by use of a depth microm-eter or a pit gage.

On stayed sections, the plate thickness read-ings should be taken on a grid not exceedingthe maximum staybolt pitch at the center of

each section of four staybolts. Additional

9 This Code is available from the National Board.10 Copies of The Engineering Standards Committee for

Steam Locomotives, Inc., Compendium, Volume1, Compilation of Calculations may be obtained fromthe Strasburg Rail Road, P.O. Box 96, Strasburg, PA17579, phone 717.687.8421.

8 Steam locomotive inspection and maintenance stan-dards, which is now codified at 49CFR Part 230,may be obtained at the FRA Web site. The final ruleat www.fra.dot.gov/downloads/counsel/fr/slfr.pdf

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readings may be taken close to each staybolt todetermine if localized thinning has occurred.Particular attention should be given to the joint between the staybolt and the plate.

On unstayed sections, the plate thickness read-

ings should be taken on a grid not exceeding12 inch (300 mm) centers. Additional readingsshould be taken if conditions warrant.

Cracks in plates may be located by the useof appropriate Nondestructive Examination(NDE) methods.

Separation of plates at riveted seams may bedetected by use of a feeler gage and magnify-ing glass or other applicable method.

Varying the intensity of inspection lights mayfacilitate discovery of defects. Placement ofthe light to shine parallel to the surface isone method of detecting pits and surface ir-regularities.

When inspecting internal stayed surfaces,placement of a light source within the stayedzone will aid the inspection.

Broken staybolts may be detected by leakage

through telltale holes and by hammer testing.Both methods are most effective when the boiler is under hydrostatic pressure of at least95% MAWP. If a hydrostatic test cannot beapplied, the hammer test may be performedalone with the boiler drained.

Visual inspection shall be performed as asupplement to all of the above.

3-2020 INSPECTION ZONES

Riveted Seams and Rivet HeadsRiveted seams and rivet heads shall be in-spected for:

• Grooving• Corrosion• Cracks• Pitting

• Leakage• Separation of the plates• Excessive or deep caulking of the plate

edges and rivet head• Seal welding of the plate edges and rivet

heads

• Rivet heads that have been built up by orcovered over completely by welding

• Rivets replaced by patch bolts• Defective components of the seam

Notes:1. Broken rivet heads or cracked plates may

result from sodium hydroxide cracking(caustic embitterment).

2. Riveted longitudinal lap seams should begiven careful examination, using NDE ifnecessary, because this type of construc-tion is prone to cracking.

3. When determining the extent of corrosionto rivet heads, it is important to know therivet size and the type of rivet head usedfor the original construction. Corrosioncan alter the appearance of these itemsand disguise the full extent of the dam-age.

4. Fire cracks extending to the rivet holes inriveted lap seams of firebox sheets may beacceptable under NBIC RB-4480.

Welded and Riveted RepairsWelded and riveted repairs shall be inspectedfor:

• Correct application of welded patches orweld application

• Correct application of riveting• Cracks• Separation of the plates• Dents or other mechanical damage• Leakage

Boiler Shell CourseThe boiler shell course shall be inspectedfor:

• Grooving or cuts• Corrosion• Cracks• Pitting

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• Separation of the plates• Dents or other mechanical damage• Leakage

Note:1. An accurate inspection often cannot be

performed until the interior has beencleaned since mud and scale make it dif-ficult to detect defects.

Dome and Dome LidThe dome and dome lid shall be inspectedfor:

• Grooving• Corrosion, especially at the interior section

attached to the boiler course• Cracks• Pitting• Separation of plates• Dents or other mechanical damage• Leakage• Stretched, bent, or corroded dome studs• Damage to the steam dome cover sealing

surfaces

Notes:1. Close inspection should be made to the

interior section at the joint attached to the

boiler course.2. If the dome studs are bent, a careful evalu-ation should be made of the lid for leakageand mechanical damage.

Mud RingThe mud ring and mud ring rivets shall beinspected for:

• Mud and scale on the waterside• Debris on the waterside• Corrosion

• Grooving• Cracks• Separation of the firebox plates from the

mudring• Dents or other mechanical damage• Leakage

Flue SheetsFlue sheets shall be inspected for:

• Grooving around flue holes, rivet seamsand braces

• Pitting

• Fireside and waterside corrosion• Fire cracks at riveted lap seams• Cracks• Bulges• Leakage• Excessive or deep caulking of the plate

edges

Note:1. Corrosion is common at the bottom section

of the front flue sheet. Close inspection ofthe joint between the front flue sheet andshell shall be made.

Flanged SheetsThe flanged section of all flanged sheets shall be inspected for:

• Pitting• Corrosion• Cracks• Grooving• Scale and mud deposits

• Correct fit up and alignment of the flangedsheet to the adjacent sheets

Notes:1. Corrosion is common at the bottom sec-

tion of the front flue sheet.2. The flanges should have a smooth uniform

curvature and should make a smoothtransition to the flat sheets.

Stayed SheetsStayed sheet shall be examined for:

• Scale and mud deposits• Grooving around staybolt holes• Deterioration of the joint between the

staybolt and the sheet• Grooving on the waterside section• Pitting• Fireside and waterside corrosion

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• Overheating• Fire cracks at riveted lap seams• Cracks• Bulges

Notes:

1. Close inspection for fireside corrosionshould be given to sections located behindrefractory or grate bars.

2. Close inspection should be made forgrooving on waterside surfaces of thestayed sheets just above the mudring.

3. Fire cracks extending to the rivet holes inriveted lap seam firebox sheets may beacceptable under RB-4480.

StayboltsStaybolts shall be inspected for:

• Cracks in or breakage of the body• Erosion of the driven head from corrosion

or combustion gases• Staybolt head flush with or below the

surface of the sheet• Plugging of telltale holes except as permit-

ted by 49 CFR Part 230.41• Waterside corrosion• Staybolt heads that have been covered

over by welding

• Correct application of seal welding tostaybolt heads

Notes:1. An indicator of waterside corrosion on

threaded staybolts is the lack of threadson the section of the staybolt body justabove the sheet.

2. Broken staybolts may be detected by leak-age through telltale holes and by hammertesting. Both methods are most effectivewhen the boiler is under hydrostatic pres-

sure of at least 95% MAWP. If a hydrostatictest can not be applied, the hammer testmay be performed alone with the boilerdrained.

3. When a broken stay is found, the staysadjacent to it should be examined closely

because these may have become over-stressed by addition of the load from the broken stay.

4. A telltale hole plugged by installation ofa nail or pin may indicate the staybolt is broken and requires replacement.

5. The plugging of telltale holes by refractoryto prevent build up of foreign matter inthe telltale hole is permitted for locomo-tives operating under FRA jurisdiction per49 CFR Section 230.41.

6. One indication that a threaded stayboltleaks during service is when the head ofit is found to have been re-driven repeat-edly.

Flexible Staybolts and SleevesFlexible staybolt sleeves and caps shall beinspected for:

• Corrosion• Cracks• Dents or other mechanical damage• Leakage• Damaged threads or welds• Scale and mud accumulations inside the

sleeve that could restrict bolt movement• Correct application of welding to welded

sleeves and welded caps

• Seal welding of threaded sleeves orthreaded caps


threaded staybolts is the lack of threadson the section of the staybolt body justabove the sheet.

2. Broken staybolts may be detected by leak-age through telltale holes and by hammertesting. Both methods are most effectivewhen the boiler is under hydrostatic pres-

sure of at least 95% MAWP. If a hydrostatictest can not be applied, the hammer testmay be performed alone with the boilerdrained.

3. On ball head flexible staybolts, onemethod of testing the stay for cracks or

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breakage is to strike the ball head usinga pneumatic hammer or hand hammer.Another method is to twist the ball headusing a long handle wrench. Access to the ball head is gained by removing the capfrom the sleeve.

4. When a broken stay is found, the staysadjacent to it should be examined closely because these may have become over-stressed by addition of the load from the broken stay.

5. A telltale hole plugged by installation ofa nail or pin may indicate the staybolt is broken and requires replacement.

6. The plugging of telltale holes by refractoryto prevent build up of foreign matter inthe telltale hole is permitted for locomo-tives operating under FRA jurisdiction per49 CFR Section 230.41.

7. One indication that a threaded stayboltleaks during service is when the head ofit is found to have been re-driven repeat-edly.

Girder Stay and Crown BarsGirder stays, crown bars, and their associ-ated fasteners including stays, rivets, pins,washers, nuts, thimbles, spacers, and theadjacent sections of the firebox plates shall

be inspected for:

• Corrosion• Cracks• Mud and scale• Correct fit and alignment of the girder stay

or crown bar to the firebox plate surface,including flanged sections

• Correct fit and alignment of the thimbles,spacers, and pins to the girder stay orcrown bar, and the firebox plates

• Dents or other mechanical damage

• Stays or rivets built up by or covered overcompletely by welding

• Leakage from the stay heads• Seal welding of rivet heads

• Correct application of retainers to all nutsand fasteners

• Missing fasteners, nuts or retainers

Notes:1. An accurate inspection often cannot be

performed until the girder stay or crown bar has been cleaned since mud and scalewill make it difficult to detect defects.

2. When a broken stay is found, the staysadjacent to it should be examined closely because these may have become over-stressed by addition of the load from the broken stay.

Sling StaysSling stays and their associated fastenersincluding the pins, retainers, washers, nuts,and their associated attachment at eyes, girderstays, or crown stays shall be inspected for:

• Corrosion• Cracks• Dents, wear or other mechanical dam-

age• Mud and scale• Wear to the pin hole or expansion slot of

the sling stay and mating component• Correct application of retainers to the

pins• Missing fasteners, nuts, or retainers• Any of the above that would restrict

movement of the sling stays

Notes:1. An accurate inspection often cannot be

performed until the sling stay has beencleaned since mud and scale will make itdifficult to detect defects.

2. When a broken or loose stay is found, thestays adjacent to it should be examined

closely because these may have becomeoverstressed by addition of the load fromdefective stay.

3. Special attention should be given to therow of sling stays adjacent to the flue sheetto ensure that these stays are not loose.

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Crown Stays and Expansion StaysCrown stays and expansion stays shall beinspected for:

• Cracks in or breakage of the body• Dents, wear, or other mechanical damage

• Erosion of the driven head from corrosionor combustion gases

• Stay head flush with or below the surfaceof the sheet

• Plugging of telltale holes, except as per-mitted by 49 CFR Part 230.41

• Waterside corrosion• Stay heads that have been covered over

by welding• Correct application of seal welding to stay

heads• Correct application of retainers to the

pins• Missing fasteners, nuts, or retainers• Correct fit and alignment of the stay

assembly• Any of the above that would restrict

movement of the stay


threaded stays is the lack of threads onthe section of the stay body just above the

sheet.2. Broken stays may be detected by leakagethrough telltale holes and by hammertesting. Both methods are most effectivewhen the boiler is under hydrostatic pres-sure of at least 95% MAWP. If a hydrostatictest can not be applied, the hammer testmay be performed alone with the boilerdrained.

3. When a broken stay is found, the staysadjacent to it should be examined closely because these may have become over-

stressed by addition of the load from broken stay.

4. A telltale hole plugged by installation of anail or pin may indicate the stay is brokenand requires replacement.

5. The plugging of telltale holes by refractoryto prevent build up of foreign matter in thetelltale hole is permitted for locomotivesoperating under FRA jurisdiction per 49CFR Part 230.41.

6. One indication that a threaded stay leaks

during service is when the head of it isfound to have been re-driven repeatedly.

7. Special attention should be given to therow of stays adjacent to the flue sheet toensure that these stays are not loose.

Diagonal and Gusset BracesDiagonal and gusset braces, and their attach-ments, shall be inspected for:

• Looseness• Corrosion• Cracks• Welded repairs• Missing pins or pin retainers• Defective rivets• Scale and mud deposits

Notes:1. Diagonal and gusset braces should be

under tension.2. The brace pins should fit the brace clevis

and eye securely and be retained from

coming out by some type of fixed or keyedretainer.3. Diagonal braces having loop-type ends

should be given close inspection forcracks and corrosion. The loop-type endis formed by the brace body being split,looped around and forged to the body.Some versions of it have a low mar-gin of material to provide the requiredstrength.

Flues

All boiler and superheater flues shall be in-spected for:

• Fire cracks• Pitting• Corrosion• Erosion

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• Obstructions in the flue interior• Mud or scale buildup on the waterside• Erosion or cracking of the flue ends, flue

beads and/or seal welds• Leakage• Number of circumferential welded joints

on flues repaired by re-ending• Correct application including expand-

ing/rolling and belling, beading, or sealwelding of the flue end

Notes:1. Erosion (cinder cutting) generally occurs

to the firebox end of the flue.2. Galvanic corrosion of the flue in the flue

sheet may occur if flues are installed withcopper ferrules.

Superheater Units and HeaderSuperheater units and the superheater headershall be inspected for:

• Pitting• Cracks• Erosion• Corrosion• Bulges• Leakage• Missing shields

• Missing or broken bands or supports onthe superheater units• Missing, damaged, or welded attachment

bolts, nuts, clamps, studs, and washers• Adequate structural bracing and support

of the superheater header

Arch Tubes, Water Bar Tubes and CirculatorsArch tubes, water bar tubes, and circulatorsshall be inspected for:

• Erosion

• Corrosion• Fire cracks• Pitting• Cracking of tube ends• Overheating and blistering• Bulges

• Mud and scale buildup in the waterside• Welded repairs• Correct application including expand-

ing/rolling and belling, beading, or sealwelding of the tube end

Note:1. Weld build up or welded patches are not

permitted on arch tubes and water bartubes of locomotives operating under FRA jurisdiction per 49 CFR Section 230.61. Thedefective tubes must be replaced.

Thermic SyphonsThermic syphons shall be inspected for: • Erosion• Corrosion• Fire cracks• Pitting• Cracking of the syphon neck• Overheating and blistering• Bulges• Mud and scale blockage in the waterside• Broken or damaged staybolts

Note:1. Refer to sections Staybolts, Stayed Sheets,

and Flanged Sheets for additional inspec-

tion procedures.

Fire Box RefractoryFirebox refractory shall be inspected to en-sure it is properly applied and maintained toprevent undesired flame impingement on thefirebox sheets.

Dry PipeThe dry pipe of boilers having dome mounted(internal) throttle valves shall be inspectedfor:

• Erosion• Corrosion• Cracks• Adequate structural bracing, support, and

attachment to the boiler and dome• Loose, bent or damaged rivets, nuts, bolts,

and studs

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Fusible PlugsFusible plugs shall be inspected for:

• Corrosion• Scale build up on the waterside• Damage

• Tampering• Leakage from the threads• Height of the plug above waterside of

crown sheet• Evidence of melting or overheating• Proper marking

Water Glass, Water Column and Gage CocksThe water glass, water column, and gagecock boiler connections and piping shall beinspected for:

• Mud and scale blockage• Kinks or sharp, restricted or flattened

bends in the piping• Sags in the piping horizontal runs• Condition of tubular or reflex water

glass• Correct type and material of piping and

fittings• Correct location, size, and installation of

the connections to the sheets• Correct installation of the safety shield (if

used)• Correct installation of the viewing light (ifused)

• Correct installation of the test and drainvalves

• Proper installation• Proper bracing to prevent vibration• Loose, bent or damaged nuts, bolts, and

studs

Steam Pressure GageThe steam pressure gage, gage cock boiler

connections, and piping shall be inspectedfor: • Kinks or sharp, restricted or flattened

bends in the piping• Correct installation of the shutoff valve

and syphon

• Proper size, type and material of pipingand fittings

• Proper installation• Proper lighting for viewing• Proper bracing to prevent vibration• Calibration

Boiler Fittings and PipingThe boiler fittings and associated piping shall be inspected for:

• Cracks• Corrosion• Pitting• Leakage• Looseness• Loose, bent or damaged nuts, bolts, and

studs• Adequate structural bracing, support, at-

tachment, and provision for expansion• Proper size, type, and material

Boiler Attachment BracketsThe boiler attachment brackets and associatedcomponents and fasteners used to secure the boiler to the frame shall be inspected for:

• Correct installation• Damaged or missing components

• Looseness• Leakage• Loose, bent or damaged rivets, nuts, bolts

and studs• Defective rivets• Provision for expansion

Fire DoorThe fire door, the locking mechanism, and theoperating mechanism shall be inspected for:

• Safe and suitable operation

• Cracked, damaged, or burned parts• Loose, damaged or bent rivets, nuts, bolts,

and studs

Note:1. The locking mechanism should be in-

spected for correct operation to confirm

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• Inspect staybolts for leakage at the headand telltale hole

• Inspect boiler fittings, controls and associ-ated piping for leakage

• Inspect water tanks, fuel tanks and associ-ated piping for leakage

• Inspect firebox door for proper operationand locking

3-3000 LOCOMOTIVE FIRETUBEBOILER REPAIRS

3-3010 REPAIR OF STAYBOLT HOLES

Staybolt holes may be repaired by welding,reaming, or retapping to a larger size or byinstalling a flush patch.

If the staybolt hole was threaded and is to be repaired by welding, the threads shall beremoved prior to welding.

3-3020 THREADED STAYBOLTS

(See Figure 3-3020)

All threaded staybolts shall have either 11- or12-thread pitch. Staybolt threads shall have agood close fit in sheets. Changing the stayboltthread pitch from 11 to 12 or the reverse shall beconsidered a repair.

All staybolts shorter than 8 in.(200 mm) inlength shall have telltale holes. Staybolt tell-tale holes in existing bolts shall be 3/16 in.(5 mm) to 7/32 in. (5.5 mm) in diameter andat least 1-1/4 in. (32 mm) deep in the outer

Taper Head CrownBolt-Type Staybolts

Rigid Staybolt EquippedWith Telltale Holes

Bucking Bar For BallSocket Flexible Staybolts

Ball Socket-TypeFlexible Staybolt

TaperHeadType

ButtonHeadType

ReducedSection

FIGURE 3-3020 — Threaded Staybolts

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end. When staybolts 8 in. (200 mm) or lessin length are replaced, they shall be replacedwith staybolts that have a telltale hole 3/16 in.(5 mm) to 7/32 in. (5.5 mm) in diameter theirentire length or with ones that have a 3/16in. (5 mm) to 7/32 in. (5.5 mm) diameter hole

in each end, drilled a minimum of 1-1/4 in.(31 mm) deep. On reduced body staybolts thetelltale hole shall extend beyond the fillet andinto the reduced section of the staybolt. Ballsocket-type flexible staybolts may have telltaleholes that extend from the threaded end of the bolt into the bolt head for a distance of 1/3the spherical bolt head diameter.

Telltale holes shall be reopened after driv-ing.

Staybolt length shall be sized so the lengthof bolt projecting through the sheet is notless than 1/8 in. (3 mm) and is sufficient toproduce a full head after driving.

The thread lead of both bolt ends and bothfirebox sheets shall be synchronized to permitthe bolt to be installed without stripping thethreads.

When driving staybolt heads, the bolt’s oppo-

site end shall be bucked or braced to preventdamaging the bolt’s threads. Bracing can bedone several ways, such as using a pneumaticholder or a heavy steel bucking bar. Drivingthe heads on both ends of the staybolt simulta-neously using two pneumatic rivet hammers(double gunning) is acceptable. Bolts are to bedriven in such a manner as to expand radiallythe bolt body and threads into the sheet priorto forming the head. Merely driving over thehead is not acceptable.

Ball socket-type flexible staybolts shall not be braced by inserting a spacer under the cap.

Installation of different diameter stayboltsshall be considered a repair.

3-3030 BALL SOCKET-TYPEFLEXIBLE STAYBOLTS,SLEEVES, AND CAPS

Welded flexible staybolt sleeves shall be ap-plied as shown in Figures 3-3030-a through

3-3030-e. Sleeve axis shall be in alignmentwith centerline through holes in wrapper andfirebox sheets.

Welded sleeves and welded caps that leak atthe welds or the sleeve shall be repaired.

Wasted caps and sleeves shall not berepaired by weld buildup.

Welded sleeves that have damaged cap threadsshall be repaired or replaced. If the sleeve haswasted to less than 60% of the original thicknessat the threaded cap section, it may be repaired bycutting off the threaded section and weldingon a replacement section using full penetra-tion welds.

Threaded or welded sleeves that are crackedor have wasted to less than 60% of the origi-nal thickness at any section other than thethreaded cap section shall be replaced.

Threaded sleeves that leak where screwed intothe boiler shell or wrapper sheet shall be re-paired. Seal welding of one pass not exceeding3/16 in. (5 mm) leg size is permissible for caulk-ing purposes only. If seal welding is applied,the sleeve threads in the weld zone shall beremoved prior to welding.

New threaded sleeves seal welded af-ter installation shall have the threadsremoved from the weld zone of the sleeveprior to welding.

Threaded staybolt caps that leak shall not beseal welded.

Substitution of one type of flexible stayboltsleeve by another type shall be considereda repair.

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FIGURE 3-3030-a — Flexible Staybolts — Welded Sleeves, Caps, and Gaskets

threaded cover cap

threaded sleeve

ball socket staybolt consistingof a spherical nut on a threaded

rigid staybolt

ball socket staybolt

FIGURE 3-3030-b — Ball Socket-Type FlexibleStaybolts

Welded Cover Cap Type

ball socket staybolt

welded covercap

Welded Sleeve With ThreadedCover Cap Type

threaded cover cap ball socketstayboltwelded sleeve

Threaded Sleeve WithThreaded Cover Cap Type

FIGURE 3-3030-c — Half Sleeve RepairProcedure for Damaged Ball SocketFlexible Staybolt Welded Sleeve

welded sleevedamaged atthreadedsection

remove threadedsection down togasket surface

do not remove existingflexible staybolt

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Where necessary for boiler expansion, ball sock-et-type flexible staybolts shall be positioned insuch a manner as to not interfere with boilerexpansion. Where individual bolts are re-

placed, care should be taken to assure that thestress load of the new bolt is compatible to theloading on adjacent bolts.

Note: Some locomotive boiler designs po-sitioned the bolts by backing the bolt headaway from the sleeve socket bottom a certainamount.

3-3040 SEAL WELDED STAYBOLTS (See Figure 3-3040)

Replacement threaded staybolts may be sealwelded before or after driving.

Existing threaded staybolts that leak shall be repaired and may be seal welded. Whenused, seal welding shall not be the sole meansof repair.

3-3050 WELDED INSTALLATION OFSTAYBOLTS

The installation of unthreaded staybolts using

full penetration welds is permissible.

this surface machined forfull penetration weld joint

thread for standard flexiblestaybolt cap and gasket

FIGURE 3-3030-d — Half Sleeve RepairProcedure for Damaged Ball SocketFlexible Staybolt Welded Sleeve

half sleeve

FIGURE 3-3030-e — Half Sleeve Repair Proce-dure for Damaged Ball Socket Flexible StayboltWelded Sleeve

half sleeve

installed with fullpenetration weld

FIGURE 3-3040 — Seal WeldedStaybolts

staybolt head seal welded before driving

staybolt head seal weldedafter driving

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3-3080 PATCH BOLTS (See Figure 3-3080)

Patch bolts may be replaced in kind.

Seal welding of bolts is permitted.

3-3100 FLUES, ARCH TUBES,CIRCULATORS, THERMICSYPHONS

3-3110 FLUE AND TUBERE-ENDING

Each boiler tube or flue that is repaired bywelding is limited to not more than threecircumferential welded joints.

Re-ending is permitted provided the thicknessof the tube or flue to be re-ended is not lessthan 90% of that required by Table 3-3110.

Re-end pieces shall be new material and meetthe thickness requirements of Table 3-3110.

3-3120 ARCH TUBES

Arch tubes that are damaged or reduced toless than minimum required wall thicknessshall be replaced in entirety by new one-piecearch tubes. Welded repairs or partial replace-ment is not permitted. Damage includes de-fects such as bulging, burns, and cracks.

When arch tubes are installed by rolling, thetube end shall project through the fireboxsheet not less than 1/4 in. (6 mm) nor morethan 3/4 in. (19 mm) before flaring. At a mini-

mum the tube shall be expanded and flared atleast 1/8 in. (3 mm) greater than the diameterof the tube hole. Additionally, the tube may be beaded and/or seal welded provided thethroat of the seal weld is not more than 3/8in. (10 mm) and the tube is finished rolledafter welding.

An arch tube installed by welding shall beconsidered a welded nozzle. Some acceptableweld joints are shown on Figure 3-3120. Ref.ASME Section I, Part PW 16.1

A change in tube attachment from rolled towelded or welded to rolled shall be consid-ered an alteration.

3-3121 TUBE WALL THICKNESS FORARCH TUBES

The minimum wall thickness of replacementarch tubes shall be as shown in Table 3-3121.

Table 3-3121

Size Wall Thickness

Up to 3 in. (75 mm) OD 8 BWG

More than 3 in. (75 mm) ODto 4 in. (100 mm) OD

7 BWG

3-3130 THERMIC SYPHONS

For repairs to syphon knuckles see Repair ofFirebox and Tubesheet Knuckles, and Figures3-3130-a and 3-3130-b.

FIGURE 3-3080 — Patch Bolts

Typical Patch Bolts

Typical Patch Bolt Application

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FIGURE 3-3130-a — Locomotive Firebox Thermic Syphon Installation

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FIGURE 3-3130-b — Thermic Syphon Repair

full penetrationwelds

length to suit

section on w-w full penetration weldradiographicallyexamined after welding

syphon neck repair

flush patch on stayboltsyphon body

FIGURE 3-3120 — Welded Installation of Arch Tube

t = thickness of vessel shell or head, in.t

n = thickness of nozzle wall, in.

tw = dimension of partial penetration attachment welds (fillet, single bevel, or single J), measured as shown in

Figure PW-16.1, in.t

c = not less than the smaller of 1/4 in. (6 mm) or 0.7 tmin. (inside corner welds may be further limited by a

lesser length of projection of the nozzle wall beyond the inside face of the vessel wall)t

min = the smaller of 3/4 in. (19 mm) or the thickness of either of the weld parts joined by a fillet, single bevel, or

single J-weld, in.

1

1

tc

tn

tn but not less than

1/4 in. (6 mm)

Section1-1

tw

tc

(y)t

n but not less

than 1/4 in. (6 mm)

tw

tn

tc

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All weld repairs to the unstayed sectionsof the syphon neck and body shall beradiographically examined.

3-3140 CIRCULATORS

All butt welds on circulators shall be radio-graphically examined.

Welds applied to the circulator/fireboxsheet joint shall be in accordance with theweld requirements for arch tubes. See Figure3-3120.

3-3200 REPAIRS ANDALTERATIONS TO BOILERBARREL UNSTAYED AREAS

Defects such as cracks and wastage may berepaired by weld buildup, a welded flushpatch or a riveted patch. Installation of a riv-eted patch shall be considered an alteration.Prior to repairing cracks, the plate shall beexamined for defects. Affected sections shall be repaired.

Weld buildup shall not be used if the affected

section of plate has wasted below 60% of theminimum required thickness.

If the cracked section of plate is retained and is to be repaired by installation of a rivetedpatch, the crack may be stopped by drillingstop holes at each end or removed by a methodsuch as grinding, cutting, or machining. Re-sults of stop drilling or crack removal shall beverified by NDE.

Welded repairs at or near riveted seams

requiring preheating or postweld heattreatment shall be carefully made inorder to prevent loosening in the rivetedseams, especially when localized heat-ing is used. Where necessary to controlexpansion or to gain access for weld-

ing, rivets at the defective section and toeach side of it may be removed. Reuse ofrivets and staybolts is prohibited.

All welded repairs to boiler barrel unstayedareas shall be radiographically examined in

accordance with the ASME Code, Section I,when the size of the repaired area is greaterthan the maximum size of an unreinforcedopening as calculated in accordance with thelatest edition of the ASME Code, Section I.

Riveted patches may be any shape or sizeprovided the lowest patch efficiency is equalto or greater than the lowest equivalent seamefficiency of the boiler course to which it isapplied. Ref: ASME Code, Section I.

The factor of safety of all riveted patches shallnot be less than four for locomotives operat-ing under Federal Railroad Administrationregulations.

3-3300 REPAIRS ANDALTERATIONS TO BOILERBARREL STAYED AREA

3-3310 FIREBOX SHEET REPAIR

Cracks in all stayed firebox sheets may berepaired by welding or the installation of aflush patch.

If the crack extends into a staybolt or rivethole, the staybolt or rivet shall be removedprior to making the repair.

3-3320 FIREBOX PATCHES

Patches may be any shape provided they areadequately supported by staybolts, rivets,tubes, or other forms of construction. Patcheson stayed surfaces should be designed so

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weld seams pass between staybolt rows. SeeFigure 3-3320.

Patches are to be flush type, using full penetra-tion welds. If the load on the patch is carried by other forms of construction, such as stay-

bolts, rivets, or tubes, radiographic examina-tion of the welds is not required.

If the patch includes an existing rivetedseam, the patch shall be riveted at that seam.Changing a riveted seam to a welded seam isconsidered an alteration.

All rectangular or angled patches shall haveadequate radius at all corners. Minimumradius to be not less than three times platethickness.

Patches shall fit flush on the waterside of the

sheet. Misalignment shall not exceed one-quarter plate thickness on edge alignmentwith the sheet water side.

Staybolts and rivets should be installed afterwelding of patch is completed. Reuse of staybolts and rivets is prohibited.

Weld seams parallel to a knuckle shall be lo-cated no closer to the knuckle than the pointof tangency of the knuckle unless the weldis radiographically examined. Weld seamsnot located in the knuckle are preferred. SeeFigure 3-3350-b.

Patches shall be made from material that isat least equal in quality and thickness to theoriginal material.

FIGURE 3-3330 — Stayed Firebox SheetGrooved or Wasted at Mudring

First Staybolt Row

MudringMudring Rivet

Sheet Wasted BelowMudring Waterside

Firebox Sheets

Figure 3-3320-b - Rectangular Shaped Patch

FIGURE 3-3320 —Figure 3-3320-a illustrates what would be considereda saw-tooth patch. Its advantage is that a maximumamount of welding is obtained for securing a givenpatch and by zig-zagging the weld, the weld is sup-ported by three rows of staybolts instead of two.

Its disadvantage is its irregular shape which causesgreater difficulty in fitting and applying.

Figure 3-3320-a - Saw-Tooth Patch

Figure 3-3320-c - Diamond Shaped Patch

W E L D

W E L D

W E L D

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FIGURE 3-3340 — Mudring Repair

mudring

remove firebox sheets for access

full penetration weld

3-3330 REPAIR OF STAYEDFIREBOX SHEETS GROOVEDOR WASTED AT THE

MUDRING (See Figure 3-3330)

Grooved or wasted firebox sheets havinggreater than 60% of the minimum requiredthickness remaining may be repaired by weld buildup provided the wastage does not extend below the waterside surface of the mudringand the strength of the structure will not beimpaired. If extensive welding is required, theaffected area shall be removed and replacedwith a flush patch.

If the sheet thickness has been reduced to lessthan 60% of the minimum required thickness,the affected section shall be removed andreplaced with a flush patch.

If wastage and grooving extends be-low the mudring waterside surface andif the plate thickness remaining has been reduced to less than the minimumrequired thickness, the affected section shall be removed and replaced with a flush patch.

Flush patches shall be arranged to include

the mudring rivets and at least the first rowof staybolts above the mudring.

3-3340 MUDRING REPAIRS (See Figure 3-3340)

Pitted and wasted sections of mudrings may be built up by welding provided the strengthof the mudring will not be impaired. Whereextensive weld buildup is employed, the In-spector may require an appropriate method

of NDE for the repair.

Cracked or broken mudrings may be repaired by welding or installation of flush patchesusing full penetration welds. Patches shall bemade from material that is at least equal in

quality and thickness to the original material.Patches shall fit flush on waterside surfaces.Where necessary, firebox sheets on both sidesof the defect may be removed to provide ac-cess for inspection and welding.

3-3350 REPAIR OF FIREBOX ANDTUBESHEET KNUCKLES

Welds within the points of tangency of aknuckle are permitted. Welds with angles ofless than 45 degrees to the longitudinal axis ofthe knuckle shall be radiographically exam-ined. See Figures 3-3350-a through 3-3350-f .

Any patch not supported by means otherthan the weld, such as rivets, staybolts, tubes,

or other forms of construction, shall have allweld seams radiographically examined.

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FIGURE 3-3350-a — Firebox TubesheetKnuckle Repair

knuckle patch welded around tube holes

knuckle patch welded through tube holes

top flue

fluesheet

line of weld is to be as nearlyhorizontal as conditioning willpermit

knuckle

staybolts transverse crack intubesheet knuckle

parallel crack intubesheet knuckle

tubesheet

point of tan-gencyof knuckle

FIGURE 3-3350-b — Repair of Firebox andTubesheet Knuckles

knuckle radius

welds located no closerto knuckle than point oftangency do not requireradiographic examination

see layoutmethod inFigure 15A

FIGURE 3-3350-b1 — Layout Method of Determining Knuckle Weld Angle

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Illustrations are of inside surface of knuckle.

longitudinalaxis point PT

b

bPT

R

To find the points of tangency(PT) of the knuckle:

b = R - (R * cos )

Where:R = inside knuckle radius

ß = Angle of weld relative tothe Reference LongitudinalAxis of Knuckle.

ß

weld

Reference LongitudinalAxis of Knuckle Longitudinal Axis Point

True Longitudinal Axis

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staybolt rows point of tangency of knuckle

knuckle

tube orstaybolt rows

FIGURE 3-3350-c — Repair of Firebox and TubesheetKnuckles

STAYED PATCH APPLIED TO BUTT WELDED SEAM

patch length

weld seams located betweenstaybolt rows and above firsttube row or staybolt row

STAYED PATCH APPLIED TO RIVETED SEAM

riveted seam

weld seams located be-tween tube rows belowstaybolt rows or tube rows

weld seam located above firsttube row or staybolt row

REPAIRS REQUIRING RADIOGRAPHICEXAMINATION OF WELD SEAMS

weld seam locatedin knuckle

patch notsupported bytubes, staybolts,or rivets

if access for welding or riveting is required,remove section of exterior or interior sheets

FIGURE 3-3350-d — Firebox ThroatSheet Knuckle

typical flush patches installed with fullpenetration welds

FIGURE 3-3350-e — Backhead Knuckle

Repair

if access forwelding andriveting isrequired,remove section

of exterior orinterior sheets

typical flush patch

patch lengthoriginal wrapper sheet

new rivets

weld located between staybolt rows

staybolts

transverse weld

FIGURE 3-3350-f — Fire Door Opening

Repair

flush patchinstalled withfull penetra-tion welds

patch installed with fullpenetration welds andeither patch bolts or rivets

SEC A-A

SEC A-A

patch bolts or rivets

patch length

patch lengthpatch length

weld seam located between tuberows or staybolt rows

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typical tubesheet flush patches

tubesheet welded around tube holes

tubesheet welded through ligaments and tube holes

FIGURE 3-3360 — Tubesheet Repairs

Caulking Tool

Caulked Edge of Plate

FIGURE 3-3410

Patches shall be formed to proper shape andcurvature.

Wasted sections of knuckles that have notwasted below 60% of the minimum requiredthickness may be repaired by weld buildup

provided the strength of the structure willnot be impaired. Where weld buildup isemployed, the Inspector may require an ap-propriate method of NDE for the repair.

Wasted sections of knuckles that havewasted below 60% of the minimum requiredthickness shall be replaced.

3-3360 TUBESHEET REPAIRS (See Figure 3-3360)

Cracked tubesheet ligaments may be re-paired by welding using full penetrationwelds.

Damaged tubesheet holes may be repaired by welding.

Sections of tubesheets damaged or wasted toless than 60% minimum required thicknessshall be repaired by installing a flush patch

using full penetration welds.

Sections of tubesheets that have not wasted below 60% minimum required thickness may be repaired by weld buildup provided thestrength of the structure will not be impaired.Where weld buildup is employed, the Inspec-tor may require an appropriate method ofNDE for the repair.

3-3400 SEAMS AND JOINTS

3-3410 CAULKING RIVETED SEAMSAND RIVET HEADS

(See Figure 3-3410)

Caulking refers to the sealing of plate seamsand rivet heads by driving the edge of one

surface onto the other by use of an impacttool.

Riveted seams and rivet heads may be caulkedin accordance with ASME Section I, 1971.

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3-3500 THREADED OPENINGSIN VESSEL WALLS,BUSHINGS, AND WELDEDNOZZLES (WASHOUT PLUGHOLES AND OTHERCONNECTIONS)

Threaded openings in vessel walls andwelded nozzles with damaged threadsthat cannot be repaired by retappingor rethreading should be repaired by weld-ing a nozzle in the sheet. The nozzle shall beof such a size as to not interfere with properwashout and inspection.

Threaded bushings and nozzles found to bedefective shall be replaced. Seal welding isnot permitted.

New threaded bushings equipped with shoul-ders may be seal welded at the shoulder.

New threaded bushings without shouldersthat are seal welded after installation shallhave the threads removed from the weld zoneof the bushing prior to welding.

Threaded holes with damaged threads may berepaired by weld buildup and retapping. The

threads shall be removed prior to welding.

3-3600 FITTINGS AND GAGES

3-3610 WATER GAGE CONNECTION

Water gage glasses shall be applied so that thelowest water reading in the water gage glassof a horizontal firetube boiler on level trackshall be at least 3 in. (75 mm) above the highest

point of the tubes, flues, or crown sheet.

The bottom mounting for water gage glass(and for water column if used) must notextend less than 1-1/2 in. (38 mm) inside the boiler and beyond any obstacle immediatelyabove it. The passage must be straight and

approximately horizontal. Connections must be applied without pockets, traps, sags, orsyphons. Tubular water gage glasses must beequipped with a protection shield.

Locomotive water gage glasses shall be pro-

vided with one top and one bottom shutoffcock and a means to illuminate each glass.Each top and bottom shutoff cock or valveshall be of such through flow construction asto prevent stoppage by deposits of sediments.Straight run globe valve of the ordinary typeshall not be used on such connections. SeeFigure 3-3610. The water gage glass connec-tion and pipe connection shall be fitted witha drain cock or valve having an unrestrictedopening of not less than 3/8 in. (10 mm) indiameter to facilitate cleaning.

The top and bottom water gage glass fittingsare to be aligned, supported, and securedso as to maintain the alignment of the watergage glass.

FIGURE 3-3610 — Straight Run GlobeValve Not Permitted

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The lower edge of the steam connection toa water column or water gage glass in the boiler shall not be below the highest visiblewater level in the water gage glass. There shall be no pockets, traps, sags, or syphons in thepiping that will permit the accumulation of

sediments.

The upper edge of the water connection to awater gage glass and the boiler shall not beabove the lowest visible water level in thewater gage glass. There shall be no pockets,traps, sags, or syphons in the connection.

3-3700 MATERIAL LIST FOR STEAM LOCOMOTIVE BOILERS

The following list is intended as a basic guide-line only and covers just the basic carbon steeland some alloy steel material specifications.Other alloy materials may be available forthese applications if necessary.

Application Specification

Boiler Tubes & SA-178 Grade A, Flues, Arch Tubes SA-192, SA-210 Superheater Units

Boiler & Firebox Plate SA-285 Grade C,SA-515, SA-516,SA-203, SA-204

Staybolts SA-675, SA-36,ASTM A-31

Staybolt Sleeves and SA-105 Forging, Caps SA-675

Boiler Braces SA-675, SA-36

Rivets SA-675,ASTM A-31

Forged Parts & Fittings SA-105, SA-181

Pressure-Retaining SA-216, SA-217 Steel Castings

Hollow Cylindrical SA-105 ForgingsPressure-Retaining SA-675 Bar Stock Parts

Superheater Unit Bolts Bolts - SA-193, & Nuts Nuts -SA-194

Pipe Flanges SA-181, SA-105

Pipe SA-106, SA-53seamless

Bronze Castings & SB-61, SB-62Washout Plugs

a. SA-516 steel is recommended for fireboxrepairs. It is a fine grain that acceptsflanging and bending with less chance ofcracking than course grain steels such asSA-515 or SA-285 Grade C. Course grainsteels have, on occasion, been found tocrack or split after complicated flanging, bending, and forming.

b. SA-36 is not to be used to make any pres-sure-retaining part such as shells, stayboltsleeves, or caps.

c. When rivets are made from SA-675,

the finished rivets must meet the physi-cal and test requirements of the originalASME rivet specification ASTM A-31Grade A or B.

d. When staybolt material tensile strengthis stronger than that of the firebox sheets,the firebox sheets deflect instead of thestaybolts, which can result in the sheetsdeveloping cracks and leaking staybolts.In addition, high tensile strength steels aredifficult to drive.

3-4000 GUIDELINES FOR STEAM LOCOMOTIVE STORAGE

The steam locomotive guidelines publishedherein list the general recommendations forstorage of locomotive boilers and locomotives.A05

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3-4020 WET STORAGE METHOD

When utilizing the “wet storage method” the boiler is completely filled with treated waterto exclude all air.

NOTE: This method cannot be used if thelocomotive is exposed to freezing weatherduring storage.

Chemicals may be added to the storage wa-ter to further inhibit corrosion. However,depending on the chemical used the treatedwater may have to be disposed of as a hazard-ous waste to prevent chemical contaminationof the surrounding property.

The procedure applies only to the sections ofthe boiler that contain water. The firebox in-terior, cylinders, piping, and auxiliary equip-ment of the locomotive still require draining,preservation, and dry storage.

3-4030 DRY STORAGE METHOD

When utilitizing the “dry storage method” the boiler is completely emptied of water, driedout, and allowed to stand empty. Several

variations of the “dry method” may be used.These include but are not limited to:

• Air tight storage with moisture absorbentplaced in trays in the boiler;

• Air tight storage with the boiler filled withinert gas to exclude all oxygen;

• Open air storage with the mudring wash-out plugs removed to enable air circula-tion for evaporation of formed moisture.

Each variation has positive and negative

points that must be taken into account beforeuse. If the boiler is filled with inert gas suchas nitrogen, care must be taken because thismethod can result in asphyxiation of person-nel if the gas escapes the boiler through aleaking valve or washout plug and enters apit, sump, or enclosed room. In addition, the

The exact procedures used by the owner/operator must be reviewed by the railroadmechanical officers/engineers and be basedon the conditions and facilities at the railroadshop or storage facility.

3-4010 STORAGE METHODS

The methods for preparing a steam locomo-tive for storage depend upon several factors,including:

• The anticipated length of time the locomo-tive will be stored

• Whether storage will be indoors or out-doors

• Anticipated weather conditions duringthe storage period

• The availability of climate-controlledstorage

• Type of fuel used• Equipment available at the storage site.

Indoor storage can be broken into two types:indoor with climate control and indoor with-out climate control.

Outdoor storage can also be broken into two

types: outdoors during a warm time of year orin a geographic location where it can reason-ably be expected to be above freezing duringstorage, and outdoors during a time periodor in a geographic location where it can beexpected that freezing temperatures will occurduring storage.

Locomotive boilers may be stored using the“wet method” or the “dry method.”

Before any method of storage, the boiler must

be thoroughly washed out with all mud andscale removed from the mudring, crownsheet, bottom of the barrel, and the top of the firingdoor.

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boiler must be completely vented to removeall gas, then tested and declared gas free be-fore personnel may enter.

Although the use of dry storage with severalwashout plugs removed for air circulation is

the most common method, there are somepotential drawbacks. The boiler interior may be subject to moisture forming from conden-sation created from humidity changes in theambient air. Small animals may take up resi-dence inside if screens are not used to coverhandholes and washouts.

Before storage, the boiler must be thoroughlywashed out with all mud and scale removedfrom the mudring, crownsheet, bottom of the barrel, and top of the firing door. Any mud orloose scale left in the boiler will retain mois-ture leading to corrosion. After washing, allwater must be removed and the boiler dried before storage. A portable gas or electricheater placed in the firebox to aid evapora-tion and drying along with a vacuum used tosiphon water out via the lower washout plugsis recommended.

NOTE: Use of the common railroad dryingout procedure of building a small wood fire in

the firebox is not recommended because of thedanger of overheating the firebox sheets.

The typical railroad dry storage method re-quired blow down of the boiler until emptywhile steam pressure registered on the gageand removal of the washout plugs while theshell plates were hot and there was no steampressure. This allowed the heat remaining inthe boiler plates to evaporate all remainingwater in the boiler. However, this method mayresult in staybolt damage from temperature

change and requires extreme care, if used.

Oil should not be applied to the interiorsurfaces of the boiler because it is difficultto remove. Further, all of the oil must be re-moved before steaming or it will form scaleand contribute to foaming.

3-4040 RECOMMENDED GENERALPRESERVATIONPROCEDURES

When the locomotive is under steam, inspectall piping, fittings, and appliances for steamand water leaks that may introduce moisture

into the lagging. Repair all leaks as necessaryand remove wet lagging. Wet lagging can ac-celerate corrosion of the boiler external sur-faces, especially staybolt sleeves and caps.

Thoroughly wash the boiler and firebox andremove all mud and scale from the mudring,crownsheet, bottom of the barrel, and top ofthe firing door. Any mud or loose scale left inthe boiler will retain moisture leading to cor-rosion. Wash out thermic siphons, arch tubes,and circulators.

To protect the boiler interior during storage,dry the boiler by using compressed air to blowout as much water as possible. A portableheater placed in the firebox to warm the boilerto 200°F (95°C) along with a vacuum used tosiphon water out via the lower washout plugscan aid evaporation and drying of any mois-ture that collects in low or impossible-to-drainlocations without harming the sheets.

CAUTION: To prevent a build up of steampressure during the drying process, the steamdome cover or top washout plugs should beremoved to enable the moisture to escape.In addition, the driving wheels should be blocked and the throttle and cylinder cocksshould be opened to permit any steam thatforms in the superheater units to escape.

Superheater units, by nature of design, can bedifficult to drain and dry out. Typical methodsinclude:

a. Pressurize the boiler with compressedair with the locomotive stationary and blocked in place. Using the throttle toregulate the airflow, allow the air to blowthrough the entire bank of superheaterunits and dry pipe and discharge intothe cylinders. The cylinder cocks must beopen.

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b. Pressurize the boiler with compressedair, then operate the locomotive under airpressure over a short distance of track. Thecylinder cocks should be opened duringthe initial operation to prevent damagingthe cylinders by hydraulic lock.

If the air pressure draining procedure is notpractical or cannot be accomplished correctly,the superheater units can be protected againsttrapped moisture by filling the entire super-heater bundle with a standard antifreeze/wa-ter mixture or with diesel fuel.

NOTE: The air pressure dryout methods “1”or “2” may have to be performed several timesto discharge all of the moisture. Refer to Sec-tion 3-4050, “Use of Compressed Air To DrainLocomotive Components,” for additionalinformation on compressed air drying.

NOTE: If the locomotive is operated underair pressure, the air brake system should bemade operational to provide safe stoppingor other steps taken to control and stop thelocomotive.

After drying, it will be necessary to eithervent the boiler or to place containers of desic-

cant inside the boiler through the dome capto absorb any condensation that may occurduring storage. Venting the boiler to allowair circulation is accomplished by leaving twoor more of the lower washout plugs out andopening the vent valve on the top of the boiler.A vent line consisting of two 90° elbows andpipe nipples should be installed in the ventvalve to locate the opening to the downwarddirection in order to keep rain or snow fromentering the open valve.

If the locomotive will be stored outdoors, thefollowing should be completed:

a. Inspect the boiler jacket and confirm it istight with no gaps leading into the lag-ging or shell. Pay close attention to areasat shell openings such as for studs, safety

valves, etc. Repair all gaps or damaged jacket sections as necessary. Consider-ation should be given to covering theentire locomotive and tender with a tarp.Otherwise, all jacket openings should becovered to prevent the entrance of rain

or snow. Where necessary, apply a water-proof covering over the exposed or opensections.

b. The smokestack should be sealed by ap-plying a wood and sheet rubber coverheld in place by clamps or a through bolt.

c. The safety valves should either be coveredor removed, with plugs or caps installedin the holes if the valves are removed.

d. The dynamo, air pump, and feedwaterheater exhausts should also be covered.

e. Empty and clean the smokebox, front tubesheet, superheater units, steam pipes, andfront end plates of all coal, ash, or burntoil. This work is especially critical at the bottom section of the smokebox and fronttubesheet rivet flange. The smokebox doorshould be sealed by applying a gasket

or sealant and any other air openings inthe smokebox sealed. The exhaust nozzleshould be sealed by applying a woodand sheet rubber cover held in place byclamps.

f. The potential for corrosion of the smokebox interior can be further minimized by applying coating of outdoor paint orprimer. All inspection of the smokeboxand front tubesheet must be accomplished before painting since it will cover up many

types of defects. The coating will burn offquickly when the locomotive is returnedto service.

g. Thoroughly clean the firebox sheets, flues,and superheater return bends of all ashand clinker.

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h. On coal burners, empty and clean thegrates and ash pan of all coal and ashcompletely. This work is especially criticalat the sections between the grate bearers,the mudring rivets and firebox sheets;and from the grate segment air openings.

On oil burners, care should be taken toremove ash from between the flash wallrefractory and the firebox sheets.

i. If the locomotive will be out of servicefor longer than 12 months, removal ofthe brick arch or flash wall refractorythat extends above the mudring should be considered to prevent condensationand corrosion from occurring between the brick and the steel. Temporary removalof the brick arch or flash wall to permitapplication of a preservative to fireboxsides, arch tubes, or siphons should beconsidered for shorter storage periods.

j. All appliances and piping that mightcontain water or condensation should be drained and blown dry using drycompressed air. This includes the air andequalizing reservoirs, dirt collectors, injec-tors, cylinders, stoker engine cylinders,dynamos, the steam and water sides of

feedwater heaters and pumps, the steamside of air pumps, the steam side of lubri-cators, atomizers, oil tank heaters, gagesiphons, tank hoses, and cab heater pip-ing. A small quantity of valve oil should be sprayed into the valve chambers,cylinders and the steam side of all appli-ances to protect against corrosion. Refer to3-4050, “Use of Compressed Air To DrainLocomotive Components,” for details.

k. The cylinder castings, exhaust cavities,

and steam lines must be drained of allmoisture and blown dry. Typical methodsinclude:

1. Pressurize the boiler with compressedair with the locomotive stationary and

blocked in place. Using the throttle toregulate the airflow, allow the air to blow through the dry pipe and dis-charge into the cylinders. The cylindercocks must be open.

2. Pressurize the boiler with compressedair then operate the locomotive underair pressure over a short distance oftrack. The cylinder cocks should beopened during the initial operationto prevent damaging the cylinders byhydraulic lock.

NOTE: Methods “1” or “2” may have to be performed several times to dischargeall of the moisture from the cylinders andsteam pipes. If the locomotive is operatedunder air pressure, the air brake systemshould be made operational to providesafe stopping or other steps taken to con-trol and stop the locomotive.

Refer to the 3-4050, “Use of CompressedAir To Drain Locomotive Components,”for additional information.

l. Drain and wash tender water spaces. Thetank should be inspected afterward and

any remaining water removed by syphonor vacuum. When dry, spray the waterspace with outdoor paint or a commercialrust preventative. Drain and dry tendertank hoses and clean screens.

m. On coal or wood burners, spray any ex-posed surfaces of the tender fuel spacewith outdoor paint or a commercial rustpreventative. If the locomotive is to bestored outdoors for long term, removeall coal and spray the surfaces as above

or cover the coal space with a tarp or aroof.

n. On oil burners, drain and blow out all fuellines, tank heater and blowback lines, andthe burner itself. Drain sludge and water

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from the bottom of the fuel tank. Insurethat tank hatches are secure and the tank isvented to prevent condensation. Drainingthe oil tank is recommended if the fuel oilis known to lose its volatile content duringstorage.

o. After cleaning thoroughly, coat all sideand main rods, cross heads, valve gear,guides, piston rods, brake pistons, feed-water pump pistons, and air pump pis-tons with water-resistant grease or a rustpreventative. Grease should be applied tothe junction of each axle and driving boxand journal box to prevent water enter-ing. Grease should be applied to junctionof rod and pin in valve gear and rods toprevent water entering.

p. If the locomotive is moved after this is ap-plied, it will be necessary to reapply thecoating to piston rods and guides.

NOTE: Heavy oil or unrefined oil suchas any of the Bunker types (Bunker 6,etc.) should not be used for preservationof any components because the sulfurcontained in it can accelerate corrosion.Standard motor oil or journal oil will not

stick to and preserve wetted surfaces. Allsurfaces, to be so coated, must be dry. Ifmoisture is a problem, steam cylinder oilshould be applied.

q. Plain journal bearings should be inspectedfor water and repacked. Roller bearing boxes should have all moisture drainedand the boxes filled with lubricant. Greaseplugs should be screwed down so that thethreads are not exposed.

r. If the locomotive is to be stored outdoorswith questionable or no security, removeand store all cab gages, water glasses,lubricators, brass handles, seatboxes, andany other items that thieves or vandalsmight attack. Remove the whistle, bell,

headlight, and marker and/or classifi-cation lights. Remove tools, radios, andspare parts. Secure wood or metal coversover all windows and doors and board upthe back of the cab. Secure all manholeson the top of the tender.

s. Inspect stored locomotives regularly forsigns of rust, corrosion, damage, dete-rioration, or vandalism and immediatelytake any corrective measures necessary.

3-4050 USE OF COMPRESSED AIRTO DRAIN LOCOMOTIVECOMPONENTS

The process of using air pressure to drainand empty auxiliary components such asthe cylinders, superheater units, and pipingcompletely of water offers several advantagesover other methods.

The air compressor must be equipped with asuitable filter to enable it to supply oil-free air because the introduction of air that containsoil into the water/steam parts of the boilerand superheater will promote the formation ofscale and water foaming when the locomotive

is returned to service.

The air compressor must be a large enoughsize to provide the volume and pressure ofair required.

If the boiler is pressurized with compressedair, the air pressure must be raised slowly toprevent distorting or overstressing the fireboxsheets or staybolts because the normal expan-sion of the boiler that occurs under steampressure is not present when air pressure is

used.

Auxiliary components such as the stokers, aircompressors, turbogenerators, power reverseare drained by pressurizing the boiler to be-tween 1/2 to 3/4 of the rated boiler pressure

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with compressed air from the stationary aircompressor then operating each componentindividually until the exhaust from it containsno moisture.

When necessary, specific pipe lines can be

drained by breaking the line at each end, at-taching the air line to it directly then blowingthe line out.

3-4060 RETURN TO SERVICE

When returning a locomotive to service,the boiler, firebox, and tender tank shall beventilated to remove potentially hazardousatmosphere from the boiler interior beforepersonnel enter it. In addition, the atmospherein the boiler shall be verified to be safe forhuman occupancy before personnel enter it.For the boiler this can be accomplished byremoving the washout plugs and placing afan or air blower on top of the steam domeopening to force air into the boiler. For thefirebox this can be accomplished by openingthe smokebox door and firebox door andplacing a fan or air blower at either locationto force air through. Failure to do this couldresult in asphyxiation of the first personnel to

enter the boiler or firebox.

If possible, the locomotive should be movedinto a heated engine house and the boiler al-lowed to warm up in the air for several daysuntil it is the same temperature as the air.

The initial fire up should be done slowly toallow even heating of the boiler.

Before movement, the cylinders should bewarmed up by allowing a small quantity

of steam to blow through them and out thecylinder cocks and exhaust passages. This isnecessary to reduce the stress in the castingfrom thermal expansion of the metal.

Steam should be discharged through the cyl-inder cocks for several minutes to aid removalof any solvent, debris, or rust that may haveformed in the superheater units, steam pipes,and dry pipe.

All appliances should be tested under steampressure before the locomotive is moved.

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Glossary of Terms

Appendix 4

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APPENDIX 4 — GLOSSARY OF TERMS

For the purpose of applying the rules ofthe NBIC, the following definitions of theterms used herein shall apply:

Address of Record (applicable to RA-2200)– Complete address of the company to whichthe National Board Certificate of Authoriza-tion is issued (shop facility). For field-onlycertificates of authorization, the address fromwhere the work is controlled.

Alteration – Any change in the itemdescribed on the original Manufacturer’s DataReport which affects the pressure contain-ing capability of the pressure-retaining item.Nonphysical changes such as an increase inthe maximum allowable working pressure(internal or external), increase in design tem-perature, or a reduction in minimum tem-perature of a pressure-retaining item shall beconsidered an alteration.

ANSI – The American National StandardsInstitute

ASME Code – The American Society ofMechanical Engineers’ Boiler and Pressure

Vessel Code published by that Society, includ-ing addenda and Code Cases, approved byits council.

Assembler (applicable to RA-2200) – An or-ganization who purchases or receives from amanufacturer the necessary component partsof valves and assembles, adjusts, tests, seals,and ships safety or safety relief valves at a geo-graphical location, and using facilities otherthan those used by the manufacturer.

Audit (applicable to RA-2300) – A docu-mented activity performed to verify byexamination and evaluation of objective evi-dence that applicable elements of the qualityprogram have been developed, documented,and implemented in accordance with speci-fied requirements. An audit is separate from

inspection or examination for the purpose ofprocess control or acceptance of materials oritems.

Authorized Inspection Agency –New Construction: An Authorized InspectionAgency is one that meets the qualification anddefinition of NB-360, Criteria for Acceptance ofAuthorized Iinspection Agencies for New Con-struction.

Inservice: An Authorized Inspection Agencyis either:

a. A jurisdictional authority as defined in theNational Board Constitution; or

b. An entity that is accredited in accordancewith NB-369, Qualifications and Duties forAuthorized Inspection Agencies (AIAs) Per- forming Inservice Inspection Activities andQualifications for Inspectors of Boilers andPressure Vessels.

Authorized Nuclear Inspection Agency (applicable to RA-2300) – An AuthorizedInspection Agency which employs Autho-

rized Nuclear Inspectors and provides nuclearinspection services in accordance with theNBIC and Section XI of the ASME Code.

Authorized Nuclear Inspector (ANI) (appli-cable to RA-2300) – An Authorized Inspectoremployed by an Authorized Nuclear Inspec-tion Agency, qualified in accordance withthe National Board Rules for CommissionedInspectors.

Authorized Nuclear Repair Organization

(applicable to RA-2300) – See “NR” CertificateHolder.

Capacity Certification – The verification bythe National Board that a particular valvedesign or model has successfully completedall capacity testing as required by the ASMECode.

A05

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Conversion – The change of a pressure reliefvalve from one capacity-certified configura-tion to another by use of manufacturer’sinstructions.

Critical Parts (applicable to RA-2200) – Criti-

cal Parts are those that may affect the valveflow passage, capacity, function, or pressure-retaining integrity.

Demonstration – A program of making evi-dent by illustration, explanation, and comple-tion of tasks documenting evaluation of anapplicant’s ability to perform code activitiesincluding the adequacy of the applicant’squality program, and by a review of the imple-mentation of that program at the address ofrecord and/or work location.

Field – A temporary location, under the con-trol of the Certificate Holder, that is used forrepairs and/or alterations to pressure-retain-ing items at an address different from thatshown on the Certificate Holder’s Certificateof Authorization.

Field Repairs (applicable to RA-2200) – Fieldrepairs are any repair conducted outside ofthe Certificate Holder’s fixed repair shop

location. Field repairs may be conducted withthe aid of mobile facilities with repair capabili-ties and with or without testing capabilities.Field repairs may be conducted in user facili-ties without the use of mobile facilities as de-scribed above, or in any other “VR” CertificateHolder’s fixed repair shop location.

Inspector – See National Board Commis-sioned Inspector and National Board Owner-User Commissioned Inspector.

Jurisdiction – A governmental entity withthe power, right, or authority to interpret andenforce law, rules, or ordinances pertaining to boilers, pressure vessels, or other pressure-retaining items. It includes National Boardmember jurisdictions defined as “jurisdic-tional authorities”.

Jurisdictional Authority – A member of theNational Board, as defined in the NationalBoard Constitution.

Lift Assist Device – A device used to apply anauxiliary load to a pressure relief valve stem or

spindle, used to determine the valve set pres-sure as an alternative to a full pressure test.

Manufacturer (applicable to RA-2200) – Anorganization holding an ASME Certificateof Authorization to apply the Code Symbolstamp responsible for design, material selec-tion, capacity certification, manufacture of allcomponent parts, assembly, testing, sealing,stamping, and shipping of pressure reliefvalves.

Manufacturer’s Documentation – The docu-mentation that includes technical informationand certification required by the original codeof construction.

Modification (applicable to RA-2300) – Anychange to an item which affects the existingdesign requirements. Modifications includenonphysical changes (such as an increase inthe MAWP or design temperature, or a re-duction in minimum temperature such that

additional mechanical tests are required),design reconciliation and revision of designspecifications, and the process of makingphysical changes to an item as required tomeet revised design requirements.

“NR” Certificate Holder – An organizationin possession of a valid “NR” Certificate ofAuthorization issued by the National Board.

NBIC – The National Board Inspection Codepublished by The National Board of Boiler

and Pressure Vessel Inspectors.

National Board – National Board of Boilerand Pressure Vessel Inspectors.

National Board Commissioned Inspector – An individual who holds a valid and currentNational Board Commission.

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Nuclear Items – Items constructed in accor-dance with recognized standards to be usedin nuclear power plants.

Original Code of Construction – Documentspromulgated by recognized national stan-

dards writing bodies that contain technicalrequirements for construction of pressure-retaining items or equivalent to which thepressure-retaining item was certified by theoriginal manufacturer.

Owner (applicable to RA-2300) – The organi-zation legally responsible for the operation,maintenance, safety, and power generationof the nuclear power plant, including therepair, modification, or replacement of itemsin the plant.

Owner or User – As referenced in lower caseletters means any person, firm or corporationlegally responsible for the safe operation ofany pressure-retaining item.

Owner-User Inspection Organization – Anowner or user of pressure-retaining items thatmaintains an established inspection program,whose organization and inspection proce-dures meet the requirements of the National

Board rules and are acceptable to the jurisdic-tion or jurisdictional authority wherein theowner or user is located.

Owner-User Inspector – An individual whoholds a valid and current National BoardOwner-User Commission.

Pressure-retaining Items (PRI) – Any boiler,pressure vessel, piping, or material used forthe containment of pressure, either internal orexternal. The pressure may be obtained from

an external source, or by the application ofheat from a direct source, or any combinationthereof.

Quality System (applicable to RA-2200 andRA-2300) – Those planned and systematicactions necessary to provide adequateconfidence that items repaired, modified,

or replaced are in accordance with therequirements of the NBIC and Section XI ofthe ASME Code.

Repair (applicable to RA-2200 and Part RE) – Repair of a pressure relief valve is consid-

ered to be the replacement, remachining orcleaning of any critical part, lapping of theseat or disk, or any other operation whichmay affect the pressure relief valve functionor pressure-retaining integrity. Disassembly,reassembly and/or adjustments that affect thepressure relief valve function are also consid-ered a repair. The initial installation, testingand adjustments of a new pressure relief valveon a boiler or pressure vessel are not consid-ered a repair if made by the manufacturer orassembler of the valve.

Repair – The work necessary to restore pres-sure-retaining items to a safe and satisfactoryoperating condition.

Repair (applicable to RA-2300) – The processof restoring a component or system to a safeand satisfactory condition such that the exist-ing design requirements are met.

Replacement (applicable to RA-2300) – A type

of repair completed by the fabrication andinstallation of spare or renewal components,appurtenances, and sub-assemblies, or partsof a component or system.

Re-rating – See alteration.

“R” Certificate Holder – An organizationin possession of a valid “R” Certificate of Au-thorization issued by the National Board.

Safety Relief Valves – A safety relief valve

is a pressure relief valve characterized byrapid opening or pop action, or by openingin proportion to the increase in pressure overthe opening pressure, depending on applica-tion.

Shop – A permanent location, the addresswhich is shown on the Certificate of Autho-

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rization, from which a Certificate Holdercontrols the repair and/or alteration of pres-sure-retaining items.

Testing Laboratory – National Board acceptedlaboratory which performs functional and

capacity tests of pressure relief devices.

Unique Identifier (applicable to RA-2200) – Repair serial number, shop order number,etc., that appears on a valve repair nameplatesuch that traceability to the repair documenta-tion is established.

“VR” Certificate Holder – An organizationin possession of a valid “VR” Certificate ofAuthorization issued by the National Board.

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National Board Forms

Appendix 5

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APPENDIX 5 — NATIONAL BOARD FORMS

1 2 (name of repair organization) (Form R No.)

53 (PO No., Job No., etc.)

3

(name)

4 (address)

4 (name)

(address)

5 6 (boiler, pressure vessel)

7 8 8 8 9 (mfg serial no.) (National Board No.) (jurisdiction No.) (other) (year built)

10 10 (edition) (addenda)

11 11 (name/section/division) (edition/addenda)


55

12 (use supplemental sheet, Form R-4, if necessary)

13 54

14 (name of part, item number, data report type, mfg’s name, and identifying stamp)

15

16

17 18 19 20 21 (name of repair organization) (authorized representative)

22

23 24 25

26

19 27 28 (inspector) (National Board and Jurisdiction No.)

FORM R-1 REPORT OF REPAIR

in accordance with provisions of the National Board Inspection Code

1. Work performed by

2. Owner

3. Location of installation

4. Unit identification Name of original manufacturer

5. Identifying nos.:

6. NBIC Edition/Addenda:

Original Code of Construction for Item:

Construction Code Used for Repair Performed:

7. Repair Type: Welded Graphite Pressure Equipment FRP Pressure Equipment

8. Description of work:

Pressure Test, if applied psi MAWP psi

9. Replacement Parts. Attached are Manufacturer’s Partial Data Reports or Form R-3s properly

completed for the following items of this report:

10. Remarks:

CERTIFICATE OF COMPLIANCE

I, , certify that to the best of my knowledge and belief the statements in this report are

correct and that all material, construction, and workmanship on this Repair conforms to the National Board Inspection Code.

National Board “R” Certificate of Authorization No. expires on ,

Date , Signed

CERTIFICATE OF INSPECTION

I, , holding a valid Commission issued by The National Board of Boiler and PressureVessel Inspectors and certificate of competency issued by the jurisdiction of and employed

by of have

inspected the work described in this report on , and state that to the best of my knowledge and

belief this work complies with the applicable requirements of the National Board Inspection Code.

By signing this certificate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerning

the work described in this report. Furthermore, neither the undersigned nor my employer shall be liable in any manner for

any personal injury, property damage, or loss of any kind arising from or connected with this inspection.

Date , Signed Commissions

This form may be obtained from The National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Ave., Columbus, OH 43229 NB-66 Rev. 10

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FORM R-2 REPORT OF ALTERATION


1a. Construction performed by ____________________________________________ _________________

__________________________________________________________________________________________

1b. Design performed by ___________________________________________________________________

__________________________________________________________________________________________

2. Owner _________________________________________________________________________________

__________________________________________________________________________________________

3. Location of installation ___________________________________________________________________

__________________________________________________________________________________________

4.Unit identification ________________ Name of original manufacturer _________________________

5. Identifying nos.: ___________ __________________ _______________ ____________ ___________

6. NBIC Edition/Addenda: ____________________________ ________________________________

Original Code of Construction for Item: _____________________ ___________________________

Construction Code Used for Alteration Performed: ___________________ ____________________

7a. Description of construction work: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

7b. Description of design scope: _____________________________________________________________

______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

Pressure Test, if applied psi MAWP psi

8. Replacement Parts. Attached are Manufacturer’s Partial Data Reports or Form R-3s properlycompleted for the following items of this report:

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

____________________________________________________________________________________________________________________________________________________________________________________

9. Remarks: _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

This form may be obtained from The National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Ave., Columbus, OH 43229 NB-229 Rev.4

1 2 (name of “R” organization responsible for construction) (Form “R” No.)

53 (address) (PO No., Job No., etc.)

1 2 (name of “R” organization responsible for design) (Form “R” No.)


3 (name)

(address)

4 (name)

(address)

5 6 (boiler, pressure vessel)

7 8 8 8 9

(mfg serial no.) (National Board No.) (jurisdiction no.) (other) (year built) 10 10 (edition) (addenda)





13 54

14 (name of part, item number, data report type, mfg’s name, and identifying mark)

15

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Form R-2 (back)

DESIGN CERTIFICATION


correct and that the Design Change described in this report conforms to the National Board Inspection Code.National Board “R” Certificate of Authorization No. expires on ,

Date , Signed

CERTIFICATE OF DESIGN CHANGE REVIEW

I, , holding a valid Commission issued by The National Board of Boiler and Pressure

Vessel Inspectors and certificate of competency issued by the jurisdiction of and employed

by of have

reviewed the design change as described in this report and state that to the best of my knowledge and belief such change

complies with the applicable requirements of the National Board Inspection Code.





CONSTRUCTION CERTIFICATION


correct and that all material, construction, and workmanship on this Alteration conforms to the National Board Inspection Code.


Date , Signed


I, ,holding a valid Commission issued by The National Board of Boiler and PressureVessel Inspectors and certificate of competency issued by the jurisdiction of and em-

ployed by of

have inspected the work described in this report on , and state that to the best of my knowledge and

belief this work complies with the applicable requirements of the National Board Inspection Code.





2 (Form “R” No.)

16

17 18 19 20 21 (name of design organization) (authorized representative)

22

23 24 25

26 27 28 (inspector) (National Board and jurisdiction no.)

16

17 18

19 20 21 (name of construction organization) (authorized signature)

22 23 24 25

26


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FORM R-3 REPORT OF PARTS FABRICATED BY WELDING


1. Manufactured by

2. Manufactured for

3. Design Condition specified by Code design by

4. Design Code

5. Identification of Parts

Name of Part Qty.LineNo.

Manufacturer’sIdentifying No.

Manufacturer’sDrawing No. MAWP

ShopHydro PSI Year Built

6. Description of Parts

(a) Connections other than tubes Heads or Ends (b) Tubes

Line

No.

Size and

Shape

Material

Spec. No.

Thickness

(in.) Shape

Thickness

(in.)

Material

Spec. No.

Diameter

(in.)

Thickness

(in.)

Material

Spec. No.

7. Remarks


1 2 (name of manufacturer) (Form “R” No.)


29 (name of purchaser)

30 31 (name of organization) (name of organizations)

32 33 34 35 (code type and section) (code year) (addenda year) (formula on which MAWP is based)

36 37 38 39 40 41 13 9

38 42 43 44 45 46 43 47 48 43

15

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2 (Form “R” No.)

16

17 18

19 20 21

(name of “R” Certificate Holder) (authorized representative)

22

23

24 25

26


Form R-3 (back)



correct and that all material, fabrication, construction, and workmanship of the described parts conforms to the NationalBoard Inspection Code and standards of construction cited.


Date , Signed


I, ,holding a valid Commission issued by The National Board of Boiler and Pressure

Vessel Inspectors and certificate of competency issued by the jurisdiction of and

employed by of

have inspected the parts described in this report on , and state that to the best of my knowledge and

belief the parts comply with the applicable requirements of the National Board Inspection Code.

By signing this certificate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerningthe work described in this report. Furthermore, neither the undersigned nor my employer shall be liable in any manner for



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FORM R-4 REPORT SUPPLEMENTARY SHEET



2. Owner


ReferenceLine No. Continued from Form R–

Date , Signed Name



1 49 2 49 (name) (Form “R” referenced)

53 49 (address) (PO No., Job No., etc.)

3 or 29 49 (name)

(address)

(name)

(address)

50

51 52

19 21 20 49 (authorized representative) (authorized organization)

19 27 28 49 (inspector) (National Board and jurisdiction no.)

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GUIDE FOR COMPLETING NATIONAL BOARD FORM R REPORTS

1. Name and address of the “R” Certificate organization that performed the constructionwork (Line 1a) or the design (Line 1b).

2. For NBIC Report Forms registered with the National Board, indicate the sequentialForm R Number assigned by the “R” Certificate organization that is registering theform; otherwise indicate “N/A”. For rerating only, the Design Organization registersthe Form R-2. Where physical work is also performed, the Construction Organizationregisters the Form R-2.

3. Name and address of the Owner of the pressure-retaining item.

4. Name and address of plant or facility where the pressure-retaining item is installed.

5. Description of the pressure-retaining item, such as boiler or pressure vessel.

6. Name of original manufacturer of the pressure-retaining item if a boiler or pressurevessel. If other than a boiler or pressure vessel, complete if known.

7. Serial number of the pressure-retaining item as assigned by the original manufacturer.

8. Identification of the pressure-retaining item by applicable registration number. If in-stalled in Canada, indicate the Canadian design registration number (CRN), and listthe drawing number under “other.”

9. Identify the year in which fabrication/construction of the item was completed.

10. Indicate edition and addenda of the NBIC under which this work is being performed.

11. Indicate the name, section, division, edition, and addenda of the original code ofconstruction for the pressure-retaining item. Also indicate the name, section,

division, edition, and addenda of the construction code used for the work being per-formed. If code cases are used, they shall be identified in the “Remarks” section.

12. State exact scope of work, and attach additional data, sketch, Form R-4, etc. as neces-sary. If additional data is attached, so state.

13. Indicate test pressure applied.

14. To be completed for all welded pressure components added during the work. Indicatepart, item number, manufacturer’s name, stamped identification, and data reporttype.

15. Indicate any additional information pertaining to the work involved (e.g. routine re-pairs, code cases). For Form R-3 the part manufacturer is to indicate the extent hehas performed any or all of the design function. If only a portion of the design, statewhich portion.

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39. Indicate manufacturer’s serial number for the named part.

40. Indicate drawing number for the named part.

41. Indicate Maximum Allowable Working Pressure for the part, if known.

42. Use inside diameter for size; indicate shape as square, round, etc.

43. Indicate the complete material specification number and grade.

44. Indicate nominal thickness of plate and minimum thickness after forming.

45. Indicate shape as flat, dished, ellipsoidal, or hemispherical.

46. Indicate minimum thickness after forming.

47. Indicate outside diameter.

48. Indicate minimum thickness of tubes.

49. Complete information identical to that shown on the Form R to which this sheetis supplementary.

50. Indicate the Form R type. Example: Form R-1, Form R-2, Form R-3

51. Indicate the reference line number from the Form R to which this sheet is supplemen-tary.

52. Complete information for which there was insufficient space on the reference

Form R.

53. If applicable, purchase order, job number, etc. assigned by the organizationperforming the work.

54. Indicate the maximum allowable working pressure of the pressure-retaining item.

55. Indicate the type of repair, i.e., welded (RC-2000), graphite pressure equipment (Ap-pendix 8), or fiber reinforced plastic pressure equipment (Appendix 9).

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1

2 3 (name of NR certificate holder) (PO No., Job No., etc.)

(address)

5 (name)

(address)

6

7

9 10 12 13 16 17 18 19 20 20 20 21

9 22 23 24 25 26 27 28 29 30 30 30

31 31 31

32 32 32

33 33 33

34

35 35

FORM NR–1 REPORT OF REPAIR MODIFICATION OR REPLACEMENTTO NUCLEAR COMPONENTS AND SYSTEMS IN NUCLEAR POWER PLANTS


2. Owner

3. Name, address, and identification of nuclear power plant

4. System

5a. Items that Required Repair, Modification, or Replacement Activities

Identification Construction Code Activity

No.Type ofItem

Mfg.Name

Mfg.SerialNo.

Nat’l BdNo.

Juris.No. Other

YearBuilt

Name/Section/Division

Edition/Addenda

CodeCase(s)

CodeClass

Repair/Mod/Replace

1

2

34

5

6

7

8

9

10

11

12

5b. Items Installed During Replacement ActivitiesIdentification Construction Code

Type ofItem

Installed orReplaced5a Item No.

Mfg.Name

Mfg.Serial No.

Nat’l BdNo.

Juris.No. Other

YearBuilt

Name/Section/Division

Edition/Addenda

CodeCase(s)

CodeClass

6. ASME Code Section XI applicable for inservice inspection:

7. ASME Code Section XI used for repairs, modifications, or replacements:

8. Construction Code used for repairs, modifications, or replacements:

9. Design responsibilities

10. Tests conducted: hydrostatic pneumatic design pressure pressure psi Code Case(s)

This form may be obtained from The National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Ave., Columbus, OH 43229 NB-81

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40 (use of properly identified additional sheet(s) or sketch(es) is acceptable)

41

42

43 44

45 (name)

46 47 48 (authorized representative) (title)

49

50

51 52

53


11. Description of work

12. Remarks


I, , certify that to the best of my knowledge and belief the statements made in this report are

correct and the repair, modification, or replacement activities described above conform to Section XI of the ASME Code and

the National Board Inspection Code “NR” rules.

National Board Certificate of Authorization No. to use the “NR stamp expires ,

NR Certificate Holder

Date , Signed


I, , holding a valid commission issued by The National Board of Boiler and Pressure Ves-

sel Inspectors and certificate of competency issued by the jurisdiction of and employed byof

have inspected the repair, modification, or replacement described in this report on , and state that to

the best of my knowledge and belief, this repair, modification, or replacement activity has been completed in accordance with

Section XI of the ASME Code and the National Board Inspection Code “NR” rules.



any personal injury, property damage, or a loss of any kind arising from or connected with this inspection.


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GUIDE FOR COMPLETING NATIONAL BOARD

FORM NR-1 AND NVR-1 REPORTS

1. Indicate whether the report is to cover repair, modification, or replacement activity.

2. Name and address of the organization, as shown on the Certificate of Authorization,

which performed the repair, modification, or replacement activity.

3. Indicate the purchase order number, job number, etc., as applicable, assigned by theorganization which performed the work.

4. Name and address of the organization for which the work was performed.

5. Name and address of the Owner of the nuclear power plant.

6. Name and address of the nuclear power plant and, if applicable, identification of theunit.

7. Identify the system (e.g. residual heat removal, reactor coolant, etc.) with which therepair, modification, or replacement activity is associated.

8. Describe the type of pressure relief device (e.g. safety valve, safety relief valve, pressurerelief valve, etc.)

9. Indicate the type of component (e.g. vessel, line valve, pump, piping system, etc.)

10. Manufacturer’s name of the repaired, modified, or replaced item.

11. Indicate the pressure relief device by the manufacturer’s valve series or catalog num-

ber.

12. Manufacturer’s serial number of the repaired, modified, or replaced item.

13. National Board number, if applicable, of the repaired, modified, or replaced item.

14. Indicate the service as steam, liquid, gas, air, etc.

15. Indicate the pressure relief device by inlet size, in inches.

16. Indicate Jurisdiction number, if applicable, of the repaired, modified, or replaceditem.

17. Indicate plant tag or identification number, if applicable, of the repaired, modified, orreplaced item.

18. Year the repaired, modified, or replaced item was manufactured.

19. Identify the name, section, and division of the original construction Code for the re-paired, modified, or replaced item.

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20. Identify the edition, addenda, and as applicable, Code Cases and class of the originalconstruction Code for the repaired, modified, or replaced item.

21. Indicate the activity performed on this item, i.e. repair, modification, or replacement.

22. Indicate the Item No. from Section 5a with which this replacement item is associated.

Attach the Manufacturer’s Data Report, as applicable.

23. Manufacturer’s name of this replacement item.

24. Manufacturer’s serial number of this replacement item.

25. National Board number, if applicable, of this replacement item.

26. Jurisdictional number, if applicable, of this replacement item.

27. Plant tag or identification number of this replacement item.

28. Year this replacement item was manufactured.

29. Name, section, and division of the construction Code for this replacement item.

30. Edition, addenda, and as applicable, Code Cases and class of the construction Code forthis replacement item.

31. Identify the edition, addenda, and any applicable Code cases of the ASME Section XICode used for inservice inspection.

32. Identify the edition, addenda, and any applicable Code Cases of the ASME Section XI

Code for the repair, modification, or replacement activity.

33. Identify the edition, addenda, and any applicable Code Cases of the construction Codefor the repair, modification, or replacement activity.

34. Identify the organization responsible for design or design reconciliation, if appli-cable.

35. Identify the type of pressure test (i.e. hydrostatic, pneumatic, or design) and applied testpressure. Also indicate any Code Cases used in connection with the pressure test.

36. Indicate the set pressure of the valve.

37. Indicate blowdown, if applicable, as a percentage of set pressure.

38. Indicate the repair organization’s name and address.

39. Indicate the medium (steam, air, etc.) used for the adjustment of set pressure and, ifapplicable, blowdown.

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REPLACEMENT OF STAMPED DATA FORM


Submitted to Submitted by

1. Manufactured by

2. Manufactured for


4. Date installed

5. Previously installed at

6. Manufacturer’s Data Report attached No Yes

7. Item registered with National Board No Yes, NB Number

8. Item identification Year built

Type Dimensions

Mfg. serial no. Jurisdiction no.

MAWP psi Safety relief valve set at psi

9. Complete the reverse side of this report with a true facsimile of the legible portion of the nameplate.

10. If nameplate is lost or illegible, documentation shall be attached identifying the object to theManufacturer’s Data report referenced on this form.

11. I request authorization to replace the stamped data and/or nameplate on the above described pressure-retaining item in accordance with the rules of the National Board Inspection Code (NBIC),

Part RB-1030.

Owner’s name

Signature Date

Title

12. Authorization is granted to replace the stamped data or to replace the nameplate of the above described pressure-retaining item.

Signature Date

Jurisdiction

This form may be obtained from The National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Ave., Columbus, OH 43229 NB-136 Rev.5

(name of jurisdiction) (name of owner)

(address) (address)

(telephone no.) (telephone no.)

(name and address)

(name and address)

(address)

(chief inspector or authorized representative)

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The following is a true facsimile of the legible portion of the item’s nameplate. (Please print. Wherepossible, also attach a rubbing of the nameplate.)

I certify that to the best of my knowledge and belief, the statements in this report are correct, andthat the replacement information, data, and identification numbers are correct and in accordancewith provisions of the National Board Inspection Code , Part RB-1030. Attached is a facsimile or rubbingof the stamping or nameplate.

Name of Original Manufacturer

Signature Date

Certificate of Authorization No. Expires

Witnessed by Employer

Signature Date Commissions

(authorized representative)

(name of inspector)

(inspector)

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FORM NB-4NEW BUSINESS OR DISCONTINUANCE

USED BY AUTHORIZED INSPECTION AGENCIES

To:JURISDICTION 1. DATE OF SERVICE

New insurance business High pressure boiler2. Notice of: Discontinuance or cancellation 3. Effectve date 4. Type of object: Low pressure boiler Refusal to insure Pressure vessel

5. OBJECT 6. OWNER’S NO. 7. JURISDICTION NO. 8. NATIONAL BOARD NO. 9. NAME OF MANUFACTURER

10. NAME OF OWNER

11. NAME OF OWNER INCLUDING COUNTY

12. LOCATION OF OBJECT INCLUDING COUNTY

13. USER OF OBJECT (IF SAME AS OWNER SHOW “SAME”)

14. DATE OF LAST CERTIFICATE INSPECT., IF ANY 15. CERTIFICATE ISSUED 16. REASON FOR DISCONTINUANCE OR CANCELLATION

Yes No Phys. condition Out of use Other

17. REMARKS (USE REVERSE SIDE)

18. By:CHIEF INSPECTOR BRANCH OFFICE


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FORM NB-5 BOILER OR PRESSURE VESSEL DATA REPORTFIRST INTERNAL INSPECTION

Standard Form for Jurisdictions Operating Under the ASME Code

DATE INSPECTED CERT EXP DATE CERTIFICATE POSTED OWNER NO. JURISDICTION NUMBER NAT’L BD NO. OTHER NO.MO | DAY | YEAR MO | YEAR Yes No

OWNER NATURE OF BUSINESS KIND OF INSPECTION CERTIFICATE

INSPECTION Int Ext Yes No

OWNER STREET ADDRESS OWNER’S CITY STATE ZIP NUMBER

USER’S NAME - OBJECT LOCATION SPECIFIC LOCATION IN PLANT OBJECT LOCATION - COUNTY

USER’S STREET ADDRESS USER’S CITY STATE ZIP NUMBER

TYPE FT WT CI AIR TANK WATER TANK YEAR BUILT MANUFACTURER YEAR INST

New

Other Second Hand

USE Power Process Steam Htg HWH HWS FUEL (BOILER) METHOD OF FIRING (BOILER) PRESSURE GAGE TESTED

Storage Heat Exchange Other Yes No

PRESSURE SAFETY-RELIEF VALVES EXPLAIN IF PRESSURE CHANGED

This Inspection Prev. Inspection Set at

IS CONDITION OF OBJECT SUCH THAT A CERTIFICATE MAY BE ISSUED? HYDRO TEST

Yes No (If no, explain fully on back of form - listing code violation) Yes psi Date No

SHELL DIAMETER ID OVERALL LENGTH THICKNESS TOTAL HTG SURFACE (BOILER) MATERIAL

No. in. OD ft. in. in. Sq Ft ASME Spec Nos

ALLOWABLE STRESS BUTT STRAP Single HEADERS - WT BOILERS TYPE

psi Thks in Double Thickness in. Box Sinuous Wtr Wall Other

TYPE LONGITUDINAL SEAM RIVITED PITCH SEAM EFF

Lap Butt Welded Brazed Rivited Dia Hole in. in. X in. X in. %

HEAD THICKNESS HEAD TYPE Fixed Movable RADIUS DISH ELLIP RATIO BOLTING

in. Plus Minus Flat Quick Opening in. No. Dia. in. Material

TUBE SHEET THICKNESS TUBES PITCH (WT BLRS) LIGAMENT EFF

in. No. Dia. in. Length ft. in. in. X in. %

FIRE TUBE DISTANCE UPPER TUBES TO SHELL STAYED AREA Above Tubes Above Tubes

BOILERS Front in. Rear in. FRONT HEAD Below Tubes REAR HEAD Below Tubes

STAYS ABOVE TUBES TYPE AREA OF STAYS

Front No. Rear No. Head to Head Diagonal Welded Weldless Front Rear

STAYS BELOW TUBES TYPE AREA OF STAYS

Front No. Rear No. Head to Head Diagonal Welded Weldless Front Rear

FURNACE - TYPE THICKNESS TOTAL LENGTH TYPE LONG. SEAM

Adamson (No. Sect .) Corrugated Plain Other in. ft. in. Welded Riveted Seamless

STAYBOLTS - TYPE DIAMETER PITCH NET AREA

Threaded Welded Hollow Drilled (Size Hole in.) in. in. X in. sq. in.

SAFETY-RELIEF VALVES TOTAL CAPACITY Cfm OUTLETS PROPERLY DRAINED

No. Size Lb/Hr Btu/Hr No. Size Yes No (If no, explain on back of form )

STOP ON STEAM LINE ON RETURN LINES OTHER CONNECTIONS STEAM LINES PROPERLY DRAINED

VALVES Yes No Yes No Yes No Yes No (If no, explain on back of form )

FEED PIPE FEED APPLIANCES TYPE DRIVE CHECK FEED LINE RETURN LINE

Size in. No. Steam Motor VALVES Yes No Yes No

WATER GAGE GLASS TRI COCKS BLOWOFF PIPE INSPECTION OPENINGS COMPLY WTH CODE

No. No. Size in. Location Yes No (If no, explain on back of form )

CAST-IRON BOILERS SECTIONS DOES WELDING ON STEAM, FEED BLOWOFF, AND OTHER PIPING COMPLY WITH CODE

Length in. Width in. Height in. No. Yes No (If no, explain on back of form )

SHOW ALL CODE STAMPING ON BACK OF FORM. Give detail s (use sketch) for DOES ALL MATERIAL OTHER THAN AS INDICATED ABOVE COMPLY WITH CODE

special objects NOT covered above - such as Double wall vessels etc. Yes No (If no, explain on back of form )

NAME AND TITLE OF PERSON TO WHOM REQUIREMENTS WERE EXPLAINED:

I HEREBY CERTIFY THIS IS A TRUE REPORT OF MY INSPECTION IDENT NO. EMPLOYED BY IDENT NO. Signature of Inspector


1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

{ {

C o m p l e t e W

h e n N o t R e g i s t e r e d N a t i o n a l B o a r d

C o m p l e t e Wh e n N o t R e g i s t e r e d N

a t i o n a l B o a r d

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OTHER CONDITIONS AND REQUIREMENTS

CODE STAMPING

(BACK)

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FORM NB-6 BOILER-FIRED PRESSURE VESSELREPORT OF INSPECTION


DATE INSPECTED CERT EXP DATE CERTIFICATE POSTED OWNER NO. JURISDICTION NUMBER NAT’L BD NO. OTHER NO.MO | DAY | YEAR MO | YEAR Yes No

OWNER NATURE OF BUSINESS KIND OF INSPECTION CERTIFICATE

INSPECTION Int Ext Yes No

OWNER STREET ADDRESS OWNER’S CITY STATE ZIP NUMBER

USER’S NAME - OBJECT LOCATION SPECIFIC LOCATION IN PLANT OBJECT LOCATION - COUNTY

USER’S STREET ADDRESS USER’S CITY STATE ZIP NUMBER

TYPE YEAR BUILT MANUFACTURER

FT WT CI Other

USE FUEL METHOD OF FIRING PRESSURE GAGE TESTED

Power Process Steam Htg HWH HWS Other Yes No

PRESSURE ALLOWED SAFETY-RELIEF VALVES HEATING SURFACE OR BTU

This Inspection Prev. Inspection Set at Total Capacity

IS CONDITION OF OBJECT SUCH THAT A CERTIFICATE MAY BE ISSUED? HYDRO TEST

Yes No (If no, explain fully under conditions ) Yes psi Date No

CONDITIONS: With respect to the internal surface, describe and state location of any s

extent of any erosion, grooving, bulging, warping, cracking, or similar condition. Report on

adverse conditions wit es, supports, etc. Describe any major changes or repairs made

since last inspection.

REQUIREMENTS: (List Code Violations)

NAME AND TITLE OF PERSON TO WHOM REQUIREMENTS WERE EXPLAINED:

I HEREBY CERTIFY THIS IS A TRUE REPORT OF MY INSPECTION

SIGNATURE OF INSPECTOR IDENT NO. EMPLOYED BY IDENT NO.


1

2

3

4

5

6

7

8

9

10

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FORM NB-7 PRESSURE VESSELSREPORT OF INSPECTION


1 DATE INSPECTEDMO | DAY | YEAR

CERT EXP DATEMO | YEAR

CERTIFICATE POSTED

Yes No

OWNER NO. JURISDICTION NUMBER NAT’L BD NO. OTHER NO.

2 OWNER NATURE OF BUSINESS KIND OF

INSPECTION Int Ext

CERTIFICATE

INSPECTION Yes No

OWNER’S STREET ADDRESS OWNER’S CITY STATE ZIP

3 USER’S NAME - OBJECT LOCATION SPECIFIC LOCATION IN PLANT OBJECT LOCATION - COUNTY

USER’S STREET ADDRESS USER’S CITY STATE ZIP

4 TYPE

AIR TANK WATER TANK OTHER

YEAR

BUILT

MANUFACTURER

5 USE

STORAGE PROCESS HEAT EXCHANGE OTHER

SIZE PRESSURE GAGE TESTED

Yes No

6 PRESSURE ALLOWEDTHIS INSPECTION PREVIOUS INSPECTION

SAFETY RELIEF VALVESSET AT TOTAL CAPACITY

EXPLAIN IF PRESSURE CHANGED

7 IS CONDITION OF OBJECT SUCH THAT A CERTIFICATE MAY BE ISSUED?

YES NO (IF NO EXPLAIN FULLY UNDER CONDITIONS)

HYDRO TEST

YES PSI DATE NO

8 CONDITIONS:

With respect to the internal surface, describe and state location of any scale, oil, or o

erosion, grooving, bulging, warping, cracking, or similar condition. Report on any defe

conditions wit es, supports, etc. Describe any major changes or repairs made since

last inspection.

9 REQUIREMENTS: (LIST CODE VIOLATIONS)

10 NAME AND TITLE OF PERSON TO WHOM REQUIREMENTS WERE EXPLAINED:

I HEREBY CERTIFY THIS IS A TRUE REPORT OF MY INSPECTION

SIGNATURE OF INSPECTOR

IDENT NO. EMPLOYED BY IDENT NO.


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BOILER INSTALLATION REPORT I-1

INSTALLATION: New Reinstalled Second Hand Date / /

INSTALLER OWNER-USER OBJECT LOCATION

Name Name Name

Street Street, PO Box, RR Street

City, State, ZIP City, State, ZIP City, State, ZIP

Jurisdiction No. National Board No. Manufacturer Mfg. Serial No. Year Built Boiler Type Boiler Use

Fuel Method of Firing Btu/kw input Btu/kw

output

Operating PSI Code Stamp(s) A S U HLW

M E H Other

Stamped MAWP Heating Surface,

Sq. Ft.

Cast Iron Manhole Specific On-Site Location, i.e., Utility Room

Pressure Relief

Valve Size

1.

2.

3.

4.

Pressure Relief

Valve Set Pressure

1.

2.

3.

4.

Pressure Relief

Valve Capacity

BTU/hr

Lb/hr

1.

2.

3.

4.

Manufacturer

1.

2.

3.

4.

Low Water Fuel Cutoff Mfg.

No.

Probe Type

Flow Switch

Float & Chamber

Other (Specify)

PRESSURE/ALTITUDE GAGE:

Dial Graduation

Valve/Cock Size MAWP

Pipe Connection Size

Siphon or Equivalent Device Yes No

EXPANSION TANK:

ASME Constructed Yes No

Other

MAWP

No. Gallons

VENTILATION AND COMBUSTION AIR

Unobstructed Opening (sq. in.)

Power Ventilator Fan (CFM)

WATER LEVEL INDICATORS:

Numer of Gage Glasses

Number of Remote Indicators

Size of Connection Piping

FEED WATER SUPPLY:

Number of Feeding Means

Pipe Size

Stop Valve Size MAWP

Check Valve Size MAWP

STOP VALVES:

Number of Valves

Valve Size

EXTERNAL PIPING ASME CODE: FUEL TRAIN:

Yes No CSD-1 NFPA-85

Other Other

BOTTOM BLOWDOWN CONNECTIONS:

Number of Valves

Valve Size MAWP

Piping Run Full Size Yes No

POTABLE WATER HEATER UNIQUE REQUIREMENTS Yes No

Inlet Stop Valve Size MAWP

Outlet Stop Valve Size MAWP

Drain Valve Size

Thermometer Yes

Manufacturer’s Certification Attached: Yes No Clearance from walls and floors:

Side Bottom TopDoes boiler replace existing one: Yes No

Additional recommendations and remarks by installer:

Installer Name (PRINT) Registration #

I HEREBY CERTIFY THAT THE INSTALLATION COMPLIES WITH APPENDIX I

Installer Signature

1

2 3 4

5 6 7 8 9 10 11

12 13 14 15 16 17

18 19 20 21 22

23 24 25 26 27

28 29 30

31 32

33

34


212.1

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212.2

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GUIDE FOR COMPLETING NATIONAL BOARD BOILER INSTALLATION REPORT

1. INSTALLATION: Indicate the type and date of installation – new, reinstalled or second-hand.

2. INSTALLER: Enter the Installer name and physical address.

3. OWNER-USER: Enter the name and mailing address of the owner-user of the boiler.

4. OBJECT LOCATION: Enter the name of the company or business and physical addresswhere the installation was made.

5. JURISDICTION NO.: Enter the number if assigned at the time of installation.

6. NATIONAL BOARD NO.: Enter the assigned National Board number. Note: Cast- ironsection boilers do not require National Board registration.

7. MANUFACTURER: Enter the boiler manufacturer’s name.

8. MFG. SERIAL NO.: Enter the assigned boiler manufacturer’s serial number.

9. YEAR BUILT: Enter the year the boiler was manufactured.

10. BOILER TYPE: Enter the type of boiler, i.e., watertube, firetube, cast iron, electric, etc.

11. BOILER USE: Enter the service the boiler will be used for, i.e., heating (steam or water),potable water, etc.

12. FUEL: Enter the type of fuel, i.e., natural gas, diesel, wood, etc. If more than one fuel

type, enter the types the boiler is equipped for.

13. METHOD OF FIRING: Enter the method of firing, i.e., automatic, hand, stoker, etc.

14. BTU/KW INPUT: Enter the Btu/hr. or kw input of the boiler.

15. BTU/KW OUTPUT: Enter the Btu/hr. or kw output of the boiler.

16. OPERATING PSI: Enter the allowed operating pressure.

17. ASME CODE STAMP(S): Check the ASME Code stamp shown on the code nameplateor stamping of other certification mark (specify).

18. STAMPED MAWP: Enter the maximum allowable working pressure shown on thenameplate or stamping.

19. HEATING SURFACE SQ. FT.: Enter the boiler heating surface shown on the stampingor nameplate. Note: This entry is not required for electronic boilers.

20. CAST IRON: Enter the total number of sections for cast-iron boilers.

21. MANHOLE: Indicate whether the boiler has a manway.

212.3

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212.4

22. SPECIFIC ON-SITE LOCATION: Enter the on-site location of the boiler in sufficientdetail to allow location of that boiler.

23. PRESSURE RELIEF VALVE SIZE: Enter the inlet and outlet size of all installed boilersafety or safety relief valves.

24. PRESSURE RELIEF VALVE SET PRESSURE: Enter the set pressure of all installed boilersafety or safety relief valves.

25. PRESSURE RELIEF VALVE CAPACITY: Enter the capacity in either lbs. of steam perhour or Btu/hr for each installed boiler safety or safety relief valve.

26. MANUFACTURER: Enter the manufacturer of each installed boiler safety and safetyrelief valve.

27. LOW WATER FUEL CUTOFF: Enter the manufacturer’s name, type, number andmaximum allowable working pressure of all installed low water fuel cutoff devices.

28. PRESSURE/ALTITUDE GAGE: Enter the dial range of the installed pressure or al-titude gage, cutout valve or cock size, a maximum allowable working pressure, andgage pipe connection size. For steam boilers, indicate gage siphon or equivalent deviceinstalled.

29. EXPANSION TANK: Indicate code of construction of installed expansion tank, tankmaximum allowable working pressure and tank capacity in gallons.

30. VENTILATION AND COMBUSTION AIR: Indicate total square inches of unobstructedopening or total cubic feet per minute of power ventilator fan(s) available for ventila-tion and combustion air.

31. WATER LEVEL INDICATORS: Enter the number of gage glasses and/or remote indica-tors and connecting pipe size.

32. FEED WATER SUPPLY: Enter the total number of feeding means, connecting pipe size,stop and check valve size, and maximum allowable working pressure.

33. STOP VALVE(S): Enter the number of stop valves installed, valve size and maximumallowable working pressure.

34. POTABLE WATER HEATER UNIQUE REQUIREMENTS: Indicate if stop valves installedand if so enter size and maximum allowable working pressure. Enter drain valve size

and indicate installation of thermometer at or near boiler outlet. • Indicate if manufacturer’s certificate is attached (mandatory for new installations). • Indicate clearances and whether the installation replaced an existing boiler. • Enter any remarks or comments you deem appropriate. • Print installer name and registration number and sign completed report.

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Examples of Repairs and Alterations

Appendix 6

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APPENDIX 6 — EXAMPLES OF REPAIRS AND ALTERATIONS

6-1000 INTRODUCTION

The purpose of this appendix is to provideowners, users, repair organizations, andInspectors with assistance in evaluatingwhether contemplated work on a pressure-retaining item should be categorized as arepair or alteration. The significance of thiscategorization affects the qualifications of theorganization performing the work as well asthe resultant documentation.

6-2000 EXAMPLES OF REPAIRS

Repairs are defined in the Glossary. Examplesof repairs are:

a. weld repairs or replacement of pressureparts or attachments that have failed in aweld or in the base material;

b. the addition of welded attachments topressure parts, such as:

1. studs for insulation or refractorylining

2. hex steel or expanded metal forrefractory lining

3. ladder clips

4. brackets, having loadings which donot affect the design of the pressure-retaining item to which they are at-tached

5. tray support rings

c. corrosion resistant strip lining, or weldoverlay;

d. weld buildup of wasted areas;

e. replacement of heat exchanger tube sheetsin accordance with the original design;

f. replacement of boiler and heat exchangertubes where welding is involved;

g. in a boiler, a change in the arrangement

of tubes in furnace walls, economizer, orsuper heater sections;

h. replacement of pressure-retaining partsidentical to those existing on the pres-sure-retaining item and described on theoriginal Manufacturer’s Data Report. Forexample:

1. replacement of furnace floor tubesand/or sidewall tubes in a boiler

2. replacement of a shell or head inaccordance with the original design

3. rewelding a circumferential or longi-tudinal seam in a shell or head

4. replacement of nozzles of a size wherereinforcement is not a consideration

i. installation of new nozzles or openingsof such a size and connection type that

reinforcement and strength calculationsare not a consideration required by theoriginal code of construction;

j. the addition of a nozzle where reinforce-ment is a consideration may be consideredto be a repair provided the nozzle is identi-cal to one in the original design, locatedin a similar part of the vessel, and notcloser than three times its diameter fromanother nozzle. The addition of such anozzle shall be restricted by any service

requirements;

k. the installation of a flush patch to apressure-retaining item;

l. the replacement of a shell course in acylindrical pressure vessel;

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Appendix 7

Procedures to Extend the “VR” Certificateof Authorization Stamp to ASME “NV”Stamped Pressure Relief Devices

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APPENDIX 7 — PROCEDURES TO EXTEND THE “VR” CERTIFICATE OF

AUTHORIZATION AND STAMP TO ASME “NV” STAMPED

PRESSURE RELIEF DEVICES

7-1000 INTRODUCTION

Approval to extend the scope of the NationalBoard “VR” Certificate of Authorization tothe Certificate Holder to use the “VR” stampon ASME Code “NV” Class 1, 2, or 3 stampedpressure relief devices, which have beencapacity certified by the National Board,may be given subject to the provisions thatfollow.

7-2000 ADMINISTRATIVE

PROCEDURES

The repair organization shall hold a valid“VR” Certificate of Authorization.

The repair organization shall obtain a Na-tional Board “NR” Certificate of Authoriza-tion and stamp to repair, modify, or replacenuclear components. The requirements forsaid certificate and stamp include, but are notlimited to, the following. The repair organiza-

tion shall:

a. Maintain a documented quality assur-ance program that meets the applicablerequirements of RA-2300 of the NBIC.This program shall also include all theapplicable requirements for the use of the“VR” stamp;

b. Have a contract or agreement with anInspection Agency to provide inspectionof repaired “NV” stamped pressure relief

devices by Inspectors who have beenqualified in accordance with the require-ments of ASME QAI-1, Qualifications forAuthorized Inspection;

c. Successfully complete a survey of the qual-ity assurance program and its implemen-tation. This survey shall be conducted by

representatives of the National Board, the

jurisdiction wherein the applicant’s repairfacilities are located, and the applicant’sAuthorized Inspection Agency. Furtherverification of such implementation bythe survey team may not be necessary ifthe applicant holds a valid ASME “NV”certificate and can verify by documenta-tion the capability of implementing thequality assurance program for repair of“NV” stamped pressure relief devices,covered by the applicant’s ASME “NV”certificate.

The application of the “NR” Certificate ofAuthorization and stamp shall clearly definethe scope of intended activities with respect tothe repair of Section III “NV” stamped pres-sure relief devices.

Revisions to the quality assurance programshall be acceptable to the Authorized NuclearInspector Supervisor and the National Board before being implemented.

Endorsement of the “VR” Certificate of Authori-zation for the repair of “NV” stamped pressurerelief devices shall be granted upon acceptance by the National Board Accreditation Com-mittee on Nuclear Repair, Modification, andReplacement.

Verification testing of valves repaired by theapplicant shall not be required provided suchtesting has been successfully completed underthe applicant’s “VR” certification program.

A survey of the applicant for the “VR” Certificateof Authorization and endorsement of the repairof “NV” stamped pressure relief devices may be made concurrently.

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APPENDIX 7 — PROCEDURES TO EXTEND THE “VR” CERTIFICATE OF AUTHORIZATION STAMPTO ASME “NV” STAMPED PRESSURE RELIEF DEVICES

7-3000 GENERAL RULES

ASME Code Section III “NV” stampedpressure relief devices, which have beenrepaired in accordance with these rules, shall be stamped with both the “VR” and “NR”

stamps.

The “VR” and “NR” stamps shall be ap-plied only to “NV” stamped (Class 1, 2, or3) National Board capacity certified pressurerelief devices that have been disassembled,inspected, and repaired as necessary, such thatthe valves’ condition and performance areequivalent to the standards for new valves.

All measuring and test equipment used inthe repair of pressure relief devices shall becalibrated against certified equipment hav-ing known valid relationships to nationallyrecognized standards.

Documentation of the repair of “NV” stampedpressure relief devices shall be recorded on theNational Board Form NVR-1 , Report of Re-pair, Modification or Replacement of NuclearPressure Relief Devices in accordance with therequirements of RA-2300 of the NBIC.

When an ASME “NV” Stamped PressureRelief Device requires a duplicate name-plate because the original nameplate isillegible or missing, it may be appliedusing the procedures of RE-1064 providedconcurrence is obtained from the AuthorizedNuclear Inspector and jurisdiction. In this casethe nameplate shall be marked “SEC. III” toindicate the original ASME Code stamping.

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Appendix 8

Inspection, Repair, and Alteration ofGraphite Pressure Equipment

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APPENDIX 8 — INSPECTION, REPAIR, AND ALTERATION OF GRAPHITEPRESSURE EQUIPMENT

8-1000 SCOPE

a. The purpose of this Appendix is to provide

requirements for inservice inspection, re-pair, and alteration of pressure equipmentmanufactured from impervious graphitematerials.

b. Repair or alteration of metallic compo-nents shall comply with Part RC.

c. The impervious graphite (carbon, graph-ite, or graphite compound) used for theconstruction of graphite pressure ves-sels is a composite material, consistingof “raw” carbon or graphite which isimpregnated with a resin using a tightlycontrolled pressure/heat cycle(s). Theinteraction between the raw material andthe resin is the determining factor whenconsidering the design characteristics ofthe material. The design characteristicsinclude the strengths (flexural, compres-sive, and tensile), permeability, coefficientof thermal expansion, thermal conductiv-ity, and ultimately, the safe operating life

of the vessel.

d. The process used in the manufacturingof the raw material is well documented.The expertise developed in this fieldallows for many different grades to bemanufactured to meet the specific needsof various industries, including corrosivechemical processing pressure vessels.In the chemical processing industry theproperties of the raw material are dictated by the Manufacturer of the impregnated

material, based on the pressure/tempera-ture cycle and the type of resin used forimpregnation. The raw material require-ments are defined and communicatedto the manufacturer of the raw material.The cycle and resin type may vary fromManufacturer to Manufacturer, and alsofor each “grade” of impregnated materiala Manufacturer produces.

e. Repairs to graphite pressure equipmentrequire the use of certified impregnated

graphite and cement. The determiningfactor in establishing the desired mate-rial properties is the resin impregnationcycle. If the resin impregnation cycle isnot controlled, it is not possible to meetthe minimum design values.

f. With over a century of experience withgraphite pressure equipment, the essen-tial variables of the process have beendefined and apply universally to allManufacturers of impervious graphiteequipment. Therefore, by requiring theessential variables of the resin impregna-tion cycle to be identified and verified, itis possible to assign a “lot” number to allcertified materials at completion of theresin impregnation process. This can bedone with the assurance of meaningfuland consistent test results.

8-1010 APPLICATION

Due to inherent resistance to chemical attack,graphite pressure equipment is often used incorrosive applications, which may includelethal service.

8-1020 OPERATIONS

The owner should maintain controlled condi-tions for use of graphite pressure equipment,including the use of temperature and pressure

recorders and/or operating logs. The ownershould maintain operating procedures, andensure that pressure and temperature arecontrolled. A thermal or pressure spike maydamage the graphite or metal components.

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APPENDIX 8 — INSPECTION, REPAIR, AND ALTERATION OF GRAPHITE PRESSURE EQUIPMENT

8-2000 INSERVICE INSPECTION

The guidelines provided in Part RB shall ap-ply to graphite pressure equipment, except asmodified herein.

a. Graphite pressure vessels, pressure parts,and vessel components should receive anexternal visual examination biennially.All accessible surfaces should be chemi-cally cleaned. Cleaning fluids containingstrong oxidants should not be used.

b. Typical indicators that should necessitategraphite pressure equipment inspection,evaluation, and repair include:

1. Cross contamination of either processor service fluids

2. External leakage is observed

3. Flow rate is reduced or excessive pres-sure drop is observed

4. Heat transfer performance is reduced

c. Cracks, bulges, blisters, delaminations,spalling conditions, and excessive erosion

are cause for repair or replacement. Anysurface discoloration should be recleanedand examined more closely to determineif a delamination or spalling conditionexists.

d. Other typical discontinuities includechipping, erosion, baffle cutting due tovibration, and cement deterioration. Allpassage ways are susceptible to fouling.

8-3000 REPAIRS

The requirements provided in Part RC-1020 ,RC-1060 , RC-1070 , RC-1110 , RC-1120 , RC-1140 , RC-1141 , RC-2020 , RC-2030, and RC-2031 except (a) shall apply, insofar as they are

applicable to graphite pressure equipment.Graphite specific requirements include:

a. Organizations performing repairs shall be accredited as described in Part RA , asappropriate for the scope of work to be

performed.

b. When the standard governing the origi-nal construction is not the ASME Code,repairs or alterations shall conform tothe edition of the original constructionstandard or specification most applicableto the work. Where the original codeof construction is unknown, the editionand addenda of the ASME Code mostappropriate for the work shall be used,provided the “R” Certificate Holder hasthe concurrence of the Inspector and the jurisdiction where the pressure-retainingitem is installed.

c. The materials used in making repairs oralterations shall conform to the require-ments of the original code of constructionexcept as provided in subparagraph (j). The “R” Certificate Holder is responsiblefor verifying identification of existingmaterials from original data, drawings,

or unit records and identification of thematerials to be installed.

d. When ASME is the original code of con-struction, replacement parts subject to in-ternal or external pressure, which requireshop inspection by an Authorized Inspec-tor, shall be fabricated by an organizationhaving an appropriate ASME Certificate ofAuthorization. The item shall be inspectedand stamped as required by the applicablesection of the ASME Code. A completed

ASME Manufacturer’s Partial Data Reportshall be supplied by the manufacturer.

e. When the original code of constructionis other than ASME, replacement partssubject to internal or external pressureshall be manufactured by an organizationcertified as required by the original code of

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j. Graphite parts that have previously beenin service in one pressure vessel shouldnot be used in a second vessel without pri-or approval of the owner. Considerationshould be given to the service conditionof the previous process and possible con-

tamination of the subsequent process.

k. Blind cracks and delaminations may not be repaired by cement injection only.

l. Cracks and porosity in tubes may not berepaired. Cracked and porous sectionsmay be removed so that the remainder ofthe tube may be used. Individual tube sec-tions shall not be less than 24 in. (600 mm)in length, and the number of segments ina tube shall not exceed the quantity listedin Table 8-3000.

m. Cementing procedure specifications shall be qualified by the repair organization.The specifications shall be qualified asrequired by the code of construction. Ce-menting procedure qualification shall beverified by the Inspector.

TABLE 8-3000 —Permitted Quantity of Tube Segments

Total Tube Number of NumberLength, ft. (m) Tube Segments of Joints 6 (1.8) 1 0 9 (2.7) 2 1 12 (3.7) 3 2 14 (4.3) 3 2

16 (4.9) 4 3 18 (5.5) 4 3

20 (6.1) 4 3 22 (6.7) 4 3 24 (7.3) 5 4 27 (8.3) 5 4

construction. The item shall be inspectedand stamped as required by the originalcode of construction. Certification to theoriginal code of construction as required by the original code of construction orequivalent shall be supplied with the item.

When this is not possible or practicable,the organization fabricating the part mayhave a National Board Certificate of Au-thorization; replacement parts shall bedocumented on Form R-3 and the “R”symbol stamp applied as described inAppendix 2.

f. Organizations performing repairs underan “R” stamp program shall register suchrepairs with the National Board.

g. Before signing the appropriate NBIC Form,the Inspector shall review the drawings,witness any required pressure test, assurethat the required nondestructive examina-tions have been performed satisfactorily,and that the other functions necessary toassure compliance with the requirementof this Code have been performed.

h. Pressure-retaining items repaired in ac-cordance with the NBIC shall be marked

as required by Appendix 2. The letter “G”shall be applied to the nameplate underthe “R” stamp when graphite repairs aremade. The procedure defined in 8-6000 may be used in lieu of the stamping andnameplate attachment requirements ofAppendix 2.

i. Legible copies of the completed FormR-1, together with attachments, shall be distributed to the owner or user, theInspector, the jurisdiction if required,

and the Authorized Inspection Agencyresponsible for inservice inspection. FormR-1 shall be registered with the NationalBoard. Distribution of Form R-1 and at-tachments shall be the responsibility ofthe organization performing the repair.

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FIGURE 8-5010-a — Typical tube-tubesheet joints

The nameplate shall be applied in accordancewith Appendix 2. The letter “G” shall be ap-plied to the nameplate under the “R” stampwhen graphite alterations are made. The pro-cedure defined in 8-6000 may be used in lieuof the stamping and nameplate attachment

requirements of Appendix 2.

Organizations performing alterations underan “R” stamp program shall register suchalterations with the National Board.

8-5000 REPAIR GUIDE FOR IMPERVIOUS GRAPHITE

8-5010 INTRODUCTION (See Figures 8-5010-a thru f)

This section is intended to provide suggestedprocess and technique details for repairs.This section is nonmandatory, but should beused as a guide by the repair organization indeveloping specific repair procedures.

Damage to domes (heads), tubesheets, ornozzles is invariably a sign of improper in-stallation, operation, or maintenance. Because

such damage is random in nature, each casemust be analyzed separately to determinethe appropriate repair procedure, and theeconomics of repair versus replacement.

Impervious graphite is a machinable material.Parts can be modified or repaired in the field,or in a repair shop.

Machining operations may be handled withhigh-speed steel tools. Extensive machiningrequires tungsten carbide or diamond tooling.

No cooling or flushing fluid is required, norshould either be used.

Cleanliness is important. Dusty, dirty, andchemically contaminated surfaces preventproper cement adhesion. Poor cement adhe-sion will result in a low strength joint or a joint

which leaks. All surfaces should be neutral-ized to a pH of 7. Graphite parts should becleaned and washed with acetone to removeall moisture.

All damage should be examined and evalu-

ated to determine the cause. Identification andelimination of the cause is essential in helpingto prevent a recurrence.

An acetone wash on the surface of the dam-aged part is useful in identifying the fullextent of the cracks. The acetone will quicklyevaporate from the surface, leaving the cracksdamp and clearly visible.

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FIGURE 8-5010-d — Typical tube-tubejoints

FIGURE 8-5010-e — Typical edge repairmaterial inlay

FIGURE 8-5010-f — Typical nozzleconnection

FIGURE 8-5010-b — Typical tube replace-ment using sleeve and insert at tubesheetjoint.

FIGURE 8-5010-c — Typical TubeReplacement Using Sleeve at TubesheetJoint

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8-5020 TYPICAL GRAPHITE FRACTURES

8-5021 MAJOR FRACTURE

An extensive fracture, such as shown inFigure 8-5021 , is best repaired by completingthe break and re-cementing the two pieces.Temporary steel banding around the circum-ference is a method of clamping the repairuntil the cement is cured.

8-5022 INTERMEDIATE FRACTURE

The break is too minor to warrant completingthe fracture. A pie-shaped cut may be madeand the segment re-cemented in place. SeeFigure 8-5022.

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11 plug: An undersized plug will allow the use of common size tooling.

FIGURE 8-5023 — Examples of minorfracture repair

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FIGURE 8-5022 — Example of intermedi-ate fracture repair

8-5023 MINOR FRACTURE

For minor fractures, such as those shown inFigure 8-5023 , plug stitching can be used. Thecrack is removed by drilling and plugging acontinuous chain of overlapping holes along

the length and depth of fracture.

8-5030 GRAPHITE REPAIR BYPLUG STITCHING

(See Figure 8-5030)

Plug stitching is a form of repair by materialinlaying. In this case, the inlays are smallcylindrical impervious graphite plugs. Thecrack or fracture is removed by drilling andplugging a continuous series of overlappingholes along its length and depth.

Most plug stitching is done with 7/8 in.(22 mm) diameter plugs. The plugs are laidout along the fracture line on a pitch of5/8 in. (16 mm) centers. The overlap of plugmaterial is 1/4 in. (6 mm) along the fractureline. A number of plug sizes are available andare used in repair, and the amount of overlap-ping is proportional to their diameters.

8-5031 PLUG STITCHING PROCEDURE (See Figure 8-5030)

The following procedure is defined for7/8 in. (22 mm) diameter plugs11. Dimensionsfor other size plugs shall be adjusted propor-tionally to the diameter.

Trace the line of fracture with acetone andmark its length and direction.

Beyond the end points of the fracture (crack),one additional plug shall be installed.

FIGURE 8-5021 — Example of extensivefracture repair

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FIGURE 8-5030

Starting 5/8 in. (16 mm) beyond the endpoint of the crack, mark drilling centers every5/8 in. (16 mm) along its length. Make surethere is a plug to be installed outside both endpoints of the line of fracture.

Drill a 1/4 in. (6 mm) pilot hole at each loca-tion.

Redrill a 7/8 in. (22 mm) hole at every other pilot hole. Holes must be drilled the full depthof the crack. The depth and direction of thecrack can be checked with acetone.

A 7/8 in. (22 mm) diameter reamer may beused to true the drilled holes.

Dry fit a plug into the holes. There should be0.005 in. to 0.010 in. (0.1 mm to 0.3 mm) clear-ance for the cement joint. At no time shouldthere be a force fit of plugs into any drilledhole. Provisions shall be provided for ventingtrapped air.

Sand the outside surface of the plugs. Thor-oughly clean all the surfaces of the repair,plugs, and drilled holes with acetone.

Apply graphite cement to both plugs andholes. All surfaces of plugs and holes to be joined are to be wetted with cement.

Insert the cemented plugs into the holes al-lowing 1/16 in. (1.5 mm) of the plug to extend

beyond the surface of the graphite part.

Cure the graphite cement according to thecement Manufacturer’s instruction.

At this point, half of the plug stitch repair iscompleted. A row of plugs has been installedwith 1/4 in. (6 mm) pilot holes betweenthem.

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Redrill the remaining pilot holes to 7/8 in.(22 mm) diameter. The drill will remove partof the plugs that were installed. It is importantto have the plugs replace all of the fracture.If the new holes do not cut into the installedplugs, it will be necessary to repeat the pro-

cedure between these holes and plug loca-tions, to ensure that all of the crack has beenrepaired. The line of fracture is completelyremoved by the overlapping effect of thegraphite plugs.

After the second set of holes have been drilled,repeat the plug cementing procedures.

Contour the plugs to provide a smooth tran-sition into the adjoining surface area. Thefinished repair may be coated with a washcoat for appearance.

8-5040 FIGURES – TYPICAL PLUGSTITCHING PROCEDURE

(See Figure 8-5030)

Step one: Layout hole centers.Step two: Drilling pilot holes.Step three: Drilling the first set of holes.Step four: Cementing and curing the first

set of plugs.Step five: Drilling the second set of holes.Step six: Plug stitching repair completed.

8-5050 REIMPREGNATION OFGRAPHITE PARTS(TUBESHEETS, HEADS, ANDBLOCKS)

As a function of time, temperature, and chemi-cal exposure, the resin used to impregnate

graphite may shrink and/or degrade. Assuch, it is possible for voids to develop inimpregnated graphite that has been in chemi-cal service for a period of time. The resin losscan vary from slight to almost complete lossof impregnation. There is no practical wayto determine the amount of resin remaining

in the pores. However, a hydrostatic test willdetermine if the graphite has continuousporosity.

Reimpregnation of a graphite componentmay be used to reduce porosity in an exist-

ing graphite component, which in turn willimprove the performance and expected lifeof the existing graphite components. A writ-ten re-impregnation procedure acceptable tothe Inspector is required. The reimpregnationprocedure shall include as a minimum:

• Decontamination and drying of thegraphite component

• Subjecting the component to a vacuum• Introducing resin under pressure• Curing the resin at a specified temperature

and time• Leak test

8-5060 CONTROL OF IMPREGNATION MATERIAL

Impregnation material shall be the same asthat specified in the Reimpregnation Proce-dure. Each impregnation material shall betraceable by the name of its manufacturer

and the trade name or number of that manu-facturer.

The impregnation material manufacturer shallsupply the Certificate Holder a Certificate ofAnalysis for each material. It shall includethe following:

• Impregnation material identification• Batch number(s)• Date of manufacture• Shelf life

• Viscosity per ASTM D 2393• Specific gravity

Prior to reimpregnation, and at subsequentintervals not to exceed 14 days, the CertificateHolder shall test each batch of impregnationmaterial to assure that the characteristics ofthe material have not changed from valuesspecified in the Reimpregnation Procedure.

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The values obtained for viscosity and specificgravity for the impregnation material shall be within the limits specified by the manu-facturer and as listed in the ReimpregnationProcedure. The test values shall be madeavailable to the Inspector.

8-5070 FINISHING THE REPAIR

The parts should be held in place to preventmovement while curing the cemented joint toachieve a proper repair. The repair firm shouldtake care to ensure that the cement joint thick-ness is within the range recommended by thecement Manufacturer. Care spent in preciselyaligning the parts while clamping will avoidmany finishing and machining operationslater. Particular attention should be given togasket and other bearing surfaces.

Gasket and bearing surfaces may have to bemachined, filed, or sanded before the job iscompleted. Gasket serrations must be cleanand continuous. Serrations can be easily recutinto graphite and any repair plugs that crossthe gasket surface.

8-6000 ALTERNATIVE MARKINGAND STAMPING

General Requirementsa. This procedure may be used in lieu of the

stamping and nameplate requirementsdefined in Appendix 2.

b. The required data as defined in Appendix2 shall be 5/32 in. (4 mm) high, mini-mum.

c. The National Board code symbol (“R”)shall be used to make the impression inthe cement.

Application of the “R” Code Symbola. The graphite surface shall be clean and

smooth.

b. Apply a thin coating of cement onto theCode part. The cement should have theconsistency of toothpaste.

c. Apply sufficient heat to the cement so thatit begins to form a skin.

d. Apply a coating of a thinned release agent,such as “ANTISEIZE” to the tip of the “R”stamp with a brush.

e. Press the coated stamp all the way tothe bottom of the cement and remove bypulling straight out before the cementhardens.

f. Cure or heat the impression as required.

g. When cured, the part may be washed toremove any excess release agent.

Application of characters directly to graphitea. Use a very thin template of a flexible ma-

terial (stainless steel; flexible and easilycleaned).

b. Place the template over a clean smoothsurface.

c. Hold the template securely and trowelover with approved cement to fill all ofthe template area.

d. Carefully lift the template from the graph-ite part and examine the detail of thecharacters.

e. If acceptable, cure the cement.

f. If the characters are incorrect or damaged,wipe off the cement with a compatible

solvent and reapply.

Note: The preceding methods can be applied jointly to identify the graphite part and totransfer the “R” stamp.

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Repair, Alteration, and Inspection of Fiber-Reinforced Thermosetting Plastic PressureEquipment

Appendix 9Table 1 Visual Inspection Acceptance Criteria Reprinted from ASME B5.54-1992 by permission of the American Society of Mechanical Engineers. Allrights reserved.

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APPENDIX 9 — REPAIR, ALTERATION, AND INSPECTION OFFIBER-REINFORCED THERMOSETTING PLASTIC PRESSURE EQUIPMENT


9-1010 SCOPE

This appendix provides general requirementsthat apply to repairs and alterations to fiber-reinforced pressure-retaining items.

The letters “RP” shall be included on the “R”Certificate of Authorization for those orga-nizations authorized to perform repairs/al-terations of fiber-reinforced plastic pressureequipment.

9-1020 LIMITATIONS

All field work shall be limited to secondary bonding.

9-1030 REPAIR LIMITATIONS FORFILAMENT WOUND VESSELS

When the MAWP is greater than 200 psig, fieldrepair of filament wound ASME Code SectionX, Class I vessels shall be limited to corrosion barrier or liner repairs only, provided thereis access to the vessel interior. No structuralrepairs, re-rating, or alterations are allowedfor filament wound ASME Code Section X,Class 1 vessels, that have an MAWP greaterthan 200 psig.

9-1031 VESSELS FABRICATED

USING ELEVATED TEMPERATURE CURED

RESIN SYSTEMS

Repair of vessels fabricated using elevatedtemperature cured resin systems shall be lim-

ited to the corrosion barrier or liners only, pro-viding there is adequate access to the vessel

surface that requires the repair. No structuralrepairs, rerating or alterations are permittedwith the following exceptions:

a. Repair of vessels fabricated using elevatedtemperature cured material is permittedonly if the following provisions are met.

1. Calculations must be submitted bya Registered Professional Engineer(P.E.) experienced in the field of FRPvessels (See 9-3022).

2. The original fabricator must provideits approval showing that the damagedoes not compromise the pressurerating of the vessel and that the safetyfactor required by the ASME Code orthe original code of construction ismaintained.

b. Repair that results in a revision to the pres-

sure rating of a vessel covered as a part

of this section is permitted providing thenew rating is less than the original ratingand as long as the safety factor required bythe ASME Code or the safety factor usedas a design basis from the original code ofconstruction is met in its entirety and allthe requirements under 9-3000 ,AdditionalRequirements for Alterations, are met.

9-1040 CODE OF CONSTRUCTION

When the standard governing the originalconstruction is the ASME Code Section X orASME RTP-1, repairs and alterations shallconform, insofar as possible, to the sectionand edition of ASME Code Section X or ASMERTP-1 most applicable to the work planned.

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When the standard governing the originalconstruction is not the ASME Code Section Xor ASME RTP-1, repairs and alterations shallconform to the original code of constructionor standard. Where this is not possible, it ispermissible to use other codes, standards,

or specifications, including the ASME Code(Section X or RTP-1), provided the “RP” desig-nated “R” Certificate Holder (hereafter calledthe Certificate Holder) has the concurrence ofthe Inspector and the jurisdiction where thepressure-retaining item is installed.

9-1050 MATERIALS

The materials used in making repairs or al-terations shall conform to the requirements ofthe original code of construction. All resinsand reinforcements must be properly storedand prevented from being contaminated bywater, soil, or other impurities. The CertificateHolder is responsible for verifying identifica-tion of existing materials from original data,drawings, or units records, and identificationof the materials to be installed. Considerationshall be given to the condition of the existinglaminate, especially in the secondary bondpreparation area.

9-1060 REPLACEMENT PARTS

Replacement parts that will be subject to in-ternal or external pressure including liquidhead that are preassembled with or withoutsecondary bonds shall have the fabricationperformed in accordance with the originalcode of construction. The fabricator shallcertify that the material and fabrication are inaccordance with the original code of construc-

tion. This certification shall be supplied in theform of bills of material and drawings withstatements of certification. Examples includeshell and head sections, or flanged nozzles.

When ASME is the original code of construc-tion, replacement parts subject to internal orexternal pressure that require shop inspection by an Authorized Inspector or by a CertifiedIndividual as defined by ASME RTP shall befabricated by an organization having an ap-

propriate ASME Certificate of Authorization.The item shall be inspected and stamped ormarked as required by the original code ofconstruction. A completed ASME Fabricator’sPartial Data Report shall be supplied by thefabricator.

When the original code of construction isother than ASME, replacement parts subject tointernal or external pressure shall be manufac-tured by an organization certified as required by the original code of construction. The itemshall be inspected and stamped as required by the original code of construction. Certifi-cation to the original code of construction asrequired by the original code of constructionor equivalent shall be supplied with the item.When this is not possible or practicable, theorganization fabricating the part may have aNational Board Certificate of Authorization.Replacement parts shall be documented onForm R-3 and the “R” symbol stamp appliedas described in Appendix 2.

9-1070 SECONDARY BONDING

Secondary bonding shall be performed inaccordance with the requirements of theoriginal code of construction used for thepressure-retaining item.

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9-1071 SECONDARY BONDINGPROCEDURE

SPECIFICATIONS

Secondary bonding shall be performed inaccordance with the lamination procedure

qualified in accordance with the original codeof construction.

9-1072 PERFORMANCE QUALIFICATIONS

Secondary bonders shall be qualified forthe lamination process that is used. Suchqualifications shall be in accordance with therequirements of the original code of construc-tion.

9-1073 RECORDS

The Certificate Holder shall maintain a recordof the results obtained in secondary bonderprocedure qualifications. These records shall be certified by the Certificate Holder and shall be available to the Inspector.

9-1074 SECONDARY BONDER’SIDENTIFICATION

The Certificate Holder shall establish a systemfor the assignment of a unique identificationmark for each secondary bonder qualifiedin accordance with the requirements of theNBIC. The Certificate Holder shall also estab-lish a written procedure whereby all second-ary bonds can be identified as to the secondary bonder who made them. The procedure shall be acceptable to the Inspector. The Certificate

Holder shall keep a record of all secondary bonded joints and the secondary bonders whomade the joints.

9-1075 SECONDARY BONDER’SCONTINUITY

The performance qualification of a secondary bonder shall be affected when one of the fol-lowing conditions occur:

a. When the secondary bonder has not made joints using a specific qualified laminationprocedure during a period of 18 monthsor more, the bonder’s qualifications forthat procedure shall expire.

b. When there is specific reason to questionthe bonder’s ability to make secondary bonds that meet the specification, thequalification which supports the second-ary bonding that is being performed shall be revoked. All other qualifications notquestioned remain in effect.

9-1080 CURING

Curing techniques shall be performed asrequired by the original code of constructionor by the resin manufacturer’s recommenda-tions in accordance with a written procedure.The procedure shall contain the parameters

for curing.

9-1090 NONDESTRUCTIVE EXAMINATION

Except as required by this appendix, the non-destructive examination (NDE) requirements,including technique, extent of coverage,procedures, personnel qualifications, and ac-ceptance criteria, shall be in accordance withthe original code of construction used for the

construction of the pressure-retaining item.Secondary bonded repairs and alterationsshall be subjected to the same nondestructive

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examination requirements as the original sec-ondary bonds. As a minimum, all secondary bonded joints made for repairs and alterationsshall be subjected to a Barcol hardness test inaccordance with ASTM D-2583 and an acetonewipe test for all polyester and vinyl ester res-

ins. A visual inspection in accordance withTable 9-4100 is always required. The criteriafor visual acceptance shall be the same as theoriginal code of construction.

9-1100 PRESSURE AND ACOUSTICEMISSION TESTS

All vessels subject to repairs other than thosedefined in 9-2040 shall be tested in accordancewith the requirements of the original code ofconstruction. In addition, all structural repairsand alterations shall be pressure tested. Allvessels acoustic emission tested as required by the original code of construction shall beretested during the pressure test concentratingon the repaired or altered part of the vessel.

9-1110 PRESSURE GAGES, MEASUREMENT, AND EXAMINATION AND TEST

EQUIPMENT

The calibration of pressure gages, measure-ment, examination and test equipment, anddocumentation of calibration shall be per-formed as required by the applicable standardused for construction.

9-1120 ACCEPTANCE INSPECTION

Before signing the appropriate NBIC report

form, the inspector:

• shall review the drawings,

• assure the secondary bonding was per-formed in accordance with the originalcode of construction,

• witness any pressure or acoustic emissiontest,

• assure that the required nondestructiveexaminations have been performed sat-isfactorily, and

• that the other functions necessary to as-sure compliance with the requirementsof this Code have been performed.

9-1130 STAMPING

The attaching of a nameplate to a repaired oraltered vessel or tank shall indicate that thework was performed in accordance with therequirements of this Code. The attachmentof a nameplate shall be done only with theknowledge and authorization of the Inspec-tor. The Certificate Holder responsible for therepair or alteration shall apply the stampingnameplate. Required stamping and nameplateinformation are shown in Appendix 2.

9-1140 REMOVAL OF ORIGINALSTAMPING OR

NAMEPLATE

If it becomes necessary to remove the originalstamping, the Inspector shall, subject to theapproval of the Jurisdiction, witness the mak-ing of a facsimile of the stamping, the oblit-eration of the old stamping, and the transferof the stamping to the new item. When thestamping is on a nameplate, the Inspectorshall witness the transfer of the nameplateto the new location. Any relocation shall bedescribed on the applicable NBIC form. ASMECode items shall not be restamped with the

ASME Code Symbol.

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9-1150 REGISTRATION OF DOCUMENTATION

Organizations performing repairs or alterationsunder an “R” stamp program shall registersuch repairs or alterations with the National

Board.

9-2000 ADDITIONAL REQUIREMENTS FOR REPAIRS

9-2010 SCOPE

This section provides additional requirementsfor repairs to pressure-retaining items andshall be used in conjunction with 9-1000 and9-4000.

9-2020 DRAWINGS

Drawings shall be prepared or modified todescribe the repair. Drawings shall includesufficient information to satisfactorily per-form the repair.

9-2030 REPAIR PLAN

When repairs other than those defined in9-2040 are being made to ASME Section Xor RTP-1 stamped equipment, the user shallprepare or cause to have prepared a detailedplan covering the scope of the repair.

a. Professional Engineer Review The repair plan shall be reviewed and

certified by a Professional Engineer who

is registered in one or more of the statesof the United States of America or theprovinces of Canada and is experiencedin reinforced plastic vessel design. Thereview and certification shall be such toensure that the work involved in the re-

pair is compatible with the User’s DesignSpecification or User’s Basic RequirementsSpecification and the Manufacturer’s De-sign Report. The certification shall alsoinclude any drawings and calculationsprepared as part of the repair plan.

b. Authorized Acceptance Following review and certification, the

repair plan shall be submitted to the In-spector for his review and acceptance. Re-pairs to pressure-retaining items shall not be initiated without the authorization ofthe Inspector. Subject to acceptance of the Jurisdiction, the Inspector may give priorapproval for routine repairs, providedthe Inspector assures that the CertificateHolder has acceptable procedures cover-ing the repairs.

9-2040 ROUTINE REPAIRS

Prior to performing routine repairs, the Cer-tificate Holder should determine that routinerepairs are acceptable to the jurisdiction wherethe work is to be performed.

a. Acceptable routine repairs are listed

below:

1. The addition or repair of non-load bearing attachments to pressure-re-taining items where post curing is notrequired.

2. Replacement and repair of damagedcorrosion liner areas in shells andheads shall not exceed 100 sq. in. (645sq. cm.) and not exceed the originalcorrosion liner thickness.

b. Routine repairs may be performed underthe Certificate Holder’s quality systemprogram; however, the requirement forin-process involvement of the Inspectorand stamping are waived. See 9-2070.

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c. The process of controlling and implement-ing routine repairs shall be documentedin the Certificate Holder’s quality systemprogram.

d. Routine repairs shall be documented on

a Form R-1 Repair form with a statementon line 10, Remarks: “Routine Repair”.

9-2050 REPAIR METHODS

The repair methods shall be acceptable tothe inspector. Some methods of repair arecontained in 9-4000.

9-2060 PRESSURE TESTING

Except as permitted in (e) below, the followingrequirements apply to all repairs to pressure-retaining items:

a. Repairs shall be pressure tested to 110% ofthe maximum allowable working pressurestamped on the pressure-retaining itemusing water or other liquid medium. TheCertificate Holder is responsible for allactivities relating to pressure testing of

repairs.

b. Replacement parts used in repairs shall bepressure tested at the maximum allowableworking pressure indicated on the pres-sure-retaining item being repaired.

c. During a pressure test, where the testpressure will exceed the set pressure of thepressure relief device, the device shall beprepared as recommended by the devicemanufacturer.

d. Hold time for the examination by the In-

spector shall be the time necessary for theInspector to conduct the examination.

e. When pressure testing using liquids is notpractical, other methods shall be used asfollows:

1. The pressure test may be a pneumatictest provided the Certificate Holder

has the concurrence of the Inspector,the jurisdictional authority where re-quired, and the owner. Precautionaryrequirements of the applicable sectionof the original code of constructionshall be followed. In addition, a pneu-matic test shall always be monitored by acoustic emission examination.

2. For vessels designed for vacuum, avacuum test shall be carried out tothe original test vacuum level of thevessel. During the vacuum test, thevacuum source may be left connectedto the vessel to compensate for leakageat fittings. All vessels acoustic emis-sion tested, as required by the originalcode of construction, shall be retestedduring the vacuum test concentratingon the repaired or altered part of thevessel.

9-2070 STAMPING

Pressure-retaining items repaired in accor-dance with the NBIC shall have a nameplateas required by Appendix 2. Subject to theacceptance of the jurisdiction and the concur-rence of the Inspector, nameplates may not berequired for routine repairs (see 9-2040). In allcases, the type and extent of repairs neces-sary shall be considered prior to waiving therequirement.

9-2080 DOCUMENTATION

Repairs that have been performed in accor-dance with the NBIC shall be documented onForm R-1 as shown in Appendix 5. Form R-4shall be used to record additional data whenspace is insufficient on Form R-1.

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9-2081 PREPARATION OF FORM R-1

a. Preparation of Form R-1 shall be theresponsibility of the Certificate Holderperforming the repair.

b An Inspector shall indicate acceptance bysigning the Form R-1.

c. The Form R-3 and the Fabricator’s DataReport described in 9-1050 shall be a partof the completed Form R-1 and shall beattached thereto.

9-2082 DISTRIBUTION

Legible copies of the completed Form R-1 , together with attachments, shall be distrib-uted to the owner-user, the Inspector, the jurisdiction if required, and the AuthorizedInspection Agency responsible for inserviceinspection. Form R-1 shall be registered withthe National Board as noted in 9-1150.

Distribution of Form R-1 and attachmentsshall be the responsibility of the organizationperforming the repair.

9-3000 ADDITIONAL REQUIREMENTS FOR

ALTERATIONS

9-3010 SCOPE

This section provides additional requirementsfor alterations to pressure-retaining items,and shall be used in accordance with 9-1000

and 9-4000.

9-3020 DESIGN

The Certificate Holder performing altera-tions shall establish controls to ensure thatall required design information, applicable

drawings, design calculations, specificationsand instructions are prepared, obtained, con-trolled, and interpreted to provide the basisfor an alteration in accordance with the origi-nal code of construction. When a Fabricator’sData Report is required by the original code of

construction, a copy of the original Data Re-port shall be obtained for use in the design ofthe alteration. When the original Fabricator’sData Report cannot be obtained, agreementson the method of establishing design basisfor the alteration shall be obtained from theInspector and the jurisdiction.

9-3021 ALTERATION PLAN

The user shall prepare or cause to have pre-pared a detailed plan covering the scope ofthe alteration.

a. Professional Engineer Review The alteration plan shall be reviewed and

certified by a Professional Engineer (P.E.)who is registered in one or more of thestates of the United States of America orthe provinces of Canada and is experi-enced in reinforced plastic vessel design.The review and certification shall be such

as to ensure that the work involved in thealteration is compatible with the user’sdesign specification and the Fabricator’sData Report.

b. Authorized Acceptance Following review and certification, the

alteration plan shall be submitted to theInspector for his review and acceptance.Alterations to pressure-retaining itemsshall not be initiated without the autho-rization of the Inspector.

9-3022 CALCULATIONS

A set of calculations shall be completed priorto the start of any physical work. All designwork shall be completed by an organizationexperienced in the design portion of the stan-

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dard used for the construction of the item. Allcalculations for ASME Code Section X andRTP-1 alterations shall be certified by a P.E.experienced in reinforced plastic vessel design(See 9-3030). All calculations shall be madeavailable for review by the Inspector.

9-3023 RERATING

Rerating of a pressure-retaining item by in-creasing the maximum allowable workingpressure (internal or external) or temperature ,or decreasing the minimum temperature shall be done only after the following requirementshave been met to the satisfaction of the juris-diction at the location of the installation:

a. Revised calculations verifying the newservice conditions shall be prepared inaccordance with the Certificate HoldersQuality Control System. Rerating calcula-tions for ASME Code Section X and RTP-1vessels shall be performed by a P.E. expe-rienced in the design of reinforced plasticpressure vessels.

b. Al l rera ting sh al l be es tab li sh ed inaccordance with the requirements of the

construction standard to which the pres-sure-retaining item was built.

c. Current inspection records verify that thepressure-retaining item is satisfactory forthe proposed service conditions.

d. The pressure-retaining item has beenpressure tested, as required, for the newservice conditions.

This code does not provide rules for de-rat-

ing pressure-retaining items; however, whenthe MAWP and or allowable temperatureof a pressure-retaining item is reduced, the jurisdiction wherein the object is installedshould be contacted to determine if specificprocedures should be followed.

9-3024 DRAWINGS

As appropriate, drawings shall be preparedto describe the alteration. Drawings shall in-clude sufficient information to satisfactorilyperform the alteration.

9-3030 PRESSURE TESTING

Except as permitted in (g) below, the follow-ing requirements apply for pressure testing ofalterations to pressure-retaining items:

a. When the alteration activity involves theinstallation of a replacement part and/orthe alteration will impact the design pres-sure, the design temperature, or the designrated capacity, a pressure test, as required by the original code of construction, shall be conducted. An acoustic emission testis also required if the original vessel wasso tested, unless a nozzle whose diameteris one tenth the vessel diameter or less is being added.

The Certificate Holder is responsible forall activities related to pressure testing ofreplacement parts. The pressure test may

be performed at the point of manufactureor point of installation.

b. The pressure test of replacement partsand connecting secondary bonds shall betested at 1.1 times the maximum allow-able working pressure or the original testpressure, whichever is greatest.

c. During the pressure test, where the testpressure will exceed the set pressure of thepressure relief device, the device shall be

prepared as recommended by the devicemanufacturer.

d. The liquid temperature used for pressuretesting shall not be less than 40°F (4°C)nor more than 120°F (49°C) unless the

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original pressure test was conducted at ahigher temperature. If an acoustic emis-sion examination is being conducted, thetemperature of the test liquid shall notvary by more than plus 5°F (3°C) or minus10°F (6°C).

e. Hold time for the pressure test shall be aminimum of 30 minutes with an acousticemission examination or a minimum of4 hours without an acoustic emission ex-amination. The following procedure shall be used to retest a vessel that has beentested under the provisions of Article 6of ASME Section X and has subsequently been repaired.

1. Load the vessel as specified in Article6 of ASME Section X without monitor-ing for acoustic emission.

2. Hold the maximum load for at least30 minutes.

3. Condition the vessel by holding atreduced load as required by SectionV, Article 11, T-1121.

4. Retest the vessel as required by this

appendix.

5. The vessel shall be judged againstthe evaluation criteria for subsequentloadings.

f. Hold time for the examination by theInspector shall be the time necessary forthe Inspector to conduct the inspection.

g. When pressure testing using liquids is notpractical, other methods shall be used as

follows:

1. The pressure test may be a pneumatictest provided the Certificate Holderhas the concurrence of the Inspector,the jurisdictional authority where re-quired, and the owner. Precautionary

requirements of the applicable sectionof the original code of constructionshall be followed.

2. For vessels designed for vacuum, avacuum test shall be carried out to as

close as practical to the design vacuumlevel of the vessel. During the vacuumtest the vacuum source may be leftconnected to the vessel to compen-sate for leakage at fittings. All vesselsoriginally acoustic emission testedshall be retested during the vacuumtest concentrating on the repaired oraltered part of the vessel.

9-3040 STAMPING

The nameplate shall be applied in accordancewith Appendix 2. The location of the name-plate shall be documented on the Form R-2.

9-3050 DOCUMENTATION

Alterations performed in accordance withthe NBIC shall be documented on Form R-2 , Report of Alteration , as shown in Appendix 5.

Form R-2 , Report Supplementary Sheet , shall beused to record additional data when space isinsufficient on Form R-4.

9-3051 PREPARATION

The following items shall be attached to and become part of the R-2 report.

a. Preparation of Form R-2 shall be the re-sponsibility of the Certificate Holder per-

forming the alteration. The Fabricator’sreports or Form R-3 , as described in 9-1060 , and for pressure vessels a copy of theoriginal Fabricator’s Data Report, whenavailable, shall be attached to and becomea part of the completed Form R-2.

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b. The Certificate Holder that certifies the“Design Change” shall complete andsign the “Design Certification” section ofthe Form R-2. An Inspector shall indicateacceptance of the design by signing the“Certification of Design Change Review”

section of Form R-2.

c. The Certificate Holder performing thealteration shall complete and sign the“Construction Certification” section ofthe Form R-2. An Inspector shall indicateacceptance of the installation by signingthe “Certificate of Inspection” section ofForm R-2.

9-3052 DISTRIBUTION

Legible copies of the completed Form R-2 , Report of Alteration , together with attachments,shall be distributed by the Certificate Holderperforming the alteration, to the Inspector, theowner-user, and the jurisdiction, if required.

One original shall be submitted to the Na-tional Board.

9-4000 REPAIR/ALTERATION METHODS


In general, when a defective or damaged ves-sel wall is to be repaired, the total structurallaminate sequence of laminate constructionremoved as part of the repair shall be replaced.The replacement laminate shall providestructural properties meeting or exceeding

the requirement of the original constructionstandard. Moreover, when damage includesthe corrosion barrier, a corrosion barrier ofthe same type, which shall meet or exceed the barrier properties of the original construction,shall replace the corrosion barrier removed aspart of the repair.

The repair shall meet the requirements of theoriginal construction standard.

9-4020 CLASSIFICATION OF REPAIRS

Vessel repairs shall be classified into the fol-lowing types:

a. Type 1a – Corrosion barrier repairs Type 1b – Corrosion barriers with preci-

sion bores b. Type 2 – Corrosion barrier and interior

structural layer repairs

c. Type 3 – External structural layer repairs

d. Type 4 – Alterations

e. Type 5 – Miscellaneous general externalrepairs or alterations

f. Type 6 – Thermoplastic repairs

g. Type 7 – Gel coat repairs

Each type of repair shall have its own corre-

sponding general repair procedure as givenin the following paragraphs.

9-4021 TYPE 1 – REPAIR OF THECORROSION BARRIER

A corrosion barrier that has been exposedto a process may be permeated to the pointthat in some cases the entire corrosion barrierlaminate may need to be removed.

After the Inspector has verified that the repairprocedure is acceptable, the repair shall beperformed by the Certificate Holder as fol-lows:

a. Surface Preparation The surface area that is damaged must be

removed by abrasive blasting or grinding,

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to remove contaminated laminate andexpose sound laminate. The edge of therepaired area must have a bevel of 2 in.minimum.

Note that any cracks, delaminations, or

permeated surface must be removed. Anadequate size abrasive, or proper sand-ing disc must be used to obtain a 2-3 milanchor pattern.

Preparation of any surface requires that basic rules, common to all substrates, be followed. These rules are as outlined below:

• Surface must be free of contami-nants.

• Surface must be structurally sound.• Surface must have adequate anchor

pattern.• Surface must be dry.• Surface must be primed with recom-

mended primer.

Note: After the surface has been properlyprepared, it must be kept clean and dry untillaminating can be started. Dust, moisture,or traces of oil that come in contact with the

surface may act as a mold release or act toinhibit the cure and prevent a good second-ary bond.

b. Applying Test Patches to Verify AdequateSurface Preparation

Test patches should be applied to anysubstrate that will require a secondary bond to determine the integrity of theprimer bond prior to the application ofthe laminate.

The subsequent steps shall be followed:

1. Apply the primer (3 to 5 mils) to theprepared surface, and allow primer tocure.

2. Coat the primed surface with the sameresin to be used in the laminate repair.Apply 4 in. (100 mm) x 14 in. (350mm) piece of polyester, such as My-lar® , strip to one edge of primed area.Allow the polyester film to protrude

from beneath the patch.

3. Apply two layers of 1-1/2 oz. (40 g)/sq. ft. chopped strand mat saturatedwith the same resin that will be usedfor the repair. Mat shall be 12 in. (300mm) x 12 in. (300 mm) square.

4. Allow the mat layers to cure complete-ly, this may be verified by checking thehardness of the laminate.

5. Pry patch from surface using a screw-driver, chisel, or pry bar.

6. A clean separation indicates a poor bond.

7. Torn patch laminate or pulled sub-strate indicates that the bond is ac-ceptable.

If the bond is not adequate, go back to step

(a) and repeat the procedure.

Note: If the repair area is smaller than the testpatch dimensions, decrease the test patch sizeaccordingly.

As a last resort, if the previous procedure doesnot provide an adequate bond, the permeatedlaminate must be handled differently usingthe following procedure:

• Hot water wash the equipment.

• Abrasive blast with #3 sand or equal andallow to completely dry.

• Prime with the recommended primer, anarea 12 in. (300 mm) x 12 in. (300 mm) andapply a test patch.

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TABLE 9-4021 — Visual Inspection Acceptance Criteria

Maximum Size and Cumulative Sum of Imperfections Allowed After(See General Notes (a) and (b). Imperfections Subject to Cumulative

Limitations are indicated with an asterisk).

Level 1

NONE

*1/8 in.

(3 mm) dia.max. by 30%of veil(s)thicknessmax.

NONE

NONE

NONE

Definition of Visual Inspection Levels(to be Specified User or User’s Agent):Level 1 = Critically Corrosion ResistantLevel 2 = Standard Corrosion Resistant

Inner SurfaceVeil(s), Surfacing Mat

ImperfectionName

BurnedAreas

Chips

(surface)

Cracks

Crazing(surface)

Delamination(internal)

Definition of Imperfection

Showing evidence of thermaldecomposition through discol-oration or heavy distortion

Small pieces broken off an

edge or surface

Actual ruptures or debondof portions of the structure

Fine cracks at the surfaceof a laminate

Separation of the layers in alaminate

Level 2

NONE

*1/8 in.

(3 mm) dia.max. by 50%of veil(s)thicknessmax.

NONE

NONE

NONE

Interior LayersThick Mat or Chopped Strand

Spray Layers

Level 1

NONE

NONE

NONE

Level 2

NONE

NONE

NONE

StructuBalance o(Including O

Level 1

NONE

*1/4 in.(6mm) dia.or 1/2 in.(13mm) lengthmax. by 1/16(1.5mm) in.deep

NONE

Max. 1 in.(25 mm) long

by 1/64 in.(.4 mm) deep,max. density3 in. (75 mm)any sq. ft.

NONE

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Refer to User’s Specification for quantity limitations

TABLE 9-4021 — Visual Inspection Acceptance Criteria, continued

Maximum Size and Cumulative Sum of Imperfections Allowed After (See General Notes (a) and (b). Imperfections Subject to Cumulative

Limitations are indicated with an asterisk.)

Level 1

NONE

NONE

*3/16 in.(5 mm) longmax. by dia.or thicknessnot more than30% of veil(s)thickness

Max. dia.1/16 in.(1.5 mm) by30% of veil(s)

thickness deep



ImperfectionName

Dry Spot(surface)

EdgeExposure

ForeignInclusion


Areas of surface where thereinforcements have not beenwetted with resin.

Exposure of multiple layersof the reinforcing matrix to thevessel contents, usually as aresult of shaping or cutting asection to be secondary bond-ed (interior of vessel only)

Particles included in a lami-nate which are foreign to itscomposition (not a minutespeck of dust)

Level 2

NONE

NONE

* 1/4 in.(6 mm) longmax. by dia.or thicknessnot morethan 50% ofveil(s) thick-ness

Max. dia.1/16 in. (1.5mm) by 50%of veil(s)thicknessdeep

Interior Layer(-0.125 in. (3 mm) Thick)Mat or Chopped Strand

Spray Layers

Level 1

* 1/2 in.(13 mm) longmax. by dia.or thicknessnot more than30% of veil(s)thickness

Max. dia.1/8 in.(3 mm)

Level 2

* 1/2 in.(13 mm) longmax. by dia.or thicknessnot more than50% of veil(s)thickness.


StructuBalance o(Including O

Level 1

NONE

NONE

*Dime size,never topenetratelamination tolamination.


Gaseous Bubbles or Blisters Air entrapmentwithin, on, or between plies of reinforcements,0.015 in. (0.4 mm) diameter and larger

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Maximum Size and Cumulative Sum of Imperfections Allowed After (See General Notes (a) and (b). Imperfections Subject to Cumulative

Limitations are indicated with an asterisk.)

Level 1

*Max. heightor diameter1/64 in.(.4 mm)

*1/8 in.(3 mm) dia.max. by 30%of veil(s)

thicknessmax.

None morethan 30% ofveil(s) thick-ness

NONE

*None over3/16 in.(5 mm) dia.

by 1/16 in.(1.5 mm)in height

NONE

Definition of Visual Inspection Levels(to be Specified User or User’s Agent):Level 1 = Critically Corrosion Resistant

Level 2 = Standard Corrosion Resistant


ImperfectionName

Pimples(surface)

Pit(surface)

Porosity(surface)

Scratches(surface)

Wet Blisters(surface)

Wet-OutInadequate


Small, sharp, conicalelevations on the surfaceof a laminate.

Small crater in the surfaceof a laminate.

Presence of numerous visualtiny pits (pinholes), approximatedimension 0.005 in. (0.1 mm)(for example, 5 in. any sq. in.[650 sq. mm.])

Shallow marks, grooves, fur-rows, or channels caused

by improper handling

Rounded elevations of the sur-face, somewhat resemblinga blister on the human skin;

not reinforced

Resin has failed to saturatereinforcing (particularlywoven roving).

Level 2

*Max. heightor diameter1/64 in.(.4 mm)

*1/8 in.(3 mm) dia.max. by 30%of veil(s)

thicknessmax.

None morethan 50% ofveil(s) thick-ness

NONE

*None over3/16 in.(5 mm) dia.

by 1/16 in.(1.5 mm)in height

NONE


Spray Layers

Level 1

NONE

Level 2

NONE

StructuBalance o

(Including O

Level 1

No Limit

*1/4 in.(6 mm) dia.max. by 1/16in. (1.5 mm)

deep max.

None to fullyexterior get cexterior veil. limit.

*None morethan 6 in.long(150 mm)

No Limit

Dry mat or prdry woven rovacceptable; difully saturatedacceptable.

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Maximum Size and Cumulative Sum of Imperfections Allowed After (See General Notes (a) and (b). Imperfections Subject to CumulativeLimitations are indicated with an asterisk.)

Level 1

Max. devia-tion 20% ofwall or 1/16in. (1.5 mm),

whichever isleast

3

16



ImperfectionName

Wrinkles andCreases

Allowable Cu-mulative Sumof HighlightedImperfections


Generally linear, abruptchanges in surface planecaused by laps of reinforcinglayers, irregular mold shape,

or Mylar® overlap.

Maximum allowable in anysquare foot (0.9 sq. m)

Maximum allowable in anysquare yard (0.8 sq. m)

Level 2

Max.deviation 20%of wall or 1/8in. (3 mm),

whichever isleast

5

20


Spray Layers

Level 1

3

20

Level 2

5

30

StructuBalance o

(Including O

Level 1

GENERAL NOTES a. Above acceptance criteria apply to condition of laminate after repair and hydro test. b. Non-catalyzed resin is not permissible to any extent in any area of the laminate.

Maximum deof wall or 1/whichever is

5

30

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vessel. The repaired area shall be beveledinto the good areas surrounding the dam-age.

Note that any cracks, delaminations, orpermeated surfaces must be removed. If

the damage is deeper than the corrosion barrier and the material removed reachesthe structural laminate, the vessel is notrepairable. An adequate size abrasive,or proper sanding disc must be used toobtain a 2-3 mil anchor pattern to the areathat requires the repair.

Preparation of any surface requires that basic rules, common to all substrates, be followed. These rules are as outlined below:

• Surface must be free of contaminants.• Surface must be structurally sound.• Surface must have adequate anchor

pattern.• Surface must be dry.• Surface must be primed with recom-

mended primer.

Note: After the surface has been properlyprepared, it must be kept clean and dry

until laminating can be started. Dust,moisture, or traces of oil that come incontact with the surface may act as a moldrelease or act to inhibit the cure and pre-vent a good secondary bond. Laminatingshould be done within two hours of thesurface preparation.

b. Applying Test Patches to Verify AdequateSurface Preparation

Test patches may be applied to any sub-strate that will require a secondary bond

to determine the integrity of the bondprior to the application of the laminate.

The subsequent steps shall be followed:

1. Apply the primer (3 to 5 mils) to theprepared surface, and allow primer tocure.

2. Coat the surface with the same resin to be used in the laminate repair. Applya small strip of polyester film, such asMylar® , strip to one edge of primedarea. Allow the polyester film to pro-trude from beneath the patch.

3. Apply two layers of 1-1/2 oz. (40 g)/sq. ft. chopped strand mat saturatedwith the same resin that will be usedfor the repair.

4. Allow the mat layers to cure complete-ly, this may be verified by checking thehardness of the laminate. If required,heat may be used to cure the materialproviding it is compatible with theinitial resin used in the fabrication ofthe vessel.

5. Pry patch from surface using a screw-driver, chisel, or pry bar.

6. A clean separation indicates a poor bond.

7. Torn patch laminate or pulled sub-strate indicates that the bond is ac-ceptable.

If the bond is not adequate, go backto step (a) and repeat the procedureagain.

Note: if the repair area is smaller than

the test patch dimensions, decreasethe test patch size accordingly.

If neither patch bonds, the vessel isprobably not capable of bonding apatch and shall not be repaired.

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c. Laminate repair Repairs can be accomplished by adding

back the correct corrosion barrier surfacematerial as specified on the Fabricator’sdesign drawings.

When possible repairs shall be made withthe same type of resin and reinforcementmaterials used to fabricate the originalvessel corrosion barrier. Laminate qual-ity shall be in accordance with Table 9-4021 , or the original code of construction.However, when the original material ofconstruction was gelled and post curedat elevated temperatures, using the sameresin may not be possible. In this case analternate resin system may be used.

1. Apply the selected primer (3 to 5 mils)(as required for polyester and vinylester resins) and allow to dry to thetouch.

2. Continue with the specified laminateusing the proper resin and cure. Thefirst layer of non-woven polyesterveil used in the repair shall extend tothe exact edge of the damaged area.If additional layers are required to

fill the removed surface, they must be applied, followed by the specifiedlayer(s) of veil.

3. Apply a final coat of resin over entiresurfacing veil. If this final coat is avinyl ester or polyester material, itshould contain a small amount of waxto prevent air contact, which mightinhibit the cure. Allow laminate toachieve the manufacturer’s recom-mended Barcol hardness before final-

izing the repair.

Note: Apply heat to finalize the cureif hardness is not achieved.

4. After the repair has been properlycured, remove any excess materialwith the appropriate sanding tools toobtain a smooth surface that blendsinto the surrounding area. Care should be taken to ensure that the final inside

diameter of the repaired area matchesthat of the surrounding area and alsoconforms to the original suppliersspecifications.

9-4023 TYPE 2 – CORROSION BARRIER AND INTERNAL

STRUCTURAL LAYER REPAIRS

The Procedure for the Type 1a repair must be followed with the exception of additionallayers (structural layers) that must be re-moved if the structure is also damaged. Therepair area must be tapered similar to theType 1, and all of the structural layers must be replaced making sure that the mat layersincrease in length and width by at least 1 in.The structural laminate sequence and thick-ness must be approved by the Inspector, andproper calculations and the repair plan must be reviewed and approved by a P.E. familiar

with the work involved prior to the job.

Surface preparation, priming, and laminaterepair must be done per Type 1 procedure.

9-4024 TYPE 3 – EXTERNAL STRUCTURAL LAYER REPAIRS

a. Surface Preparation The surface area that is damaged is to be

repaired by removing the damaged areaeither by abrasive blasting or grinding toexpose sound laminate. The repair areamust have a bevel of 2 in. (50 mm) mini-mum. The ground or blasted surface mustextend a minimum of 4 in. (100 mm) past

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1. Apply the selected primer (3 to 5 mils)and allow to dry to the touch.

2. Continue with the specified laminateusing the proper resin and cure.

3. Fill the removed layers with the samesequence as the original structuralthickness, making sure that the layersare increasingly larger as the laminateis applied (in the case of filamentwound structure, an equivalent con-tact molded thickness must be usedfor the repair calculations). The first bond of the repair shall cover one de-gree times the width in the axial direc-tion and shall be centered. The repairshall extend completely around thecircumference using contact moldedprocedures as set forth in the code ofconstruction.

4. After the area is completely filled withthe proper laminate, a reinforcinglaminate shall be applied over the en-tire surface with a minimum overlapof four inches over the original shell,or as shown in the calculations, which-ever is greater. This overlay thickness

shall be calculated in the same way asthe reinforcing pad of a nozzle withthe diameter equal to the damagedarea. The design shall be in accordancewith the original construction code.Allow the laminate to achieve themanufacturer’s recommended Barcolhardness before finalizing the repair.Note: Apply heat to finalize the cureif hardness is not achieved.

5. A pressure test shall be performed per

9-3030.

9-4025 TYPE 4 – ALTERATIONS

Alterations, such as the addition of a nozzleor supports, must be designed according tothe original construction standard. In the case

of nozzles, the internal overlay is requiredaccording to ASME RTP-1 Figure 4-8 or 4-9(overlay “ti”). The procedure for preparing theinside surface is the same as the Type 1 repair.The external reinforcing pad shall be designedand installed according to the original con-

struction standard. Surface preparation forthe external overlay shall be according to theType 3 repair procedure.

After the alteration is completed, a pressuretest shall be performed in accordance with9-3030. As an option, an Acoustic Emissiontest can be performed to monitor the repairedarea during the pressure test.

9-4026 TYPE 5 – MISCELLANEOUS GENERAL EXTERNAL

REPAIRS OR ALTERATIONS

External repairs or alterations that are per-formed on nonpressure-containing parts,shall be calculated according to the originalconstruction standard. The Inspector and theP.E. must review and approve such modifica-tions. All repairs and alterations shall be doneaccording to the Type 3 repair procedure, withthe exception of removing damaged layers

from the structure. Surface preparation shall be restricted to the external layer of the ves-sel.

9-4027 TYPE 6 – THERMOPLASTICREPAIRS

The surface area that is damaged must bereconditioned so that the thermoplastic linergeometry matches that of its contacting lami-nate. Surfaces that are cut or torn or missing

sections shall be repaired by plastic welding.Welding practice, including choice of weldingequipment, weld surface preparation, andweld temperature shall conform to AppendixM-14 of ASME RTP-1. For materials not speci-fied in these documents, the best practice asrecommended by the material supplier shall be used. Welding rod, pellets, powder, or

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plates shall be made with plastic of an iden-tical type with properties such as melt indexand specific gravity as close as possible to theoriginal corrosion barrier plastic.

Thickness of the repaired barrier between the

wetted surface and the original surface shall be equal to or greater than the original corro-sion barrier surface specification.

The repaired surface shall be capable of sup-porting the full pressure rating of the vesselat the temperature rating of the vessel withno fluid leakage.

9-4028 TYPE 7 – GEL COAT REPAIRS

Following restoration of the structurallaminate layers, a gel coat shall be appliedto replace the gel coat lost in the repair. Theprocedure for the Type 1 repair item (a) sur-face preparation shall be followed. Gel coatof the same type is then to be applied to thesurface. Gel coat thickness is to be checkedwith a wet thickness gage at each 36 sq. in.area element. Thickness shall be equal to orgreater than the original gel coat specificationin the “as manufactured” state of the vessel.

The entire repair surface including all seamsshall be coated. There shall be at least a 3 in.overlap of gel coat at the union of repairedsurface and nonrepaired surface.

9-5000 INSERVICE INSPECTION

Part RB shall apply to inspection of Fiber Re-inforced Plastic (FRP) equipment, except asmodified herein. This section covers vesselsand tanks only and was not written to cover

piping and ductwork, although some of theinformation contained herein may be used forthe inspection of piping and ductwork.

9-5100 GENERAL

Typical FRP equipment consists of the struc-tural laminate (pressure-retaining material)and a liner (corrosion barrier) to protect thestructural laminate; Fig 9-5100-1. The structur-

al laminate is defined as one or more layers ofreinforced resin material bonded together. Inaddition to damage from mechanical sources,FRP material may be susceptible to damagefrom acids, alkalis, compounds containingfluorine, solvents, and hot clean water. For equipment fabricated with a liner, theprimary purpose of a process side inspectionis to assure the integrity of the liner to pre-vent chemical attack and degradation of thestructural laminate. For equipment fabricatedwithout a liner, the purpose of a process sideinspection is to determine the condition of thestructural laminate.

In addition to chemical attack, the laminate isalso susceptible to damage from:

• excessive service temperatures,• mechanical or service abuse,• ultra-violet light (See 9-5520)

Note: the liner (a) and the corrosion layer (b) areoptional.a = liner

b = corrosion layerc = structural laminate

Figure 9-5100-1 — Typical Vessel Shell

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9-5200 VISUAL EXAMINATION

Exposed surfaces shall be visually examinedfor defects, and mechanical or environmentaldamage in the liner or the laminate. Classifica-tion and acceptance of any defects in the liner

or laminate shall be according to Table 9-4021in this Appendix.

Defects to look for include:

• Cracks• Separation of secondary edges• Leaks, especially around nozzles• Discolored areas• Areas of mechanical damage, such as

impacts or gouges• Surface deterioration; fiber exposure• Cracked or broken attachments• Damage due to dynamic loading• Defective supports• Delaminations• Blisters

9-5300 INSPECTOR QUALIFICATIONS

The “R” Stamp holders inspector shall have

the following qualifications:

a. No fewer than five years of currentverifiable documented experience in anoccupational function that has a directrelationship to Reinforced Thermoplastic(RTP) fabrication and inspection, follow-ing customer or national standards, and bedirectly involved in the following activi-ties:

1. the development of plans, drawings,

procedures, inspection requirements,acceptance criteria, and personnelqualification requirements;

2. fabrication, contruction, and supervi-sion of personnel in the production ofassemblies or subassemblies;

3. detection and measurement of non-conformities by application of visualor other nondestructive evaluationprocesses to written procedures;

4. supervision of personnel engaged in

material and component examina-tion;

5. repairs of equipment or supervisionof personnel performing repairs;

6. preparation of written procedures forassembly, acceptance, nondestructiveevaluation or destructive tests;

7. qualification of secondary bonders,laminators, and welders to applicablecodes, standards, or specifications;

8. operation techniques or activities usedto fulfill quality control requirementsfor RTP fabrication or assembly;

9. train the occupational skills of fabrica-tion or assembly of RTP equipment.

b. The inspector shall meet the followingvisual and educational requirements:

1. be able to read a Jaeger Type No. 1standard chart at a distance of not lessthan 12 inches;

2. be capable of distinguishing and dif-ferentiating contrast between colors;

3. have visual acuity checked annuallyto assure natural or corrected neardistance vision;

4. be a high school graduate or hold astate or military approved high schoolequivalency diploma.

c. The employer of the inspector shall cer-tify that the employee complies with theabove qualification requirements.

A05

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9-5400 ASSESSMENT OF INSTALLATION

9-5410 PREPARATION

An observation shall be made of the conditionof the complete installation, including main-tenance and operation, as a guide in formingan opinion of the care the equipment receives.The history of the equipment shall be estab-lished, and shall include: date built, servicehistory, maintenance, and a review of previ-ous inspection records. Process conditionsshall be reviewed to identify areas most likelyto be attacked. Surface cleaning proceduresand requirements shall also be reviewed.

9-5420 LEAKAGE

Any leak shall be thoroughly investigated andcorrective action initiated. Repairs shall be inaccordance with 9-2000.

9-5430 TOOLS

The following tools may be required by the

inspector.

• Adequate lighting including overall light-ing and a portable lamp for close inspec-tions

• Handheld magnifying glass• Barcol hardness tester• Small pick or pen knife• Small quantity of acetone and cotton

swabs• Camera with flash capability• Liquid penetrant testing kit

9-5440 SAFETY

Inspectors shall take all safety precautionswhen examining equipment. Proper per-sonal protective equipment shall be worn,

equipment shall be locked out, blanked off,decontaminated, and confined space entrypermits obtained before internal inspectionsare conducted. In addition, inspectors shallcomply with plant safety rules associated withthe equipment and area in which they are

inspecting. Inspectors are also cautioned thata thorough decontamination of the interior ofvessels is sometimes very hard to obtain andproper safety precautions must be adhered toprevent contact or inhalation injury with anyextraneous substance which may remain inthe tank or vessel.

9-5500 EXTERNAL INSPECTION

9-5510 INSULATION OR OTHERCOVERINGS

It is not necessary to remove insulation andcorrosion resistant covers for examinationof the pressure equipment, if the coveringsshow no sign of mechanical impact, gouging,scratching, leaks, etc., and there is no reasonto suspect any unsafe condition behind them.Where insulation coverings are impervious,such as a sealed fiberglass jacket, it is recom-

mended that weep or drain holes be installedat the bottom of the insulation jacket as ameans to detect leakage.

9-5520 EXPOSED SURFACES

Exposed surfaces of pressure equipment aresubject to mechanical, thermal, and environ-mental damage. Exposed surfaces may showdamage from impact, gouging, abrasion,scratching, temperature excursions, etc. Sunlit

areas may be degraded by ultraviolet lightwith a resulting change in surface color andincreased fiber prominence, but with no lossin physical properties. Overheating may alsocause a change in color.

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9-5530

Areas that should be closely examined are:

• Nozzle attachments• Gusset attachments

• Flanges• Secondary joints• Hold down lugs• Lifting lugs• Attachments.

9-5540 STRUCTURAL ATTACHMENTS

Attachments of legs, saddles, skirts, or othercomponents shall be examined for crackswhere the component attaches to or contactsthe vessel and the component itself. See Figure9-5900-r.

9-5550

Piping loads on nozzles may be excessive.Therefore, all nozzles shall be closely exam-ined for cracks as shown in Figs. 9-5900-p and9-5900-cc.

9-5560

The location of external damage should benoted so that the opposing internal surface atthat location can be examined. For example,an impact load applied to the outer surfacemay be transmitted through the laminatecausing a star crack in the inner surface. SeeFigure 9-5900-t.

9-5600 INTERNAL INSPECTION

9-5610

FRP surfaces shall be dry and clean for theinspection. Every effort shall be made to mini-

mize damage to the liner during inspection.Defects to look for include:

• Indentations• Cracks• Porosity

• Exposed fibers• Lack of resin• Delaminations• Thinning at points of fluid impingement• Blisters• Scratches• Gouges• Discolorations.

9-5620 GENERAL

All surfaces shall be examined with bothdirect and oblique illumination. Color differ-ences, opacity, stains, wetness, roughness, orany deviation from the original surface (origi-nal cutout sample) condition shall be notedand investigated. Liquid level lines shall bedefined so the laminate condition in both thewet and dry zones can be determined. Thefollowing areas should be closely examinedfor cracks, porosity, or chemical attacks on theliner or laminate:

• Fittings• Changes in shape• Baffles• Secondary overlays• Nozzles• Cut edges• Supports/internal structures and areas of

attachment.

9-5630 EXAMINATION

The inspector shall look for cracks, porosity,and any indication of deterioration of the linerand/or laminate. Liquid penetrant examina-tion per RT-630 of ASME Section X may beused to locate and determine the extent ofcracks. Deterioration of the surface may in-clude softening or fiber prominence.

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A Barcol 934-1 hardness test (ASTM D-2583)shall be performed on areas of suspectedlaminate degeneration and areas that appearin good condition for comparison purposes.If the average Barcol test data indicates thatthe surface hardness of the laminate surfacing

veil is below 70% of the minimum acceptablehardness specified by the resin manufacturerfor a clear resin casting, then it is recommend-ed that the inspector consult with the resinmanufacturer as to the integrity of the linerlaminate. Note that resin hardness values may be lower than the initial value for new equip-ment. This should not be cause for concernif the complete veil portion of the corrosionresistant barrier is still present; retention ofresin hardness is dependent on the environ-ment to which resin laminates are exposed.Even if the veil is gone, there is generallyanother 80-mils of corrosion resistant barrierremaining, consisting of resin and choppedstrand glass mat. The resin hardness of a cor-rosion barrier without the veil may be highersince the glass content of that portion of thelaminate is higher. The resin hardness valuesshould be used to monitor the condition ofthe laminate over time as compared to theinitial hardness value. If the corrosion resis-tant barrier shows severe attack (for example,

loose chopped strand glass mat fibers) thatpenetration of the corrosion barrier appearsimminent before the next scheduled inspec-tion, it should be repaired.

9-5700 RECORD KEEPING

A detailed record of external and internal in-spections shall be retained by the owner forthe life of the FRP equipment.

9-5800 INSPECTION FREQUENCY

9-5810 NEWLY INSTALLED EQUIPMENT

a. The following factors should be consid-ered when determining the frequency of

inspection of FRP equipment that is newand recently placed into service.

• The distance between the FRP equip-ment and personnel or critical equip-ment

• Substance contained in the vessel is ofsuch a nature that if abruptly releasedit could threaten the health or safetyof personnel

• Contains chemicals or is subject to con-ditions known to degrade or shortenthe life of FRP laminates

• Past experience has shown that theservice application warrants morefrequent internal and external inspec-tions

• Insurance or jurisdictional require-ments

b. FRP equipment should be externallyinspected

• Once every 2 to 3 years after introduc-tion of process fluid — all findings are

to be documented in the equipmentinspection file for comparison to fu-ture inspection.

• If upsets outside the vessel designconditions in the process occur, exter-nal inspections shall be performed toensure equipment integrity.

• If prior experience (i.e. if equipmentwas recently replaced using samematerial/construction) dictates that

inspection frequency other than thatlisted is acceptable (through previ-ous inspections and records), then theinspection frequency may be altered.

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It is suggested to document using pho-tographs of the interior inspection

• If prior experience (i.e. if equipmentwas recently replaced using samematerial/construction) dictates that

inspection frequency other than thatlisted is acceptable (through previ-ous inspections and records) then theinspection frequency may be altered

• Some conditions may exist where en-try is prohibited and alternate meansof inspection must be considered

9-5900

The following pages contain photographs oftypical conditions that may exist in inserviceFRP vessels and piping.

Note: Figures 9-5900-j through 9-5900-u werereprinted with permission of the CopyrightOwner. © MATERIALS TECHNOLOGY IN-STITUTE, INC. (2002). The captions of the fig-ures were revised by the NBIC Committee.

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Figure 9-5900-a — Excessive Heat. Possible causes are localized hightemperature excursions.

Figure 9-5900-b — Laminate Voids at Overlaysvoids

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Figure 9-5900-c — Surface Deterioration. Possible causes are exposureto hot water and/or steam and chemical attack.

Figure 9-5900-d — Blisters. Possible cause is exposure to steam orpurified hot water.

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Figure 9-5900-e — Surface Erosion. Possible causes are high flow rateof fluids, erosion due to particulates in fluid, and chemical attack/soft-ening of resin.

Figure 9-5900-f — Corrosion/Erosion

surface erosion

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Figure 9-5900-g — Cracks. Possible cause is impact from an externalsource.

Figure 9-5900-h — Corrosion (Loss of Veil)

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Figure 9-5900-i — Shell Fracture. Possible cause is exterior impact.

Figure 9-5900-j — Concentrated Sulfuric Acid Attack

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Figure 9-5900-k — Blister

Figure 9-5900-l — Fiber Prominence. Possible cause is exposure tosunlight and no UV protection.

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Figure 9-5900-m — Color Change

Figure 9-5900-n — Cut Edge Evaluation

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Figure 9-5900-o — Erosion in the Liner

Figure 9-5900-p — Cracked Flange. Possible causes are incorrect matchup of flanges, over torque of bolts at fit up, manufacturing defect, orexcessive piping loads.

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Figure 9-5900-q — Gouge. Possible cause is mechanical damage.

Figure 9-5900-r — Gusset Crack. Possible causes are excessive loaddue to unsupported valve, pipe or overstress and age.

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Figure 9-5900-s — Cracks at the Knuckle. Possible cause is inadequateanchoring of vessel.

Figure 9-5900-t — Star Craze in Corroded Liner. Possible cause isexternal impact.

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Figure 9-5900-u — Sulfuric Acid Attack and Thermal Shock

Figure 9-5900-v — Air Bubbles Behind the Veil (shown afterchemical exposure).

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Figure 9-5900-w — Delaminations and Blisters. Possible causes areexposure to high heat or improper surface preparation of liner priorto structural application.

Figure 9-5900-x — Flange Cracking

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Figure 9-5900-y — Elastomeric Gasket Extruding. Possible causes areexcessive bolt torque or improper bolting sequence.

Figure 9-5900-z — Incorrect Gusset Attachment. Possible causes aregussets not extending out from flange a minimum of 30° from theaxis of nozzle neck or gusset attachments used as part of the flangethickness.

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Figure 9-5900-aa — Star Craze. Possible cause is external impact.

Figure 9-5900-bb — Excessive Use of Putty.

excess putty

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Figure 9-5900-cc — Cracked Flange. Possible cause is bolting dissimilarflanges together (full-faced flange with raised-face flange).

cracks

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Standard Welding Procedures

Appendix A

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APPENDIX A — STANDARD WELDING PROCEDURES

One or more Standard Welding Procedure Specifications (WPSs) from the following list may beused as an alternative to one or more WPS documents qualified by the organization making therepair, or alteration provided the organization accepts by certification (contained therein) fullresponsibility for the application of the Standard WPS in conformance with the application as

stated in the SWP. When using SWPs, all variables listed on the standard welding procedureare considered essential and, therefore, the repair organization cannot deviate, modify, amendor revise any SWP. Standard welding procedures shall not be used in the same product jointtogether with other standard welding procedures or other welding procedure specificationsqualified by the organization.

CARBON STEEL — (P1 MATERIALS)

SMAW — Shielded Metal Arc Welding

Standard Welding Procedure Specification (WPS) for Shielded Metal

Arc Welding of Carbon Steel, (M-1/P-1, Group 1 or 2), 3/16 in. (5 mm)through 3/4 in. (19 mm), in the As-Welded Condition, With Backing.

B2.1.001-90

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. through1-1/2 in. thick, E7018, As-Welded or PWHT Condition.

B2.1-1-016-94

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. through1-1/2 in. thick, E6010, As-Welded or PWHT Condition.

B2.1-1-017-94

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. through1-1/2 in. thick, E6010 (Vertical Uphill) followed by E7018, As-Welded orPWHT Condition.

B2.1-1-022-94

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. through1-1/2 in. thick, E6010 (Vertical Downhill) followed by E7018, As-Weldedor PWHT Condition.

B2.1-1-026-94

Standard Welding Procedure Specification (WPS) for Shielded Metal Arc

Welding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through 3/4in. thick, E6010 (vertical uphill) followed by E7018, As-Welded Condition,Primarily Pipe Application.

B2.1-1-201-96

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through 3/4in. thick, E6010 (vertical uphill), As-Welded Condition, Primarily PipeApplication.

B2.1-1-203-96

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APPENDIX A - STANDARD WELDING PROCEDURES

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through 3/4in. thick, E6010 (vertical downhill root with balance vertical uphill), As-Welded Condition, Primarily Pipe Application.

B2.1-1-204-96

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through 3/4in. thick, E6010 (vertical uphill) followed by E7018, As-Welded or PWHTCondition, Primarily Pipe Application.

B2.1-1-205-96

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through3/4 in. thick, E6010 (vertical downhill) followed by E7018, As-Welded orPWHT Condition, Primarily Pipe Application.

B2.1-1-206-96


Welding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through 3/4in. thick, E7018, As-Welded or PWHT Condition, Primarily Pipe Applica-tion.

B2.1-1-208-96

GTAW — Gas Tungsten Arc Welding

Standard Welding Procedure Specification (WPS) for Gas TungstenArc Welding of Carbon Steel, (M-1/P-1, Group 1 or 2), 3/16 in. (5 mm)through 7/8 in. (22 mm), in the As-Welded Condition, With or WithoutBacking.

B2.1.002-90

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through 3/4in. thick, ER70S-2, As-Welded or PWHT Condition, Primarily Pipe Ap-plication.

B2.1-1-207-96

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding (Consumable Insert) of Carbon Steel (M-1/P-1/S-1, Group 1or 2) 1/8 in. through 3/4 in. thick, INMs1 and ER70S-2, As-Welded orPWHT Condition, Primarily Pipe Application.

B2.1-1-210-96

Standard Welding Procedure Specification (WPS) for Gas Tungsten Arc

Welding with Consumable Insert Root of Carbon Steel (M-1/P-1/S-1,Group 1 or 2) 1/8 in. through 1-1/2 in. thick, INMs-1, ER70S-2, As-Weld-ed or PWHT Condition, Primarily Pipe Applications.

B2.1-1-210:2001

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FCAW — Flux Core Arc Welding

Standard Welding Procedure Specification (WPS) for Self-Shielded FluxCored Arc Welding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2),1/8 in. through 1-1/2 in. thick, E71T-8, As-Welded Condition.

B2.1-1-018-94

Standard Welding Procedure Specification (WPS) for CO2 Shielded Flux

Cored Arc Welding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2),1/8 in. through 1-1/2 in. thick, E70T-1 and E71T-1, As-Welded Condition.

B2.1-1-019-94

Standard Welding Procedure Specification (WPS) for 75% Ar/25% CO2

Shielded Flux Cored Arc Welding of Carbon Steel (M-1/P-1/S-1, Group1 or 2), 1/8 in. through 1-1/2 in. thick, E70T-1 and E71T-1, As-Welded orPWHT Condition.

B2.1-1-020-94

Standard Welding Procedure (SWP) for Self-Shielded Flux Cored ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. through1/2 in. thick, E71T-11, As-Welded Condition.

B2.1-1-027-1998

Carbon Steel — Combination Processes GTAW/SMAW

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding Followed by Shielded Metal Arc Welding of Carbon Steel(M-1/P-1/S-1, Group 1 or 2), 1/8 in. through 1-1/2 in. thick, ER70S-2 andE7018, As-Welded or PWHT Condition.

B2.1-1-021-94


Welding followed by Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through 3/4 in. thick, ER70S-2 and E7018,As-Welded or PWHT Condition, Primarily Pipe Application.

B2.1-1-209-96

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding (Consumable Insert) Followed by Shielded Metal Arc Weldingof Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through 3/4 in. thick,INMs1 and E7018, As-Welded or PWHT Condition, Primarily Pipe Ap-plication.

B2.1-1-211-96


Welding with Consumable Insert Root Followed by Shielded Metal ArcWelding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2) 1/8 in. through1-1/2 in. thick, INMs-1, ER70S-2, and E7018 As-Welded or PWHTCondition, Primarily Pipe Applications.

B2.1-1-211:2001

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AUSTENITIC STAINLESS STEEL — (P8 MATERIALS)



Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1),1/8 in. through 1-1/2 in. thick, As-Welded Condition.

B2.1-8-023-94

Standard Welding Procedure Specification (WPS) for Shielded Metal ArcWelding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in.through 2-1/2 in. thick, E3XX-XX, As-Welded Condition, Primarily PipeApplication.

B2.1-8-213-97


Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1),1/8 through 1-1/2 in. thick, As-Welded Condition.

B2.1-8-024-94

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1),1/16 through 1-1/2 in. thick, ER3XX, As-Welded Condition, PrimarilyPlate and Structural Applications.

B2.1-8-024:2001

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in.through 2-1/2 in. thick, ER3XX, As-Welded Condition, Primarily Pipe

Application.

B2.1-8-212-97

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1),1/16 in. through 1-1/2 in. thick, ER3XX, As-Welded Condition, PrimarilyPipe Applications.

B2.1-8-212:2001

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding With Consumable Insert Root of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. through 1-1/2 in. thick, IN3XX and ER3XXAs-Welded Condition, Primarily Pipe Application.

B2.1-8-215-2001

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Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding followed by Shielded Metal Arc Welding of Austenitic StainlessSteel (M-8/P-8/S-8, Group 1), 1/8 in. through 1-1/2 in. thick, As-Welded

Condition.

B2.1-8-025-94

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding followed by Shielded Metal Arc Welding of Austenitic StainlessSteel (M-8/P-8/S-8, Group 1) 1/8 in. through 1-1/2 in. thick, ER3XX andE3XX-XX, As-Welded Condition, Primarily Plate and StructuralApplications.

B2.1-8-025:2001

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding Followed by Shielded Metal Arc Welding of Austenitic StainlessSteel (M-8/P-8/S-8, Group 1), 1/8 in. through 2-1/2 in. thick, ER3XX and

E3XX-XX, As-Welded Condition, Primarily Pipe Application.

B2.1-8-214-97

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding Followed by Shielded Metal Arc Welding of Austenitic StainlessSteel (M-8/P-8/S-8, Group 1), 1/8 in. through 1-1/2 in. thick, ER3XX andE3XX-XX, As-Welded Condition, Primarily Pipe Applications.

B2.1-8-214:2001

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding With Consumable Insert Followed by Shielded Metal Arc Weld-ing of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. through1-1/2 in. thick, IN3XX, ER3XX, and E3XX-XX As-Welded Condition,

Primarily Pipe Application.

B2.1-8-216-1998

Standard Welding Procedure Specification (WPS) for Gas Tungsten ArcWelding with Consumable Insert Root followed by Shielded Metal ArcWelding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in.through 1-1/2 in. thick, IN3XX, ER3XX, and E3XX-XX As-Welded Condi-tion, Primarily Pipe Applications.

B2.1-8-216-2001

COMBINATION CARBON STEEL TO AUSTENITIC STAINLESS STEEL


Standard Welding Procedure Specifications (SWPS) for Shielded MetalArc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2) toAustenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. through1-1/2 in. thick, E309(L)-15, -16, or -17, As-Welded Condition,Primarily Pipe Applications.

B2.1-1/8-228:2002

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Standard Welding Procedure Specification (SWPS) for Gas TungstenArc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2) to Austen-tic Stainless Steel (M-8/P-8/S-8, Group 1), 1/16 in. through 1-1/2 in.

thick, ER309(L), As-Welded Condition, Primarily Pipe Applications.

B2.1-1/8-227:2002

Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding with Consumable Insert Root of Carbon Steel(M-1/P-1/S-1, Groups 1 or 2) to Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/16 in. through 1-1/2 in. thick, IN309 and ER309(L),As-Welded Condition, Primarily Pipe Applications.

B2.1-1/8-230:2002


Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding followed by Shielded Metal Arc Welding of Carbon Steel(M-1/P-1/S-1,Groups 1 or 2) to Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. through 1-1/2 in. thick, ER309(L) and E309(L)-15,-16, or -17, As-Welded Condition, Primarily Pipe Applications.

B2.1-1/8-229:2002

Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding with Consumable Insert Root followed by Shielded MetalArc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2) toAustenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. through1-1/2 in. thick, IN3009, ER309, and E309-15, -16, or -17 or IN309,ER309(L) and ER309(L)-15, -16, or -17, As-Welded Condition, Primarily

Pipe Applications.

B2.1-1/8-231:2002

CHROMIUM MOLYBDENUM STEEL (P4 AND P5A MATERIALS)


Standard Welding Procedure Specifications (SWPS) for Shielded MetalArc Welding of Chromium-Molybdenum Steel (M-4/P-4, Group 1 or2), E8018-B2, 1/8 in. through 1/2 in. thick, As-Welded Condition,1/8 in. through 1-1/2 in. thick, PWHT Condition, Primarily PipeApplications.

B2.1-4-218:1999

Standard Welding Procedure Specifications (SWPS) for Shielded MetalArc Welding of Chromium-Molybdenum Steel (M-5A/P-5A),E9018-B3, 1/8 in. through 1/2 in. thick, As-Welded Condition, 1/8 in.through 1-1/2 in. thick, PWHT Condition, Primarily PipeApplications.

B2.1-5A-223:1999

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Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding of Chromium-Molybdenum Steel (M-4/P-4, Group 1 or2), ER80S-B2, 1/8 in. through 1/2 in. thick, As-Welded Condition,

1/8 in. through 3/4 in. thick, PWHT Condition, Primarily PipeApplications.

B2.1-4-217:1999

Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding (Consumable Insert Root) of Chromium-MolybdenumSteel (M-4/P-4, Group 1 or 2), E8018-B2, 1/8 in. through 1/2 in. thick,As-Welded Condition, 1/8 in. through 3/4 in. thick, PWHT Condition,IN515 and ER80S-B2, Primarily Pipe Applications.

B2.1-4-220:1999

Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding of Chromium-Molybdenum Steel (M-5A/P-5A), ER90S-

B3, 1/8 in. through 1/2 in. thick, As-Welded Condition, 1/8 in. through3/4 in. thick, PWHT Condition, Primarily Pipe Applications.

B2.1-5A-222:1999

Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding (Consumable Insert Root) of Chromium-MolybdenumSteel (M-5A/P-5A), 1/8 in. through 1/2 in. thick, As-Welded Condi-tion, 1/8 in. through 3/4 in. thick, PWHT Condition, IN521 and ER90S-B3, Primarily Pipe Applications.

B2.1-5A-225:1999

Chromium-Molybdenum Steel Processes GTAW/SMAW

Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding followed by Shielded Metal Arc Welding of Chromium-Molybdenum Steel (M-4/P-4, Group 1 or 2), 1/8 in. through 1/2 in.thick, As-Welded Condition, 1/8 in. through 1-1/2 in thick, PWHTCondition, ER80S-B2 and E8018-B2, Primarily Pipe Applications.

B2.1-4-219:1999

Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding (Consumable Insert Root) followed by Shielded Metal ArcWelding of Chromium-Molybdenum Steel (M-4/P-4, Group 1 or 2),1/8 in. through 1/2 in. thick, As-Welded Condition, 1/8 in. through1-1/2 in. thick, PWHT Condition, IN515, ER80S-B2, and E8018-B2,

Primarily Pipe Applications.

B2.1-4-221:1999

Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welded followed by Shielded Metal Arc Welding of Chromium-Molybdenum Steel (M-5A/P-5A), 1/8 in. through 1/2 in. thick,As-Welded Condition, 1/8 in. through 1-1/2 in. thick, PWHT Condi-tion, ER90S-B3 and E9018-B3, Primarily Pipe Applications.

B2.1-5A-224:1999

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Standard Welding Procedure Specifications (SWPS) for Gas TungstenArc Welding (Consumable Insert Root) followed by Shielded MetalArc Welding of Chromium-Molybdenum Steel (M-5A/P-5A),1/8 in. through 1/2 in. thick, As-Welded Condition, 1/8 in. through1-1/2 in. thick, PWHT Condition, IN521, ER90S-B3, and E9018-B3,

Primarily Pipe Applications.

B2.1-5A-226:1999

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Recommended Preheat Temperatures

Appendix B

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APPENDIX B — RECOMMENDED PREHEAT TEMPERATURES

B-1000 SCOPE

Some minimum temperatures for preheat-ing are given below as a general guide. It is

cautioned that the preheating temperatureslisted do not necessarily ensure satisfactorycompletion of the welded joint. Require-ments for individual materials within theP-Number listing may have preheatingrequirements more or less restrictive thanthis general guide. When reference is madein this Appendix to materials by the ASMEdesignation, P-Number and Group Num- ber, the suggestions of this Appendix applyto the applicable materials of the originalcode of construction, either ASME or other,which conform by chemical composition andmechanical properties to ASME materials hav-ing the ASME P-Number and Group Numberdesignations. (See RC-1101)

B-2000 MINIMUM TEMPERATURESFOR PREHEATING

Thicknesses referenced to are nominal at theweld for the parts to be joined.

1. P-No. 1 Group Nos. 1, 2, and 3

a. 175˚F (79˚C) for material that has botha specified maximum carbon contentin excess of 0.30% and a thickness atthe joint in excess of 1 in.

b. 50˚F (10˚C) for all other materials inthis P-Number.


a. 175˚F (79˚C) for material that haseither a specified minimum tensilestrength in excess of 70,000 psi (480MPa) or a thickness at the joint inexcess of 5/8 in. (16 mm).


3. P-No. 4 Group Nos. 1 and 2

a. 250˚F (120˚C) for material that haseither a specified minimum tensilestrength in excess of 60,000 psi (410MPa) or a thickness at the joint inexcess of 1/2 in. (13 mm).

b. 50˚F (10˚C) for all other materialsin this P-Number.

4. P-No. 5A Group 1 and 5B, Group 1

a. 400˚F (205˚C) for material that haseither a specified minimum ten-sile strength in excess of 60,000 psi(410 MPa) or has both a specified mini-mum chromium content above 6.0%and thickness at the joint in excess of1/2 in. (13 mm).



400˚F (205˚C)


None


None

8. P-No. 9 Group

a. 250˚F (120˚C) for P-9A Gr. 1 materials

b. 300˚F (150˚C) for P-9B Gr. 1 materials

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APPENDIX B — RECOMMENDED PREHEAT TEMPERATURES

9. P-No. 10 Group

a. 175˚F (79˚C) for P-10A Gr. 1 materials

b. 250 F̊ (120˚C) for P-10B Gr. 2 materials

c. 175˚F (79˚C) for P-10C Gr. 3 materials

d. 250˚F (120˚C) for P-10F Gr. 6 materials

e. For P-10C Gr. 3 materials, preheat isneither required nor prohibited, andconsideration shall be given to thelimitation of interpass temperaturefor various thicknesses to avoid det-rimental effects on the mechanicalproperties of heat treated material.

f. For P-10D Gr. 4 and P-10E Gr. 5materials, 300˚F (150˚C) with interpasstemperature maintained between350˚F and 450˚F (175˚C and 230˚C).

10. P-No. 11 Group

a. P-11A Group Group 1 - None (Note 1) Group 2 - Same as for P-No. 5

(Note 1)

Group 3 - Same as for P-No. 5(Note 1)

Group 4 - 250˚F (120˚C)

b. P-11B Group Group 1 - Same as for P-No. 3

(Note 1) Group 2 - Same as for P-No. 3






(Note 1)

Note 1: Consideration shall be given tothe limitation of interpass temperature forvarious thicknesses to avoid detrimental

effects on the mechanical properties of heattreated materials.

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APPENDIX C — HISTORICAL BOILERS

C-1000 PURPOSE

This section provides recommended require-ments for the inspection and repair of histori-

cal steam boilers.

C-1010 SCOPE

Historical steam boilers of riveted construc-tion, preserved, restored, or maintained forhobby or demonstration use.

C-2000 PRE-INSPECTION REQUIREMENT

See RB-2210 Internal Inspection of Boilers.

C-2010 INITIAL INSPECTION

The results of examinations and tests shall bedocumented by an inspector, acceptable to the jurisdiction, who has demonstrated knowl-edge with historical boilers. The followingexaminations and tests shall be performed:

a. An internal and external visual inspection(See Boiler Inspection Guideline).

b. All threaded openings in the boiler shall be inspected.

c. Ultrasonic thickness testing and evalua-tion of all pressure-retaining boundaries.Ultrasonic results in areas of generalizedthinning (3 in. (75 mm) in diameter orgreater) or where grooved thinning is

noted (2 in. (50 mm) in length or greater)are to be used in calculating MAWP inaccordance with C-8000.

d. A hydrostatic pressure test at 1.25 timesMAWP, but in no case shall the test pres-sure be exceeded by more than 6%.

e. The inspector may require other examina-tions to be performed, including but notlimited to:

1. An ultrasonic transverse wave exami-nation in two directions at 90° to eachother of the longitudinal lap seam forcracks located between or adjacent torivet holes.

2. A magnetic particle examination of100% of the longitudinal seam rivetedarea, and an ultrasonic (longitudinalwave mode) examination of 10% ofthe rivets for shear failure.

3. An ultrasonic examination (longitudi-nal wave mode) of all firebox stayboltsand rivets.

4. A liquid penetrant examination.

5. Drilling or trepanning of pressure-retaining components.

C-2020 RECURRING INSPECTION

REQUIREMENTS

The following examinations and tests shall be performed:

a. Annual visual internal and externalinspection (See Boiler Inspection Guide-line).

b. Annual visual inspection of the fusibleplugs to determine the condition of thethreads in the crown sheet and on the

fusible plug. The fusible plugs shall beremoved, inspected, and confirmed as anASME Std. plug.

c. Annual hydrostatic test at a pressure atleast equal to MAWP up to 1.25 timesMAWP, but in no case shall the test pres-sure exceed 1.25 times MAWP by morethan 6%.

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d. Every five years ultrasonic thickness test-ing.

e. Additional testing and examination asdeemed necessary by the inspector.

C- 2030 SAFETY DEVICES AND CONTROLS

Each boiler shall be equipped with the fol-lowing safety devices and controls. Pressurerelief valve(s), gage glasses, try-cocks, fusibleplugs, and pressure gages shall be tested dur-ing each inspection.

C-2031 PRESSURE RELIEF VALVES

Pressure relief valve(s) shall be NationalBoard capacity certified.

Pressure relief valve(s) shall be sealed by anASME “V” Stamp assembler or NB “VR”repair firm.

The required pressure relief valve capacity inpounds per hour shall be calculated by boilerheating surface area and type of fuel used. Ex-

cessive pressure relief valve capacity should be avoided. (Only heating surface area abovethe grates to be used.)

Minimum pounds of steam per hour persquare foot of heating surface (kg/hr/sq. 0.3 m).

Boiler Heating Firetube WatertubeSurface Boiler Boiler

hand fired 5 6

stoker fired 7 8

oil, gas, or pulverized fuel fired 8 10

Pressure relief valve(s) shall have a test lever.

No valve of any description shall be placed between the required pressure relief valve or

valves and the boiler, nor on the dischargepipe between the valve and the atmosphere.

The piping connection between the boilerand the safety valve shall not be less than theinlet size of the safety valve, and the discharge

pipe, if used, shall not be reduced between thesafety valve and the point of discharge.

C-2032 GAGE GLASS

The gage glass shall be fit with a guard toprotect the gage glass.

The gage glass shall indicate the minimumsafe operating water level.

The gage glass shall be provided with a drainvalve or petcock, piped to a safe location.

The gage glass shall be fully operational.

C-2033 TRY-COCKS

Try-cocks shall be correctly located in refer-ence to the minimum required water level.

Try-cocks shall be fully operational

C-2034 FUSIBLE PLUG

All boilers shall have a fusible plug unlessequipped and operated with automatic con-trols.

All fusible plugs shall be constructed to meetthe requirements of the ASME Code, and in-dicated as such by the ASME marking on the

filler material.

Fireside fusible plugs must protrude a mini-mum of one inch into the water.

Waterside fusible plugs may not protrude intothe fire area more than one inch.

Fusible plugs shall not be refilled.

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C-2035 PRESSURE GAGE

Tested and proven accurate at the time of theannual pressure test.

Siphon, or water seal, shall be installed be-

tween pressure gage and boiler.

If a valve is installed between the gage andthe boiler, the valve shall indicate the openposition or be wired open.

C-2040 APPURTENANCES

C-2041 PIPING AND FITTINGS All boiler piping and fittings shall meet thefollowing requirements:

a. Threaded openings shall follow acceptedstandard piping practices.

b. Schedule 80, black pipe (SA-53 B or SA-106B) shall be used from the boiler to the firstvalve.

c. All steam piping components shall be

used in the manner for which they weredesigned and shall not exceed manufac-turer’s pressure rating.

d. The boiler shall be equipped with twomeans of supplying feedwater while the boiler is under pressure. Pumped watershall be heated.

e. The blowdown line shall be plugged offduring the time the boiler is operating ondisplay, or piped to a safe point of dis-

charge.

f. All piping shall be properly supported.

C-3000 REPLACEMENTS

The installation date should be stamped orstenciled on all replaced boiler piping. Alter-natively, the installation date may be docu-mented in permanent boiler records.

C-4000 MAXIMUM ALLOWABLE WORKING PRESSURE

The maximum allowable working pressureof a boiler shall be determined by computingthe strength of each component to find theweakest point. The strength of the weakestcomponent and the factor of safety allowed by these rules shall determine the maximumallowable working pressure. The followingshall be used to compute the strength of each boiler component.

C-4010 STRENGTH

In calculating the MAWP, when the ten-sile strength of the steel or wrought iron isknown, that value shall be used. When thetensile strength of the steel or wrought ironis not known, the values to be used are 55,000

psi (380 MPa) for steel and 45,000 psi (310MPa) for wrought iron. Original steel stampmarks, original material certifications, or cur-rent laboratory tests are acceptable sourcesfor verification of tensile strength. Catalogsand advertising literature are not acceptablesources for tensile strength values.

In computing the ultimate strength of rivetsin shear, the following values in pounds persquare inch of the cross-sectional area of therivet shanks shall be used:

Iron rivets in single shear ...........38,000 (260 MPa)

Iron rivets in double shear .........76,000 (520 MPa)

Steel rivets in single shear ..........44,000 (300 MPa)

Steel rivets in double shear ........88,000 (600 MPa)

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The resistance to crushing of mild steel shall be taken as 95,000 psi (655 MPa) of cross-sec-tional area.

C-4020 RIVETS

When the diameter of the rivet holes in thelongitudinal joints of a boiler is not known,the diameter of rivets, after driving, may beascertained from the table below.

Sizes of Rivets Based on Plate Thickness

Thickness of 1/4 9/32 5/16 11/32 3/8 13/32Plate, inches (6) (7) (8) (9) (10) (10)(mm)

Diameter of 11/16 11/16 3/4 3/4 13/16 13/16Rivet after (17) (17) (19) (19) (21) (21)Driving,inches (mm)

Thickness of 7/16 15/32 1/2 9/16 5/8Plate, inches (11) (12) (13) (14) (16)(mm)

Diameter of 15/16 15/16 15/16 1-1/16 1-1/16Rivet after (24) (24) (24) (27) (27)Driving,inches (mm)

C-4030 CYLINDRICAL COMPONENTS

The maximum allowable working pressure ofcylindrical components under internal pres-sure shall be determined by the strength ofweakest course computed from the thicknessof the plate, the tensile strength of the plate,the efficiency of the longitudinal joint, the

inside diameter of weakest course, and thefactor of safety allowed by these rules usingthe following formula:

TS x t x E= maximum allowable working pressure (MAWP), psi

R x FS

C-4040 STAYED SURFACES

The maximum allowable working pressurefor stayed flat plates and those parts which, by these rules, require staying as flat plateswith stays or staybolts of uniform diameter

symmetrically spaced, shall be calculatedusing the following formulas:

t2 x TS x C = maximum allowable working pressure (MAWP), psi

FS x p2

C-4050 BRACED AND STAYED SURFACES (REQUIRED

BRACE OR STAYBOLT DIAMETER)

The MAWP based on the net minimum diam-eters of staybolts shall be computed using thefollowing formula:

π x d2 x TS = maximum allowable working pressure (MAWP), psi

FS x 4 x p2

The “d” in the formula refers to the diameterof the staybolt at the base of the threads orthe smallest diameter as specified in ASMESection I, Pg-49.2, and “TS” in the formularefers to the ultimate tensile strength of thestaybolt material. For stayed curved plates,the ratio between TS/FS in the formula shallnot exceed 7500 psi as referenced in ASMESection I, PFT 23.3.

C-4060 CONSTRUCTION CODE

In order to address the many pressure-relatedcomponents and features of construction en-countered in firetube boilers, a reprint of the

1971 Edition of Section I of ASME Boiler Code,Part PFT is provided.

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C-4070 NOMENCLATURE

The nomenclature for the terms used in theabove equations is:

C = 2.1 for welded stays or stays screwed

through plates not over 7/16 in.(11 mm) in thickness with ends riv-eted over

C = 2.2 for welded stays or stays screwedthrough plates over 7/16 in. (11 mm)in thickness with ends riveted over

C = 2.5 for stays screwed through platesand fitted with single nuts outsideof plate, or with inside and outsidenuts, omitting washers

C = 2.8 for stays with heads not less than1.3 times the diameter of the staysscrewed through plates, or madea taper fit and having the headsformed on the stays before install-ing them and not riveted over, saidheads being made to have true bear-ing on the plate

C = 3.2 for stays fitted with inside andoutside nuts and outside washerswhere the diameter of washers isnot less than 0.4p and thickness notless than t.

Note: the ends of stays fitted with nuts shallnot be exposed to the direct radiant heat ofthe fire.

d = diameter of staybolt over the threads,in.

E = efficiency of the longitudinal joint

The following is a table of efficiencies whichare the average for the different types of joints.

Type of Riveting Lap Butt

single 58double 74 82triple 88quadruple 94

Note: The efficiency of a particular jointdepends upon the strength of the plate andrivet, thickness of the plates, and the diameterof the rivets. The 1971 Edition of Section I ofthe ASME Code, Appendix A-1 through A-7,provides a method for calculating a specific

joint efficiency that should be used with theconcurrence of the jurisdiction.

FS = 5 (A jurisdiction may mandate ahigher factor of safety or permit alower factor of safety, but in no casemay the factor of safety be less than4)

p = maximum pitch measured betweenstraight lines passing through thecenters of the staybolts in the dif-ferent rows, which lines may behorizontal, vertical, or inclined, in.(mm)

R = inside radius of the weakest courseof shell or drum, in. (mm)

TS = ultimate tensile strength of shellplates, psi (MPa)

t = minimum thickness of shell plate inthe weakest course, in. (mm)

C-5000 LIMITATIONS

The maximum allowable working pressureshall be the lesser of that calculated by C-4050 or the MAWP established by the originalmanufacturer.

The shell or drum of a boiler in which a typi-cal “lap seam crack” extending parallel to thelongitudinal joint and located either betweenor adjacent to rivet holes, is discovered alonga longitudinal riveted joint for either butt orlap joint shall be permanently discontinued

for use under steam pressure.

C-6000 REPAIRS

Repairs to boilers of historical nature should be performed with consideration towardspreserving the authenticity of original design,while at the same time ensuring that the boiler

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is safe to operate at the pressure allowed byC-8000.

C-6010 CONSTRUCTION STANDARDS

Repairs shall conform to the requirements ofthe original construction standard insofar aspossible. If the original construction standardis unknown or unavailable, the boiler shall be considered a boiler of locomotive designas described in Appendix 3 , and subject tothe construction standard most applicable tothe boiler design. The construction standardselected for the repair must meet the approvalof the jurisdiction.

C-6020 ACCREDITATION

Organizations performing welded repairsshall be accredited as described in Part RA. Organizations performing nonwelded repairsshall be otherwise acceptable to the jurisdic-tion by having demonstrated competency inthe repair of boilers of locomotive design.

C-6030 MATERIALS

Materials used in making repairs shall con-form to the original construction standard, ifknown, or to a construction standard accept-able to the jurisdiction. Carbon or alloy steelshaving a carbon content greater than 0.35%shall not be welded. The repair organizationis responsible for verifying identification ofexisting and replacement materials.

C-6040 REPLACEMENT PARTS

Replacement pressure parts formed by cast-ing, forging, or die forming, and on which nowelding has been performed, shall be sup-plied as material. Such parts shall be markedwith the material identification required bythe construction standard used for the repair.Replacement pressure parts fabricated by

welding shall be manufactured by an organi-zation certified as required by the constructionstandard used for the repair. Where there is nomanufacturer prepared to supply parts fabri-cated by welding, an organization accreditedas described in Part RA may fabricate the part

with the approval of the jurisdiction.

C-6050 WELDED REPAIR INSPECTION

Prior to commencing any welded repairsto the pressure boundaries of historic boil-ers, the repair organization shall obtain anInspector’s approval of the proposed repair.The Inspector shall be an employee of eithera jurisdiction, as defined in Appendix 4 , or ofthe Authorized Inspection Agency contracted by the repair organization. The Inspector shallassure the repairs are performed in accordancewith the approved construction standard, andshall witness any nondestructive or pressuretesting of the completed repair.

C-6060 WELDING

Welding shall be performed in accordance

with the requirements of the approvedconstruction standard in consultation withthe inspector identified in C-4000. A repairorganization accredited as described in PartRA may use the Standard Welding ProcedureSpecifications shown in Appendix A , as ap-plicable. Welders shall be qualified for thewelding processes used. Qualification shall bein accordance with the approved constructionstandard, or Section IX of the ASME Code.

C-6070 HEAT TREATMENT

Preheating may be used to assist in comple-tion of the welded joint. Consideration should be given to the percentage of carbon contentand to the thickness of the original boilermaterials. Preheat temperatures shall be speci-fied by the welding procedure specification being used.

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Postweld heat treatment shall be performedas required by the accepted constructionstandard, in accordance with written proce-dures.

Welded repairs at or near riveted seams re-

quiring preheat or postweld heat treatmentshall be carefully made in order to preventloosening in the riveted seams, especiallywhen localized heat treatment is used.

Alternative postweld heat treatment methodsshould be used with the inspector’s approval.Welding methods that should be used asalternatives to postweld heat treatment aredescribed in Part RD.

C-6080 NONDESTRUCTIVE EXAMINATION

The Inspector may require nondestructiveexamination (RT, PT, MT, UT, VT) as necessaryto ensure satisfactory welded repairs have been accomplished.

C-6090 DOCUMENTATION

Organizations performing repairs to historic boilers shall document the repair as required by the jurisdiction.

Permanent documentation detailing repairs,inspections, etc. should be retained by theowner.

BOILER INSPECTION GUIDELINE

Owner

Location

Make

Year Engine No.

Heating Surface Design Pressure Current Operating Pressure

Inspector

Smoke Box

1. Front Tube Sheet

a. Check condition of sheet and thicknessaround handhole openings.

b. Check condition of threaded openingsand plugs.

c. Check condition of rivets betweensheet and shell.

2. Tubes

a. Are tubes beaded?

b. Are there signs of leakage?

3. Check condition of smoke box shell (especially around lower surfaces).

4. Check inside condition of barrel and O.D.of tubes.

5. Check back side of tube sheet (especiallyarea in contact with handhole gasket andarea where tube sheet joins barrel).

6. Check tube sheet supports (through stays,supports, or strong backs).

7. Check inside rivet heads on lap or butt-

strap joints.

8. Check front bolster (front axle) attachmentpoints inside shell.

Barrel (shell)

1. Check front bolster attachment pointson outside of shell.

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2. Check condition of tubesheet rivets onoutside of shell.

3. Check condition of threaded openings andplugs in openings.

4. Check radius rod attachment point.

5. Check attachment points of studs, cast-ings, brackets, accessories, etc.

6. Check plumbing openings on shell (feed-water nozzles, steam take off, water col-umn, etc.).

7. Check handhole openings in shell.

8. Lap seam or buttstrap

a. Check for leakage around seams or joint rivets.

b. Confirm joint eff iciency based onnumber of rows of rivets and type of joint.

9. Identify and check any external contourthat does not appear normal.

10. Jacket

a. Does jacket cover any critical areas ormake them difficult to observe?

b. Is barrel pitted or corroded under jacket?

Wrapper Sheet

1. Check handhole openings (material thick-ness, gasket area, etc.).

2. Check for seepage around attachmentpoints (wing sheets, axle supports, etc.).

3. Check condition of seams joining wrapperto throat sheet and rear head.

4. Check condition of seams joining throatsheet to barrel.

5. Check external shapes or contours that donot appear normal.

6. Check for seepage around stayboltheads.

7. Check condition of staybolt heads. 8. Check condition of threaded openings.

9. Check internal surfaces (cracks, pits, mate-rial thickness).

10. Check staybolt thickness and condition.

11. Check for scale and mud buildup in wa-terlegs.

12. Check for buildup of dirt and grease be-tween or behind attaching brackets suchas wing sheets.

13. a. Dry bottom boilers

i. Check seams at bottom of water-legs in ash pan area.

ii. Do you need to remove ashpans and grates to observe above

seams?

iii. Check condition of grate support brackets.

b. Wet bottom boilers

i. Check ash pan area for pits andstaybolt head condition.

ii. Check inside bottom of wrapper

and staybolt condition.

iii. Check condition of lap seam in

wrapper. iv. Check condition of ash pan drain

tube if present.

14. Check for presence and condition of blow-down valve.

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Dome

1. Check for presence and condition of drain- back holes in shell.

2. Check condition of main line shutoff

valve.

3. Check condition of plumbing on main-stream line and on dome.

4. Check condition of dome seams andseams between dome and boiler shell.

a. Is seepage present? b. Can interior seams be observed?

5. Check for presence and condition of pres-sure gage.

a. Is there a siphon, and what is its condi-tion?

b. Is the gage readable from the opera-

tor’s position?

c. Has the gage been calibrated orchecked against another gage?

d. If a shutoff valve is present, its handleshall indicate open position, or thehandle shall be wired open.

6. Check for presence and condition of safetyvalve.

a. Does it have its own inlet/outlet pip-ing with no possibility of closure?

b. Check that the inlet pipe size is not

smaller than the valve inlet size.

c. Check that the outlet pipe size is notsmaller than the valve outlet size.

d. Is it a National Board capacity certi-fied, ASME “V”/NB “VR” stampedvalve of proper pressure and capacityrating for the boiler heating surface?

e. Does it have a try lever?

f. Is it sealed with a factory seal?

Water Column and Water Glass

1. Is water glass calibrated to level of crownsheet?

2. Check condition of try-cock valves and blowdown valves on column and glass.

3. Check condition of glass (cracks orscratches).

4. Are there leaks around the water glassgaskets?

Firebox

1. Check for bulges or abnormal shapes(What caused them?).

2. Check seams around fire door.

3. Check for sediment buildup over fire dooropening rear head.

4. Check for sediment buildup over peep-

hole opening in wrapper sheet (whereapplicable).

5. Check condition of fusible plug. (Must beremoved for observation.)

a. Is it an ASME plug?

b. Check condition of top surface. (Mayneed to brush it off.)

6. When fusible plug is removed, check

crown sheet thickness at that location andthread condition.

7. Fireside fusible plug must protrude aminimum of 1 in. (25 mm) into water.

8. Waterside fusible plug may not protrudeinto fire area of more than 1 in. (25 mm).

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9. Water glass calibration can only be donewhen crown sheet and fusible plug can be seen and measured. (A recommendedminimum water level may be determinedas follows: With engine sitting on levelground and water just observable at the

bottom of the glass, the crown sheetshould be covered by a minimum of atleast 2-1/2 in. plus on a full-size boiler.

10. Check staybolt condition, especially neartop surface of crown sheet.

11. Check through stays, strong backs, knee braces, etc., on rear head.

12. Check handhole openings, threaded open-ings and plugs in rear head.

13. Check condition of rear tube sheet, andcheck if rear end of tubes are beaded.

14. Check condition of staybolt heads insidefire box.

15. Check condition or design of crown sheet.Is it flat-topped or able to trap water?

External Plumbing

1. Is black pipe (as opposed to galvanized)used throughout?

2. Check for use of Schedule 80 black piperequired between boiler and first valve.

3. Are fittings of proper pressure rating foroperating pressure?

4. Are isolation valves present to shut offindividual system lines?

5. Are two separate feedwater systems pres-ent and operable?

6. Check plumbing for frost damage.

7. Are plumbing support brackets presentwhere needed?

8. Fittings dates are to be stamped, stenciled,or recorded on boiler records.

9. 20-year life on piping except for mainsteam line which shall be evaluated as tolife.

Ultrasonic Testing (Every fifth year)

Hydrostatic Pressure Test (Annually)

1. Hydrostatic pressure test should be be-tween maximum allowable working pres-sure and 1.25 times maximum allowableworking pressure with water temperatureat 60° to 120° F (16° to 50° C).

2. An accurate gage with proven accuracyshall be used when hydrostatically pres-sure testing a boiler. The engine gage shall be calibrated at this time.

3. Safety valve may be checked against testgage and/or engine gage. (Test shouldonly be performed at a pressure greaterthan 75% of the stamped set pressure ofthe valve or the safety valve or lifting levermay be damaged.)

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PART PR — REQUIREMENTS FOR BOILERS FABRICATED BY RIVETING

GENERAL

PR-1 SCOPE

The rules in Part PR are applicable to boilersand parts thereof that are fabricated by rivet-ing and shall be used in conjunction with thegeneral requirements in Part PG as well aswith the specific requirements in the appli-cable Parts of this Section that pertain to thetype of boiler under construction.

MATERIALS

PR-5 GENERAL

Materials entering into the construction ofriveted boilers shall comply with the require-ments for materials given in PG-5 throughPG-14.

DESIGN

PR-9 GENERAL

The rules in the following paragraphs applyspecifically to the design of boilers and partsthereof that are fabricated by riveting andshall be used in conjunction with the generalrequirements for Design in Part PG as well aswith the specific requirements for Design inthe applicable Parts of this Section that pertainto the type of boiler under consideration.

PR-10 STRENGTH OF PLATES

In determining the maximum allowableworking pressure, the maximum allowableworking stress in Table PG-23.1 shall be usedin the computations.

PR-11 STRENGTH OF RIVETS

In computing the ultimate strength of rivets

in shear, the values given in Table PG-23.4 inpounds per square inch of the cross-sectionalarea of the rivet shank shall be used.

PR-12 CRUSHING STRENGTH OF PLATES

The resistance to crushing of steel plate inpounds per square inch of cross-sectional areashall be taken from Table PG-23.5.

PR-14 THICKNESS OF BUTTSTRAPS

The minimum thickness of buttstraps fordouble-strap joints shall be as given in TablePR-14 in which the required thickness of theshell is that obtained by the rules given inPG-27.2 employing a value of E correspond-ing to the efficiency of the buttstrap joint.Intermediate values shall be determined byinterpolation. Where the required thicknessof the plate exceeds 1-1/2 in., the thickness of

the buttstraps shall be not less than two-thirdsof the required thickness of the plate. In nocase shall either of the buttstraps have a lesserthickness than one-half the actual thicknessof the plate.

PR-15 JOINT EFFICIENCY

The efficiency of a joint is the ratio which thestrength of the joint bears to the strength ofthe solid plate. In the case of a riveted jointthis is determined by calculating the breakingstrength of a unit section of the joint, consider-ing each possible mode of failure separately,and dividing the lowest result by the breakingstrength of the solid plate of a length equal tothat of the section considered (see A-1 throughA-7 f or detailed methods and examples).

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PR-16 LONGITUDINAL JOINTS to resist the total longitudinal force acting onthe joint with a factor of safety of 5. The totallongitudinal force is determined by the fol-lowing formula:

F = 3.14R2P

where,F = total longitudinal force, poundsR = radius of the circular area acted on

by the pressure in producing thetotal longitudinal force on the joint,inches

P = pressure, pounds per square inch

17.2 When 50 percent or more of the total forceas described in PR-17.1 is relieved by the effectof tubes or through stays, in consequence ofthe reduction of the area acted on by the pres-sure and the holding power of the tubes andstays, the strength of the circumferential jointsshall be at least 70 percent of that required byPR-17.1.

PR-20 TRANSVERSE PITCH (BACKPITCH) OF ROWS OF RIVETS

20.1 For longitudinal joints the distance

between the centerlines of any two adjacentrows of rivets, or the “back pitch” measured atright angles to the direction of the joint, shallhave the following minimum values:

20.1.1 If P/d is 4 or less, the minimumvalue shall be 2d.

20.1.2 If P/d is over 4, the minimum valueshall be:

2d + 0.1 (P - 4d)

where, P = pitch of rivets in outer row where a

rivet in the inner row comes midway between two rivets in the outer row,inches

16.1 The riveted longitudinal joints of a shellor drum which exceeds 36 in. in diametershall be of butt- and double-strap construc-tion. This rule does not apply to the portion

of a boiler shell which is staybolted to thefirebox sheet.

16.2 The longitudinal joints of a shell or drumthat does not exceed 36 in. in diameter may beof lap-riveted construction, but the maximumallowable working pressure shall not exceed100 psi.

TABLE PR-14 —Minimum Thickness Of Buttstraps

Required Thickness Minimum Thicknessof Steel Plate, in. of Buttstraps, in.

1/4 1/4 9/32 1/4 5/16 1/4 11/32 1/4 3/8 5/16 13/32 5/16

7/16 3/8 15/32 3/8

1/2 7/16 17/32 7/16 9/16 7/16 5/8 1/2

3/4 1/2 7/8 5/8 1 11/16 1-1/8 3/4 1-1/4 7/8 1-1/2 1

PR-17 CIRCUMFERENTIAL JOINTS

17.1 The strength of a riveted circumferential joint of a boiler, the heads of which are notstayed by tubes or through-stays, shall besufficient, considering all methods of failure,

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P = pitch of rivets in the outer row lesspitch of rivets in the inner row wheretwo rivets in the inner row come between two rivets in the outerrow, inches (it is here assumed thatthe joints are the usual construction

where the rivets are symmetricallyspaced)

d = diameter of the rivet holes, inches

20.2 The back pitch of rivets in circumferential joints may be less than that called for by theabove formulas provided the ligaments be-tween rivets in a circumferential direction, aswell as those in a diagonal direction as deter-mined by the rules in PG-52, are sufficient towithstand the stress due to pressure, togetherwith any stress due to weight components insupport of boiler structure, with a factor ofsafety of 5.

20.3 The back pitch of rivets shall be measuredeither on the flat plate before rolling, or on themedian line after rolling, and the back pitchas there measured shall govern the locationsof rivet holes in the buttstraps.

20.4 The distance between any two rows ofrivets in a circumferential joint or back pitch

shall be not less than 1.75d.

PR-21 PREPARATION OF PLATE EDGES

The plate edge shall be beveled to an anglenot sharper than 70 degrees to the plane of theplate and as near thereto as practicable.

PR-22 EDGE DISTANCE

22.1 On longitudinal joints of all types of boilers and on circumferential joints of drumshaving heads which are not supported bytubes or through-stays, the distance from thecenters of rivet holes to the edges of the plates,except rivet holes in the ends of buttstraps,

shall be not less than 1-1/2 and not more than1-3/4 times the diameter of the rivet holes;this distance to be measured from the centerof the rivet holes to the caulking edge of theplate before caulking.

22.2 The distance from the centers of rivetholes of circumferential joints to the edgesof the plate in boilers having heads that aresupported by tubes or through-stays shall benot less than 1-1/4 times the diameter of therivet holes.

PR-23 RIVETED CONNECTIONS

Attachment by riveting shall be in accordancewith the following requirements:

23.1 Openings for nozzles and other connec-tions shall be far enough away from any mainriveted joint so that the joint and the openingreinforcement plates do not interfere withone another.

23.2 Welded connections that require post-weld heat treatment and which are attached tovessels having seams of riveted constructionshall be fabricated and stress relieved prior to

the making up or attachment of the courses by riveting. If they do not require postweldheat treatment and are attached after riveting,the welds shall be located at a distance fromthe riveted seam at least equal to the outsidediameter of the attachment weld plus 4 timesthe thickness of the shell plate.

23.3 Openings for pipe connections to vesselshaving riveted joints may be made by insert-ing pipe couplings or similar devices, notexceeding 3 in. pipe size, in the shell or heads

and securing them by welding, provided thewelding is performed by welders or weldingoperators who have been qualified under theprovisions of Section IX of the Code for thewelding position and type of joint used.

23.4 For nozzle fittings having a bolting flangeand an integral flange for riveting, the thick-

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ness of the flange attached to the pressurevessel shall not be less than the thickness ofthe neck of the fitting.

23.5 The strength of rivets in tension in aflanged frame or ring riveted to the outside of

a vessel shall be at least equal to that requiredto resist the load due to the maximum allow-able working pressure with a factor of safetyof 5 computed as follows:

23.5.1 For outside caulking the load shall be equal to the area bounded by the out-side caulking multiplied by the maximumallowable working pressure.

23.5.2 For inside caulking (and with nooutside caulking) the load shall be equalto the area bounded by the inside caulk-ing multiplied by the maximum allowableworking pressure.

23.6 The rivets attaching nozzles shall be sospaced as to avoid the possibility of the shellplate or the nozzle flange failing by tearingaround through the rivet holes. An exampleillustrating the method of calculations is givenin A-70.

PR-25 REINFORCEMENT OF OPENINGS

25.1 The area of reinforcement shall be calcu-lated by the rules in PG-32 through PG-39.

25.2 In applying reinforcement plates to thedrums of watertube boilers to strengthen theshell where the tubes enter, they shall be riv-eted to the shell, and where outside caulking isused, the tube shall be expanded into the inner

and outer plates so that the rivets and tubeswill hold the plates together in accordancewith the rules for stayed surfaces. Where areinforcing plate is inside the steam drum, itis the inner plate; where it is outside and thereis no inner reinforcing plate, the unreinforcedshell of the drum is the inner plate.

25.3 The spacing of the rivets with respect tothe tubes shall conform to PG-46 for stayedsurfaces, using a value of 2.5 for C, and shall be based on a unit pressure equal to the pres-sure that can be carried by the inner plate witha factor of safety of 5.

25.4 The tension in rivets and tubes shallconform to PFT-27 and PFT-38.

25.5 The combined drum shell and reinforcingplate or plates, and riveted connections, shallhave a factor of safety of not less than 5 in theligaments when calculated in accordance withPG-52. When reinforcing plates or buttstrapsare exposed to flame or gas of the equivalenttemperature, the joints shall be protectedtherefrom.

FABRICATION

PR-30 GENERAL

The rules in the following paragraphs applyspecifically to the fabrication of the boilersand parts thereof that are fabricated by rivet-ing and shall be used in conjunction with thegeneral requirements for Fabrication in Part

PG as well as with the specific requirementsfor Fabrication in the applicable Parts of thisSection that pertain to the type of boiler underconstruction.

PR-31 BUTTSTRAPS

31.1 Buttstraps shall be rolled or formed bypressure, not blows to the curvature of theshell with which they are to be used.

31.2 The ends of inner buttstraps of riveted buttstrap longitudinal joints may be fusionwelded to the edges of heads or of the adjoin-ing shell plate, or to circumferential buttstrapsfor tightness, provided the carbon content inthe steel does not exceed 0.35 percent. Whenthe buttstrap of a longitudinal joint does not

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Welded

max2 1”

2

FIGURE PR-31 —Allowable Welding Of Plate Edges At EndsOf Buttstraps

extend the full length of the shell plates, asshown in Figure PR-31 , the abutting edges ofthe shell plate may be welded provided thedistance from the end of the buttstrap to theedge of the flange of the head or adjacent shellplate is not greater than 2-1/2 in.

PR-32 RIVET HOLES

All holes for rivets in plates, buttstraps, heads,stays, and lugs shall be drilled; or they may bepunched at least 1/8 in. less than full diameterfor material not over 5/16 in. in thicknessand at least 1/4 in. less than full diameter formaterial over 5/16 in.

Such holes shall not be punched in materialmore than 5/8 in. in thickness.

For final drilling or reaming the hole to fulldiameter, the parts shall be firmly bolted inposition by tack bolts.

The finished holes must be true, clean andconcentric.

PR-37 ASSEMBLY OF JOINTS

After drilling or reaming rivet holes the platesand buttstraps of longitudinal joints shall beseparated, the burrs and chips removed, theplates and buttstraps reassembled metal-to-metal with barrel pins fitting the holes, andwith tack bolts.

PR-39 RIVETING

39.1 Rivets shall be of sufficient length to com-

pletely fill the rivet holes and form heads atleast equal in strength to the bodies of the riv-ets. Forms of finished rivet heads that will beacceptable are shown in ANSI B18.4-1966.

39.2 Rivets shall be so driven as to fill theholes preferably by a machine that maintainsthe pressure until no part of the head shows

red in the daylight. Barrel pins fitting theholes and tack bolts to hold the plates firmlytogether shall be used. A rivet shall be drivenon each side of each tack bolt before removingthe tack bolt.

PR-40 JOINT TIGHTNESS

40.1 The caulking edges of plates, buttstraps,and heads shall be beveled to an angle notsharper than 70 degrees to the plane of theplate, and as near thereof as practicable. Ev-ery portion of the unfinished surfaces of thecaulking edges of plates, buttstrap, and headsshall be planed, milled, or chipped to a depthof not less than one-fourth of the thickness ofthe material, but in no case less than 1/8 in.Caulking shall be done with a tool of suchform that there is no danger of scoring ordamaging the plate underneath the caulkingedge, or splitting the caulked sheet.

40.2 Fusion welding may be used to seal thecaulked edges of circumferential-riveted lap joints of power boilers provided the platesdo not exceed 0.35 percent carbon and theirthickness is at least 1/8 in. more than thatrequired for a seamless shell of the samediameter, same working pressure, and same

grade of material.

40.3 Seal welding may be used on nozzlesand their reinforcing plates under the sameconditions. On unstaying dished heads, sealwelding shall not be applied closer than 1/2

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in. to the point of tangency of the knuckle ofthe flange. Seal welding may be applied onlywhen the weld metal is deposited in a singlelayer having a throat thickness of not less than3/16 in., nor more than 5/16 in. The heat fromwelding shall not distort the plate or loosen

the rivets in such a manner as to break theinitial bond effected in the riveted joint. Afterseal welding, the vessel shall be resubjectedto the prescribed hydrostatic test.

40.4 The inner buttstraps in locomotive-type boilers may be seal welded, provided thecarbon content of the plates does not exceed0.35 percent and the weld metal is depositedin a single layer having a weld size not greaterthan 3/8 in.

INSPECTION AND TESTS

PR-50 GENERAL

At least two inspections shall be made ofriveted construction (one before reaming rivetholes and one at the hydrostatic test) and, atthe option of the inspector, at such other stagesof the work as he may designate.

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PART PFT — REQUIREMENTS FOR FIRETUBE BOILERS

GENERAL

PFT -1 GENERAL

The rules in Part PFT are applicable to fire-tube boilers and parts thereof and shall beused in conjunction with the general require-ments in Part PG as well as with the specificrequirements in the applicable Parts of thisSection that apply to the method of fabrica-tion used.

MATERIALS

PFT-5 GENERAL

5.1 Materials used in the construction of pres-sure parts for firetube boilers shall conformto one of the specifications given in SectionII of the Code and shall be limited to thosefor which allowable stress values are givenin Table PG-23 or as otherwise specificallypermitted in Parts PG and PFT.

5.2 Waterleg and doorframe rings of verticalfiretube boilers and of locomotive and othertype boilers shall be of wrought iron or steel,or cast steel as designed in the SpecificationSA-216. The ogee or other flanged construc-tion may be used as a substitute in any case.

DESIGN

PFT-8 GENERAL

The rules in the following paragraphs apply

specifically to the design of firetube boilersand parts thereof and shall be used in conjunction with the general requirements ofDesign in Part PG as well as with the specificrequirements for Design in the applicable Partsof this Section that apply to the method offabrication used.

PFT-9 MINIMUM THICKNESS

9.1 Plates

The minimum thicknesses of shell plates,and dome plates after flanging, shall be asfollows:

Diameter of Shell Minimum Thickness

36 in. or under 1/4 in.Over 36 to 54 in. 5/16 inOver 54 to 72 in. 3/8 in.Over 72 in. 1/2 in.

9.2.1 Except as otherwise provided in

PFT-9.2.2, the minimum thickness of tubesheets for firetube boilers shall be as fol-lows:

Diameter of MinimumTube Sheet Thickness

42 in. or under 3/8 in.Over 42 to 54 in. 7/16 in.Over 54 to 72 in. 1/2 in.Over 72 in. 9/16 in.

9.2.2 Tube sheets with a straight flangelonger than 1-1/2 times the tube sheetthickness, when butt-welded to the shellof a firetube boiler, shall have a minimumthickness as specified in PFT-9.2.1 but inno case shall be less than 0.75 times therequired shell thickness, based on themaximum allowable working pressure.

PFT-10 SHELL JOINTS

10.1 Welded JointsWelded longitudinal and circumferential joints of a shell or drum shall comply withthe rules in Part PW.

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10.2 Riveted Longitudinal Joints

10.2.1 The longitudinal joints of horizon-tal-return tubular boilers shall be locatedabove the fire line of the setting.

10.2.2 In horizontal-return tubular boilersof riveted construction, no course shall beover 12 ft. long.

10.2.3 The inner buttstraps in locomotive-type boilers may be seal welded, providedthe carbon content of the plates does notexceed 0.35% and the weld metal is depos-ited in a single layer having a weld sizenot greater than 3/8 in.

10.3 Riveted Circumferential Joints

10.3.1 In the portion of circumferential joints of horizontal-return tubular boilersexposed to the products of combustion,the shearing strength of the rivets shall be not less than 50% of the full strength ofthe plate corresponding to the thicknessat the joint.

10.3.2 When shell plates exceed 5/8 in.in thickness in horizontal-return tubular

boilers, the portion of the plates form-ing the laps of the circumferential joints,where exposed to the fire or products ofcombustion, shall be planed or milleddown as shown in Figure PFT-10 to athickness of not over 9/16 in., providedthe requirements in PR-17 are compliedwith. The entire circumference may be soplaned or milled. The radius of the filletat the edge of the planing shall be not lessthan 1 in.

10.3.3 Where the circumferential joints offiretube boilers are to be seal welded, thethickness of the plates at the calking edgesof such seams shall be at least 1/8 in. morethan 60% of that required for a seamlessshell of the same diameter, the sameworking pressure, and the same grade of

material. Such seal welding shall not beapplied until after the boiler is made tightas evidenced by the regular hydrostaticpressure test prescribed in PG-99.

PFT-11 ATTACHMENT OF HEADSAND TUBE SHEETS

Flat heads and tube sheets of firetube boil-ers shall be attached by one of the followingmethods:

11.1 By flanging and riveting in accordancewith Part PR.

11.2 By flanging and butt welding in accor-dance with Part PG and Part PW.

11.3 By attaching an outwardly or inwardlyflanged tube sheet to the shell by fillet weld-ing provided the following requirements aremet:

11.3.1 The tube sheet is supported bytubes, or stays, or both;

11.3.2 The joint attaching an outwardlyflanged tube sheet is wholly within the

shell and forms no part thereof;

11.3.3 Inwardly flanged tube sheets arefull fillet welded inside and outside;

11.3.4 The throat dimension of the fullfillet weld is equal to, not less than 0.7 ofthe thickness of the head;

11.3.5 The shell at the welds is not incontact with primary furnace gases; 12

11.3.6 The construction conforms in allother respects to the requirements of thisSection, including welding and postweldheat treating, except that radiographicexamination is not required;

12 Primary Furnace gases are those in a zone where thedesign temperature of those gases exceeds 850°F.

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Not less than 1”

Not less than 1”

9 ”

1 6

9 ”

1 6

FIGURE PFT-10 — Circumferential JointFor Thick Plates Of Horizontal-ReturnTubular Boilers

11.3.7 This construction shall not be usedon the rear head of a horizontal-returntubular boiler and inwardly flanged tubesheets shall not be used on a boiler withan extended shell;

11.3.8 On inwardly flanged tube sheets,the length of flange shall conform to therequirements of PW-13 and the distanceof the outside fillet weld to the point oftangency of the knuckle radius shall benot less than 1/4 in.

11.4 By attaching an unflanged tube sheet tothe shell by welding provided the followingrequirements are met:

11.4.1 The tube sheet is supported bytubes, or stays or both;

11.4.2 The welded joint is wholly withinthe shell or wrapper sheet and forms nopart thereof;

11.4.3 The weld is a full penetration weldequal at least to the full thickness of thetube sheet and applied from either or bothsides;

11.4.4 The shell or wrapper sheet, whereexposed to primary furnace gases12 andnot water cooled does not extend morethan 1/8 in. beyond the outside face ofthe tubesheet;

11.4.5 The weld attaching a furnace ora lower tube sheet of a vertical firetube boiler to the furnace sheet is wholly withinthe furnace sheet and is ground flush withthe upper or waterside of the tubesheet;

11.4.6 The construction conforms in allother aspects to the requirements of thisSection including welding, and postweldheat treatment, except that radiographicexamination is not required;

11.4.7 This construction shall not be usedon the rear head of a horizontal-returntubular boiler.

PFT-12 TUBES

12.1 Allowable Working Pressure

12.1.1 The maximum allowable workingpressure of tubes or flues of firetube boil-ers shall be as given in Table PFT-12.1.

12.1.2 The maximum allowable work-ing pressure for copper tubes or nipplessubjected to internal or external pressureshall be as given in Table PFT-12.2.

The maximum allowable working pres-sure for copper-clad tubes subjected toexternal pressure shall be determined bythe formula in Table PFT 12.1 , in which t may be increased by one-half the thickness

of the cladding.

12.2 Attachment of Tubes

12.2.1 A firetube boiler shall have the endsof the tubes firmly rolled and beaded, orrolled and welded around the edge of thetube (see Figure PFT-12.1). Tube ends at-tached by rolling and welding are subjectto the following provisions:

12.2.1.1 The tube sheet hole may be

beveled or recessed to a depth at leastequal to the thickness of the tubes.Where the hole is beveled or recessed,the projection of the tube beyond thetube sheet shall not exceed a distanceequal to the tube thickness. The depth

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of any bevel or recess shall not be lessthan the tube thickness or 1/8 in.,whichever is greater, nor more thanone-third of the tube sheet thickness[see Figure PFT-12.1(f) and (g)].

12.2.1.2 Where no bevel or recessis employed, the tube shall extend beyond the tube sheet not less than adistance equal to the tube thickness,nor more than twice the tube thickness[see Figure PFT-12.1 (e)].

12.2.1.3 On all types of welded attach-ments, the tubes shall be rolled beforewelding and again rolled lightly afterthe welding procedure.

12.2.2 Expanding of tubes by the Prossermethod in lieu of rolling may be em-ployed in combination with any beadedor welded attachment method.

12.2.3 Seal welding is permissible on anytype of beaded attachment. Where sealwelding is employed, a single hydrostatictest of the boiler after seal welding shallsuffice.

12.2.4 The inner surface of the tube holein any form of attachment may be groovedor chamfered.

12.2.5 The sharp edges of tube holes shall be taken off on both sides of the plate witha file or other tool.

COMBUSTION CHAMBER ANDFURNACES

PFT-13 COMBUSTION CHAMBER TUBE SHEET

13.1 The maximum allowable working pres-sure on a tube sheet of a combustion chamber,where the crown sheet is not suspended from

the shell of the boiler, shall be determined bythe following formula:

t(D - d) P = 27,000

WDwhere, P = maximum allowable working pres-

sure, pounds per square inch D = least horizontal distance between

tube centers on a horizontal row,inches

d = inside diameter of tubes, inches t = thickness of tube plate, inches W = distance from the tube sheet to op-

posite combustion chamber sheet,inches

Where tubes are staggered the vertical dis-tance between the centerlines of tube in adja-cent rows must be not less than

� �

Example: Required the minimum allowableworking pressure of a tube sheet supporting acrown sheet stayed by crown bars. Horizontaldistance between centers, 4-1/8 in.; insidediameter of tubes, 2.782 in.; thickness of tubesheets 11/16 in; distance from tube sheet to

opposite combustion-chamber sheet, 34-1/4in.; measured from outside of tube plate tooutside of back plate; material, steel. Substitu-tion and solving:

� �

13.2 Sling stays may be used in place of gird-ers in all cases covered in PFT-13.1, provided,however, that when such sling stays are used,

girders or screw stays of the same section areashall be used for securing the bottom of thecombustion chamber to the boiler shell.

13.3 When girders are dispensed with and thetop and bottom of combustion chambers aresecured by sling stays, the sectional area ofsuch stays shall conform to the requirementsof rules for stayed surfaces.

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TABLE PFT-12.2 — Maximum Allowable Working Pressure For Copper Tubes For FiretubeBoilers Conforming To The Requirements Of Specification SB-752 (For use at PressuresNot to Exceed 250 psi or Temperatures Not to Exceed 406° F)

Outside Gage — BwgDiameterof Tube in. 12 11 10 9 8 7 6 5 4

2 170 240 250 250 250 250 250 250 250 3-1/4 . . . . . . 110 150 220 250 250 250 250

4 . . . . . . . . . . . . 130 160 250 250 250 5 . . . . . . . . . . . . . . . . . . 150 190 230

2 These values have been rounded out to the next higher unit of 10.

where P = maximum allowable working pressure, pounds per square inch t = thickness of tube wall, inches D = outside diameter of tube, inches

TABLE PFT-12.1 — Maximum Allowable Working Pressure For Steel Tubes Or Flues ForFiretube Boilers For Different Diameters And Gages Of Tubes Conforming To The Require-ments Of Specifications SA-178, SA-192, SA-209, SA-210, SA-226, OR SA-2501

Wall Nearest Size Outside Diameter, In.Thickness, Bwg

in. No. 1 1-1/2 1-3/4 2 2-1/4 2-1/2 3 3-1/4 3-1/2 4 4-1/2 5 5-3/8 5-1/2 6

0.095 13 420 280 240 210 190 170 . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.105 12 560 380 320 280 250 230 190 180 160 . . . . . . . . . . . . . . . . . . 0.120 11 770 520 440 390 350 310 260 240 220 200 180 . . . . . . . . . . . .

0.135 10+ 980 660 570 490 430 400 330 310 280 250 220 200 . . . . . . . . . 0.150 9+ . . . 800 680 600 530 480 400 370 340 300 270 240 230 220 . . . 0.165 8 . . . 940 800 700 630 560 470 430 400 350 320 280 270 260 240

0.180 7 . . . . . . 920 810 720 650 540 500 460 410 360 330 300 300 270 0.200 6- . . . . . . 1090 950 840 760 630 590 540 480 420 380 360 350 320 0.220 5 . . . . . . 1240 1090 970 870 730 670 620 550 490 440 410 400 370 0.240 4+ . . . . . . 1410 1230 1090 990 820 760 700 620 550 490 460 450 410

1 These values have been increased to the next higher unit of 10 where the actual values exceed an even unit of 10.

where P = maximum allowable working pressure, pounds per square inch t = minimum wall thickness, inches D = outside diameter of tubes, inches

For pressures other than those given in the table, the allowable working pressures shall be the next higherunit of 10 above the values given by the formulas.

For pressures below those given in the table, the gage thickness shall be not less than the minimum given in thetable.

� �

� �

�

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(a)

(b)

(c) (d)

Not over 2 t nor lessthan t but in no casemore than 1/4 in. norless than 1/8 in.

Not less than t

and in no caseless than 1/8 in.

Max t

t t(f)(e)

Max t and notmore than T /3 or1/8 in. whicheveris the greater

Not more than T /3nor less than t or1/8 in. whicheveris the greater

(g)

T

t

FIGURE PFT-12.1 — Acceptable Forms OfTube Attachment On Firetube Boilers

PFT-14 PLAIN CIRCULARFURNACES

14.1 The shells of unstayed circular furnacesmay be of any length or height and of any ofthe following constructions:

14.1.1 Seamless Construction

14.1.2 Double-welded butt-type con-struction subject only to the require-ments that the welds are postweld heattreated in accordance with PW-39, anda bend test of a sample of the weldingfor each furnace meets the requirementsof PW-53. Radiographic examination is

not required. When the longitudinal andcircumferential joints have been subjectedcompletely to radiographic examination,the individual bend test for each furnaceis not required.

14.1.3 Riveted construction that meets thefollowing requirements:

14.1.3.1 Circumferential and longi-tudinal joints shall have an efficiencynot less than 50% nor less than PD/20,000t%,

where, P = maximum allowable working pres-

sure, pounds per square inch D = outside diameter, inches t = thickness of furnace walls, inches

14.1.3.2 Buttstrap seams shall be usedonly where they are protected fromcontact with the fire or flame.

14.2 The walls shall not be less than 5/16 in.in thickness.

14.3 The furnace may be of any length orheight.

14.4 The following rules apply specifically tounstayed circular furnaces 12 in. in diameterand over:

14.4.1 Furnaces 12 to 18 in. in Outside Di-ameter, Inclusive. The maximum allowableworking pressure for furnaces not morethan 4-1/2 diameters in length or heightshall be determined by formulas (1) and(2) as follows:

Where the length does not exceed 120times the thickness of the plate:

� �

(1)

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Where the length exceeds 120 times thethickness of the plate:

�

(2)


sure, pounds per square inch D = outside diameter of furnace, inches L = total length of furnace between cen-

ters of head rivet seams (not lengthof a section), inches

T = thickness of furnace walls, sixteenthsof an inch

14.4.2 The maximum allowable workingpressure for furnaces over 4-1/2 diametersin length or height shall be determined inaccordance with PFT-15.

14.4.3 Furnaces Over 18 in. in Outside Di-ameter to and Including 30 in. in Inside Di-ameter. The maximum allowable workingpressure shall be determined by formulas(1) and (2); if over six diameters in lengthor height, L in the formula shall be takenas 6 times the diameter.

14.4.4 Furnaces Over 30 in. in Inside Diam-eter to and Including 36 in. in Inside Diameter. A riveted longitudinal joint may be of thelap type provided the furnace does notexceed 36 in. in length or height.

14.4.5 If the length of a horizontal furnaceexceeds 36 in. and the joint is riveted, a butt- and single- or double-strap construc-tion shall be used and shall be located below the grate.

14.4.6 The maximum allowable workingpressure shall be determined by formulas(1) and (2); if over six diameters in length,L in the formula shall be taken as 6 timesthe diameter.

14.4.7 Furnaces Over 36 in. in Inside Diam-eter to and Including 38 in. in Outside Diam-eter. When riveted the longitudinal joint of

a horizontal furnace shall be of butt- andsingle- or double-strap construction andshall be located below the grate.

14.4.8 The maximum allowable workingpressure shall be determined by formulas

(1) and (2); if over six diameters in length,L in the formula shall be taken as 6 timesthe diameter.

14.4.9 Furnaces Over 38 in. in Diameter. Furnaces over 38 in. in diameter shall befully stayed as flat surfaces in accordancewith requirements of PFT-23.4.

Where it is desired to apply staybolting toa furnace 38 in. or less in diameter, whichis of proper thickness for the requiredworking pressure under the above rules,the requirements of the Code for the stressallowed upon and the spacing of the staybolts may be disregarded.

PFT-15 CIRCULAR FLUES

The maximum allowable working pressurefor seamless or welded flues over 5 in. indiameter, and including 18 in. in diameter

shall be determined by one of the followingformulas:

15.1 Where the thickness of the wall is notgreater than 0.023 times the diameter:

10,000,000t3

P =D3

15.2 Where the thickness of the wall is greaterthan 0.023 times the diameter:

17,300t P = - 275 D


sure, pounds per square inch D = outside diameter of flue, inches t = thickness of wall of flue, inches

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15.3 The above formulas may be applied toriveted flues of the size specified provided thesections are not over 3 ft. in length and theefficiency of the joint is not less than:

PD

20,000t

Example: Given a flue 14 in. in diameter and5/16 in. in thickness. The thickness of the wallis less than 0.023 times the diameter, hence theformula in (1) applies. Substituting the valuesin this formula:

10,000,000 x 5/16 x 5/16 x 5/16P= =110 psi 14 x 14 x 14

PFT-16 ADAMSON TYPE

When plain horizontal flues are made in sec-tions not less than 18 in. in length and not lessthan 5/16 in. in thickness:

16.1 They shall be flanged with a radius mea-sured on the fireside of not less than 3 timesthe thickness of the plate, and the flat portionof the flange outside of the radius shall be atleast 3 times the diameter of the rivet holes.

16.2 The distance from the edge of the rivetholes to the edge of the flange shall be notless than the diameter of the rivet hole, andthe diameter of the rivets before driving shall be at least 1/4 in. larger than the thickness ofthe plate.

16.3 The depth of the Adamson ring betweenthe flanges shall be not less than 3 times thediameter of the rivet holes, and the ring shall be substantially riveted to the flanges. The fireedge of the ring shall terminate at or about thepoint of tangency to the curve of the flange,and the thickness of the ring shall be not lessthan 1/2 in.

16.4 An Adamson furnace may be assembled by welding, provided the outside edges of theflue flanges are attached to Adamson rings byfull fillet welds; inside edges of the rings arewelded to the flat portions of the flue flanges by full fillet welds; and the welds are postweld

heat treated in accordance with PW-39.

The maximum allowable working pressureshall be determined by the following for-mula:

57.6 (300t - 1.03L) P =

D


sure, pounds per square inch D = outside diameter of furnace, inches L = length of furnace section, inches t = thickness of plate, inches

Example: Given a furnace 44 in. in diam-eter, 48 in. in length, and 1/2 in. in thick-ness. Substituting values in formula:

57.6 P = [(300 x 0.5) - (1.03 x 480] 44

= 1.309 (150 - 49.44) = 131 psi

The longitudinal and circumferential jointsmay be of the double-welded butt type, theonly requirements being that the welds arepostweld heat treated in accordance withPW-39 and a bend test of a sample of thewelding for each furnace meets the require-ments of PW-53, no radiographic examination being required. When the longitudinal andcircumferential joints have been subjectedcompletely to radiographic examination, theindividual bend test for each furnace is notrequired.

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PFT-17 RING REINFORCED TYPE

Horizontal cylindrical flues or furnaces (Fig-ure PFT-17.2) may be constructed with com-pletely circular stiffening rings provided thefollowing requirements are met:

17.1 The stiffening ring is rectangular incross section and is fabricated from onepiece of plate, or from plate sections or barsprovided full penetration welds are used inassembling.

17.2 The stiffening ring after fabrication hasa thickness of not less than 5/16 in. and notmore than 13/16 in. and in no case thickerthan 1-1/4 times the furnace wall thickness.

17.3 The ratio of the height of the stiffeningring to its thickness (H

r /T

r ) is not greater than

8 nor less than 3.

17.4 The stiffening ring is attached to the fur-nace by a full penetration weld on each side.

17.5 The thickness of the furnace wall or flueis a minimum of 5/16 in.

17.6 The spacing, L, of the rings on the furnace

is not greater than 60t or 36 in., whichever issmaller.

17.7 The design temperature of the furnaceis taken as 100° F higher than the water tem-perature.

17.8 The boiler design permits replacementof the furnace. A flared or welded OG ring isan acceptable type of assembly.

17.9 The completed furnace assembly is post-

weld heat treated but radiographic examina-tion is not required.

17.10 The thickness of the furnace wall anddesign of stiffening rings are determined bythe use of Figure PFT-17.1. The symbols de-fined below, and shown in Figures PFT-17.1 and PFT-17.2 are used in the formulas of thisparagraph:

t = minimum required wall thickness offurnace or flue, inches

L = design length of a furnace section,taken as the greatest center-to-centerdistance between any two adjacentstiffening rings, or the distance from

the center of the first stiffening ringto the center of the furnace weldattachment, inches. In case a flaredend assembly is used, the distanceshall be measured to the point oftangency of the flare and the furnaceand the adjacent stiffening ring.

Do

= outside diameter of furnace or flue,inches

P = maximum allowable working pres-sure, pounds per square inch

The required wall thickness of a ring rein-forced furnace or flue shall not be less thanthat determined by the following procedure:

Step 1: Assume value for t and L. Deter-mine the ratios L/D

o and D

o/t;

Step 2: Enter left-hand side of Figure PFT17.1 at the value of L/D

o determined in

Step 1;

Step 3: Move horizontally to the line rep-resenting the value of Do/t determined in

Step 1;13

Step 4: From this intersection move ver-tically to the material line of the propertemperature; 13

Step 5: From this intersection move hori-zontally to the right and read the value ofB;

Step 6: Compute the allowable workingpressure, P

a , by the following formula:

�

13 For immediate temperatures and Do/t ratios, interpo-

lations may be made between the lines on the chartin Figure PFT-17.1.

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0.000012 3 4 5 6 78

0.00012 3 4 5 6 78 2 3 4 5 67 8

0.001 0.01 0.12 3 4 5 6 7 8

50

140

100

6070

80

90

120

160

180

200

250

300

350

400

500

600

700

800

9001,000

1,200

1,400

1,6001,800

2,000

2,500

3,000

3,500

4,000

5,000

6,000

7,000

8,000

9,00010,000

12,000

14,000

16,000

18,00020,000

25,000

40,000

50,000

35,000

30,000

0.05

0.06

0.07

0.080.090.10

0.12

0.14

0.16

0.20

0.25

0.30

0.18

0.35

0.50

0.60

0.70

0.40

0.901.0

0.80

1.2

1.4

1.82.0

1.6

2.5

3.0

3.5

4.0

5.0

6.0

7.0

9.0

8.0

10

12

14

16

18

20

25

30

35

40

50

FACTOR A

L e n g t h

/ O u t s i d e D i a m e t e r = L / D

0

UP TO 300 FUP TO 500 F

UP TO 700 FUP TO 800 FUP TO 900 F

F A C T O R

B = P ( D

/ t ) 0

o

o

o

o

o

o

D

/ t = 3 0 0

o

D

/ t = 2 5 0

o

D

/ t = 2 0 0

o

D

/ t = 1 5 0

o

D

/ t = 6

0

o

D

/ t = 8

0

o

D

/ t = 1 0 0

o

D / t =

1 2 5

o

D

/ t = 5

0

o

D

/ t = 4

0

o

D

/ t = 3

0

o

D

/ t = 2

5

o

D

/ t = 2

0

o

D

/ t = 1

5

o

D

/ t = 1

0

o

D / t =

3 0 0

o

D / t =

2 5 0

o

D / t =

2 0 0

o

D / t =

6 0

o

D / t =

8 0

o

D / t =

1 0 0

o

D / t =

1 2 5

o

D

/ t = 5 0

o

D / t =

4 0

o

D / t =

3 0

o

D / t =

2 5

o

D / t =

2 0

o

D / t =

1 5

o

D / t =

1 0

o

D / t =

1 5 0

o

D / t =

4 0 0

o

D / t =

5 0 0

o

D / t =

6 0 0

o

D / t =

8 0 0

o

D / t =

1 0 0 0

o

D / t =

4 0 0

o

D / t =

5 0 0

o

D / t =

6 0 0

o

D / t =

8 0 0

o

D / t =

1 0 0 0

FIGURE PFT-17.1 — Chart for Determining Wall Thickness of Ring Reinforced FurnacesWhen Constructed of Carbon Steel (Specified yield Strength 30,000 to 38,000 psi)

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14 For immediate temperatures and Do/t ratios,

interpolations may be made between the lineson the chart in Figure PFT-17.1.

Alternate End AssembliesHr

Tr

Hr

Tr

L

D

L

o

L

t

Full PenetrationContinuous WeldBoth Sides of Rings

FIGURE PFT 17.2 — Acceptable Type OfRing Reinforced Furnace

Step 7: Compare Pa with P. If P

a is less

than P, select greater value of t or a smallervalue of L or some combination of both toincrease P

a , so that it is equal to or greater

than P. (An example shown in AppendixA-200.)

The required moment of inertia of a circum-ferential stiffening ring shall not be less thanthat determined by the formula:

�

�

where, I

s= required moment of inertia of the

stiffening ring about its neutral axisparallel to the axis of the furnace,inches

As = cross-sectional area of the stiffening

ring, square inches A = factor determined from Figure PFT

17.1

P, Do , L, and t are as defined above

The moment of inertia for a stiffening ringshall be determined by the following proce-dure:

Step 1: Assuming that the furnace has beendesigned and D

o , L and t are known, se-

lect a rectangular member to be used for astiffening ring and determine its area, A

s ,

and its moment of inertia, I. Then calculateB by the formula:

�

where B = factor on the right-hand side of Fig-

ure PFT-17.1 and P, Do , t, A

s , and L

are as defined above;

Step 2: Enter the right-hand side of Figure

PFT-17.1 at the value of B determined inStep 1;

Step 3: Follow horizontally to the materialline for the correct temperature; 14

Step 4: Move down vertically to the bot-tom of the chart and read the value of A;

Step 5: Compute the value of the requiredmoment of inertia, I

s , from the formula

given above;

Step 6: If the required Is is greater

than the moment of inertia, I for thissection selected in Step 1, select anew section with a larger moment ofinertia and determine a new value ofI

s.

If the required Is is smaller than I for

the section selected in Step 1, thatsection should be satisfactory. (An ex-

ample is shown in Appendix A-200.)

The longitudinal and circumferential joints may be of the double-welded butt type, the only requirements being

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that the welds are postweld heat treated inaccordance with PW-39 and a bend test of asample of the welding for each furnace meetsthe requirements of PW-53, no radiographicexamination being required. When the lon-gitudinal and circumferential joints have

been subjected completely to radiographicexamination, the individual bend test for eachfurnace is not required.

PFT-18 COMBINED PLAINCIRCULAR ANDCORRUGATED TYPE

Combination-type furnaces for externalpressure may be constructed by combining aplain circular section and a corrugated sectionprovided:

18.1 Each type of furnace is designed to beself-supporting, requiring no support from theother furnace at their point of connection.

18.2 Paragraphs PFT-14 and PFT-15 are usedfor calculating the maximum allowable work-ing pressure of the plain section. In applyingthe length in the text or L in the formulas, thevalue used shall always be twice the actual

length of the plain section. The actual lengthof the plain section is the distance measuredfrom the centerline of the head attachmentweld to the centerline of the full penetrationweld joining the two sections.

18.2.1 Furnaces 12 in. to 18 in. in outsidediameter inclusive. A plain furnace sectionwhose length is such that twice the actuallength does not exceed 4-1/2 diametersshall have its maximum allowable work-ing pressure calculated by Equation (1)

or (2) in PFT-14.4. If twice the actuallength of the plain furnace section doesnot exceed 120 times the thickness of theplate, Equation (1) shall be used. If twice

the actual length of the plain furnace sec-tion exceeds 120 times the plate thickness,Equation (2) shall be used.

A plain furnace section whose length issuch that twice the actual length exceeds

4-1/2 diameters shall have its maximumallowable working pressure determinedin accordance with PFT-15.

18.2.2 Furnaces over 18 in. to and including38 in. in outside diameter. The maximumallowable working pressure of a plainfurnace section shall be determined byEquation (1) and (2) in PFT-14.4. Whentwice the actual length of the plain fur-nace section exceeds 6 times the furnacediameter, L in the formulas shall be takenas 6 times the diameter.

18.3 The maximum allowable working pres-sure of the corrugated section shall be deter-mined from PFT-19.

18.4 The full penetration weld joining a plainself-supporting section to a corrugated self-supporting section, shall be located as shownin Figure PFT-18.

18.5 The longitudinal and circumferential joints may be fusion welded of the double-welded butt type, the only requirements beingthat the welds are postweld heat treated inaccordance with PW-39 and a bend test of asample of the welding for each furnace meetsthe requirements of PW-53, no radiographicexamination being required. When the lon-gitudinal and circumferential joints have been subjected completely to radiographicexamination, the individual bend test for eachfurnace is not required.

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Max 3 t or 1-1/2"(whichever is less)

c

31

ct

Point of Tangency

FIGURE PFT-18 — Connection BetweenPlain And Corrugated Furnace

PFT-19 CORRUGATED FURNACES

19.1 The maximum allowable working pres-sure on corrugated furnaces, such as the Leedssuspension bulb, Morison, Fox, Purves, orBrown, having plain portions at the ends not

exceeding 9 in. in length (except flues espe-cially provided for), when new and practicallycircular, shall be computed as follows:

Ct P =

D


sure, pounds per square inch t = thickness, inches, not less than 5/16

in. for Leeds, Morison, Fox, and

Brown, and not less than 7/16 in.for Purves and other furnaces cor-rugated by section not over 18 in.long

D = mean diameter, inches C = 17,300, a constant for Leeds furnaces,

when corrugations are not morethan 8 in. from center to center andnot less than 2-1/4 in. deep.

C = 15,600, a constant for Morison fur-naces, when corrugations are notmore than 8 in. from center to center

and the radius of the outer corruga-tion is not more than one-half of thesuspension curve.

C = 14,000, a constant for Fox furnaces,when corrugations are not morethan 8 in. from center to center andnot less than 1-1/2 in. deep.

C = 14,000, a constant for Purves fur-naces, when rib projections are notmore than 9 in. from center to centerand not less than 1-5/8 in. deep.

C = 14,000 a constant for Brown furnac-es, when corrugations are not more

than 9 in. from center to center andnot less than 1-5/8 in. deep.

C = 10,000, a constant for furnaces cor-rugated by sections not more than 18in. from center to center and not lessthan 1-1/2 in. deep, measured fromthe least inside to the greatest out-side diameter of the corrugations,and having the ends fitted one intothe other and substantially rivetedtogether, provided that the plainparts at the ends do not exceed 12in. in length.

In calculating the mean diameter of the Mori-son furnace, the least inside diameter plus 2in. may be taken as the mean diameter.

The longitudinal and circumferential jointsmay be fusion welded of the double-welded butt type, the only requirements being that thewelds are postweld heat treated in accordancewith PW-39 and a bend test of a sample of the

welding for each furnace meets the require-ments of PW-53, no radiographic examination being required.

When the longitudinal and circumferential joints have been subjected completely to ra-diographic examination, the individual bendtest for each furnace is not required.

19.2 The thickness of a corrugated or ribbedfurnace shall be ascertained by actual mea-surement by the furnace manufacturer, by

gaging the thickness of the corrugated por-tions. If a hole is used, the diameter of a holedrilled through the sheet to determine itsthickness shall be 3/8 in. When the furnaceis installed the hole shall be located beneaththe bottom of the grate and closed by a plug.For the Brown and Purves furnaces, the holesshall be in the center of the second flat; for

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the Morison, Fox and other similar types, inthe center of the top corrugation, at least asfar in as the fourth corrugation from the endof the furnace.

PFT-20 ATTACHMENT OFFURNACES

20.1 Riveted Construction. Furnaces may beattached to an inwardly or outwardly flangedhead or tube sheet by riveting in accordancewith the rules of Part PR and applicable rulesin Part PFT.

20.2 Fillet Welded Construction. In a scotch-type boiler, a furnace may be attached to anoutwardly flanged opening in a front tubesheet by a circumferential fillet weld, or afurnace may be attached to either tube sheet by flaring the end which extends beyond theoutside face of the head to an angle of 20 to30 degrees and using a circumferential filletweld, provided the following requirementsare met:

20.2.1 The area of the head around thefurnace is stayed by tubes, stays, or bothin accordance with the requirements of

this Section.

20.2.2 The joint is wholly outside thefurnace.

20.2.3 The throat dimension of the fullfillet weld is not less than 0.7 times thethickness of the head.

20.2.4 Unless protected by refractorymaterial, the furnace does not extend be-yond the outside face of the tube sheet, a

distance greater than the thickness of thetube sheet. Any excess shall be removed before welding.

20.2.5 The construction conforms in allother respects to the requirements of thisSection including welding and postweldheat treating, except that radiographicexamination is not required.

20.3 Full Penetration Weld Construction. Afurnace may be attached by a full penetra-tion weld, with the furnace extending at leastthrough the full thickness of the tube sheet butnot beyond the toe of the weld, and the toeshall not project beyond the face of the tube

sheet by more than 3/8 in. unless protectedfrom overheating by refractory material orother means.

20.4 Throat Sheets. Throat sheets and insideand outside front furnace sheets when fullystayed may be attached as required in PFT-11.4.

20.5 Furnace Sheets. Attached by WeldingVertical firetube boilers may be constructed by welding the ogee bottom of the furnacesheet to the outside shell as shown in FigurePFT-20 provided the following requirementsare met:

20.5.1 The tube or crown sheet is fullysupported by tubes, or stays or both.

20.5.2 The joint is wholly within the shelland forms no part thereof.

20.5.3 The weld is not in contact with

primary furnace gases.15

20.5.4 The throat dimension of the fullfillet weld is not less than 0.7 times thethickness of the furnace sheet.

20.5.5 The maximum depth of the water-leg does not exceed 4 in., and the radius

d (max = 4")d (max) (max)

Pitch12

FIGURE PFT-20 — Welding Ogee Ring

15 Primary Furnace gases are those in a zone where thedesign temperature of those gases exceeds 850°F

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of the ogee is not greater than the insidewidth of the waterleg.

20.5.6 The pitch of the lower row of staybolts meets the requirements of PFT-26.6.

20.5.7 The construction conforms in allother respects to Code requirements in-cluding welding and postweld heat treat-ing, except that radiographic examinationis not required.

PFT-21 FIREBOXES ANDWATERLEGS

21.1 Fireboxes and waterlegs may be of riv-eted construction provided the rules in PartPR and all applicable rules in Part PFT arefollowed.

21.2 Welded construction may be used in lieuof riveted joints in the fireboxes of internallyfired boilers provided the welds are betweentwo rows of staybolts, or in the case of flatsurfaces the weld is not less than one-half ofa staybolt pitch from the corner. In verticaltubular and firebox types of boilers the bottomedges of the plates may be attached by fusion

welding, provided the load due to internalpressure is carried by staybolting and theinside width of the waterleg does not exceed4 in. An acceptable construction is as shownin Figure PWT-12.2 with both plates flanged.As an alternative construction one plate onlyneed be flanged, provided the weld joining theflanged plate to the straight plate is a grooveweld having penetration for its full depth andthe weld is outside of the header. The platesmay be considered to be fully supported ifstayed in accordance with the requirements

of PFT 26.8.

The welds shall be postweld heat treated butradiographic examination is not required.

21.3 Mud rings of plate material permissibleunder this Section of the Code may be usedin the construction of waterlegs of verticalfiretube boilers and may be attached as shown

in Figure PG-31(g) in compliance with therequirements of Par. PG-31 provided:

21.3.1 The width of the waterleg does notexceed 4 in.

21.3.2 The thickness of the mud ring plateis at least 1/2 in.

The welds shall be postweld heat treated butradiographic examination is not required.

Any crevices between the mud ring and thesheets of the furnace section of a locomo-tive-type boiler may be made tight with sealwelding when the mud ring is secured byrivets. The abutting ends of mud rings may be welded.

STAYED SURFACES

PFT-22 GENERAL

The rules of Part PG pertaining to stayed sur-faces which are applicable to firetube boilersshall be used in conjunction with the follow-ing requirements.

PFT-23 WORKING PRESSURE FORCURVED SURFACES

23.1 The maximum allowable working pres-sure for curved stayed surfaces subject tointernal pressure shall be obtained by thefollowing two methods, and the minimumvalue obtained shall be used:

23.1.1 The maximum allowable work-ing pressure shall be computed without

allowing for the holding power of thestays, due allowance being made forthe weakening effect of the holes for thestays or riveted longitudinal joint or otherconstruction. To this pressure there shall be added the pressure obtained by theformula for stayed surfaces given in PG-46using 1.3 for the value of C.

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23.1.2 The maximum allowable workingpressure shall be computed without allow-ing for the holding power of the stays, dueallowance being made for the weakeningeffect of the holes for the stays or rivetedlongitudinal joint or other construction.

To this pressure there shall be added thepressure corresponding to the strength ofthe stays for the allowable stress values inTable PG-23.1, each stay being assumed toresist the pressure acting on the full areaof the external surface supported by thestay.

23.2 The maximum allowable working pres-sure for a stayed wrapper sheet of a locomo-tive-type boiler shall be determined by thetwo methods given above and by the fol-lowing formula and the smallest of the threevalues obtained shall be used:

�

� �where, P = maximum allowable working pres-

sure, pounds per square inch t = thickness of wrapper sheet, inches E = minimum efficiency of wrapper

sheet through joints or stay holes R = radius of wrapper sheet, inches ∑(s x sin a)

= summated value of transversespacing s x sin a for all crown staysconsidered in one transverse planeand on one side of the vertical axisof the boiler

s = transverse spacing of crown stays inthe crown sheet, inches

a = angle any crown stay makes withthe vertical axis of boiler

11,000 = allowable stress, pounds per square

inch

The above formula applies to the longitudinalcenter section of the wrapper sheet, and incases where E is reduced at another section,the maximum allowable working pressure based on the strength at that section may beincreased in the proportion that the distance

from the wrapper sheet to the top of the crownsheet at the center bears to the distance mea-sured on a radial line through the other sec-tion, from the wrapper sheet to a line tangentto the crown sheet and at right angles to theradial lines (see Figure PFT-23.1).

23.3 A furnace for a vertical firetube boiler 38in. or less in outside diameter which requiresstaying shall have the furnace sheet supported by one or more rows of staybolts, the circum-ferential pitch not to exceed 1.05 times thatgiven by the formula in PG-46.

The longitudinal pitch between the staybolts,or between the nearest row of staybolts andthe row of rivets at the joints between the fur-nace sheet and the tube sheet or the furnacesheet and mud ring, shall not exceed thatgiven by the following formula:

�

where, L = longitudinal pitch of staybolts P = maximum allowable working pres-

sure, pounds per square inch t = thickness of furnace sheet, inches R = outside radius of furnace, inches

When values by this formula are less than thecircumferential pitch, the longitudinal pitchmay be as large as the allowable circumfer-ential pitch.

90o

FIGURE PFT-23.1 — Stayed Wrapper Sheetof Locomotive-Type Boiler

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For other types of stays—Use the C factorwhich applies to the thickness of the headplate and type of stay used [see Figure A-8(i)and (j)].

26.4 For unflanged heads, the maximum

distance between the inner surface of theshell and the centers of stays, or rivets attach-ing crowfeet of stays, shall not be more thanone-half the maximum allowable pitch asdetermined by PG-46, using 2.5 for the valueof C, plus 2 in. [see Figure A-8(k)].

26.5 The pitch of diagonal stays attached bywelding between the shells and tube sheetsof horizontal tubular and scotch boilers, andfor other stays when supported plate is notexposed to radiant heat, as determined byPG-46, may be greater than 8-1/2 in., but shallnot exceed 15 times the stay diameter.

26.6 The pitch of the lower row of stayboltsof a vertical firetube boiler, which is requiredto be stayed by the rules in this Section, andthat is fabricated by welding the ogee bottomof the furnace sheet to the outside shell, shallnot exceed one-half the maximum allowablepitch as determined by PG-46, measured fromthe center of the staybolt to the tangent of the

ogee (see Figure PFT-20).

26.7 The spacing of staybolts around doorholes fabricated by fusion welding of thefull penetration type of two-flanged sheets,which are required to be stayed by the rulesof this Section (see Figure PWT-12.2), shallnot exceed one-half the maximum allowablepitch determined by PG-46, measured fromthe center of the staybolt to the points of tan-gency of the flanges.

26.8 If the furnace sheets are required to bestayed by the rules of this Section, the spac-ing of staybolts around door holes and thespacing of the first row of staybolts from the bottom of the mud ring fabricated by fusionwelding of the full penetration type when ei-ther or both sheets are not flanged [see FigureA-8(l), (m) and (n)] shall not exceed one-halfthe maximum pitch determined by PG-46,

plus 2 in., measured from the center of thestaybolt to the root of the weld.

26.9 The maximum distance from the firstrow of stays to a full penetration weld in com-pression applied from either or both sides of

the tube sheet, attaching the crown sheet ofa furnace or combustion chamber to a stayedhead or tube sheet shall not exceed the pitchdetermined by PG-46, measured from thecenter of the stay to the furnace or combustionchamber side of the head or tube sheet [seeFigures A-8(o) and (p)].

26.10 When a flanged-in manhole openingwith a flange depth of not less than 3 timesthe required thickness of the head, or when anunflanged manhole ring meeting the require-ments of PG-32 through PG-39 is provided ina flat stayed head of a firetube boiler, as shownin Figures A-8(q) and (r), the area to be stayedas required by PFT-31 may be reduced by 100sq. in. provided both the following require-ments are met:

26.10.1 The distance between the manholeopening and the inside of the shell doesnot exceed one-half the maximum allow-able pitch for an unflanged manhole and

one-half the maximum allowable pitchplus the radius of the head flange for aflanged-in manhole in a flanged head.

26.10.2 The distance between the centersof the first rows of stays, or the edges oftube holes, and the manhole opening doesnot exceed one-half the maximum allow-able pitch as determined by PG-46.

26.11 In applying these rules and those inPG-46 to a head or plate having a manhole

or reinforced opening, the spacing appliesonly to the plate around the opening and notacross the opening.

26.12 For stays at the upper corners of fireboxes, the pitch from the staybolt next to thecorner to the point of tangency to the cornercurve shall be (see Figure PFT-26):

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��

where T = thickness of plate in sixteenths of an

inch P = maximum allowable working pres-

sure, pounds per square inch C = factor for the thickness of plate and

type of stay used as required in PartPG-46.

PFT-27 AREA SUPPORTED BY STAY

27.1 The full pitch dimensions of the staysshall be employed in determining the area to be supported by a stay, and the area occupied by the stay shall be deducted therefrom to ob-tain the net area. The product of the net areain square inches by the maximum allowableworking pressure in pounds per square inchgives the load to be supported by the stay.

27.2 Where stays come near the outer edgeof the surfaces to be stayed and special allow-ances are made for the spacing, the load to be

carried by such stays shall be determined byneglecting the added area provided for thesespecial allowances.

Example: If the maximum pitch by PG-46would make a staybolt come 6 in. from theedge of the plate and a special allowance

would make it come 7 in., the distance of 6in. shall be used in computing the load to becarried.

PFT-28 STAYBOLTS AND STAYS

28.1 The required area at the point of leastnet cross section of staybolts and stays shall be as given in PG-49. The maximum allow-able stress per square inch at point of leastnet cross-sectional area of staybolts and staysshall be given as in Table PG-23.11. In deter-mining the net cross-sectional area of drilledor hollow staybolts, the cross-sectional areaof the hole shall be deducted.

28.2 The length of the stay between supportsshall be measured from the inner faces of thestayed plates. The stresses are based on ten-sion only. For computing stresses in diagonalstays, see PFT-32.

28.3 When stay rods are screwed throughsheets and riveted over, they shall be sup-ported at intervals of not to exceed 6 ft. Stayrods over 6 ft. in length may be used withoutsupport if fitted with nuts and washers orattached by welding under PW-19, provided

the least cross-sectional area of the stay rod isnot less than that of a circle 1 in. in diameter.

PFT-29 STRUCTURAL REINFORCEMENTS

29.1 When channels or other structural shapesare riveted to the boiler heads for attachingthrough stays, the transverse stress on suchmembers shall not exceed 12,500 psi. Incomputing the stress, the section modulus of

the member shall be used without additionfor the strength of the plate. The spacing ofthe rivets over the supported surface shall bedetermined by the formula in PG-46, using2.5 for the value of C.

29.2 Provided the outstanding legs of the twomembers are fastened together so that they

�

�

�

�

�

FIGURE PFT-26 — Pitch of Staybolts Adja-cent to Upper Corners of Fireboxes

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act as one member in resisting the bendingaction produced by the load on the rivetsattaching the members to the head of the boiler, and provided that the spacing of theserivets attaching the members to the head isapproximately uniform, the members may

be computed as a single beam uniformlyloaded and supported at the points where thethrough stays are attached.

PFT-30 STAYING SEGMENTS OF HEADS

30.1 A segment of a head shall be stayed byhead-to-head, through, diagonal, crowfoot, orgusset stays, except that a horizontal-returntubular boiler may be stayed as provided inPFT-35.

30.2 Stays shall be used in the tube sheets ofa firetube boiler if the distance between theedges of the tube holes exceeds the maximumpitch of staybolts for the corresponding platethickness and pressure given in PG-46.

Any part of the tube sheet which comes be-tween the tube or cylindrical furnace and theshell need not be stayed if the greatest distance

measured along a radial line from the innersurface of the shell to the center point of tan-gent to any two tube holes or tube hole andcylindrical furnace on the shell side of suchholes does not exceed 1.5 times the value ofp obtained by applying the formula of PG-46with C equal to 2.1 or 2.2 depending upon theplate thickness. The tube holes, or tube hole and cylindrical furnace (see Figure PFT-30), to which a common tangent may be drawnin applying this rule, shall not be a greaterdistance from edge to edge than the maximum

pitch referred to.

PFT-31 AREAS OF HEADS TO BE STAYED

31.1 The area of a segment of a flanged headto be stayed shall be the area enclosed by linesdrawn 2 in. from the tubes and a distance d

from the shell as shown in Figures PFT-31.1 and PFT-31.2. The value of d used may be thelarger of the following values:

d = the outer radius of the flange, notexceeding 8 times the thickness of

the head d = 80t/√Pwhere d = unstayed distance from shell,

inches t = thickness of head in inches P = maximum allowable working pres-

sure, pounds per square inch

31.2 The area of a segment of an unflangedhead to be stayed shall be the area enclosed by the shell and a line drawn 2 in. from thetubes.

31.3 The rules on PFT-30.2 shall be used todetermine if staying is required.

31.3.1 The net area to be stayed in a seg-ment of a flanged head may be determined by the following formula:

� � �

� �

� � � �

where, A = area to be stayed, square inches H = distance from tubes to shell, inches d = distance determined by formula in

PFT-31.1 for flanged heads d = zero for unflanged heads R = radius of boiler head, inches

31.3.2 The net area to be stayed in a seg-ment of an unflanged head may be deter-

mined by the following formula:

� �

� � �

where, A = area to be stayed, square inches

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1 p12

1 p12

1 p12

1 p12

1 p12

FIGURE PFT-30 — Example of Staying of Heads Adjacent to Cylindrical Furnaces

FIGURE PFT-31.1 — Method of

Determining Net Area of Segmentof a Head

FIGURE PFT-31.2 — Method of DeterminingNet Area of Irregular Segment of a Head

FIGURE PFT-32 — Measurements forDetermining Stresses in DiagonalStays

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31.4 When stays are required, the portion ofthe heads below the tubes in a horizontal-return tubular boiler shall be supported bythrough stays attached by welding underPW-19 or with nuts inside and outside at thefront head and by attachments that distribute

the stress at the rear head.

The distance in the clear between the bodiesof the stays or of the inside stays where morethan two are used shall not be less than 10 in.at any point.

When horizontal firetube boilers are set so thatthe products of combustion do not come incontact with the lower part of the shell, tubesshould be used instead of through stays at thesides of the manhole opening, if used.

PFT-32 STRESSES IN DIAGONALAND GUSSET STAYS

32.1 To determine the required area of a di-agonal stay, multiply the area of a direct stayrequired to support the surface by the slantor diagonal length of the stay; and divide thisproduct by the length of a line drawn at rightangles to surface supported to center of palm

of diagonal stay as follows:

�

where, A = sectional area of diagonal stay,

square inches a = sectional area of direct stay, square

inches L = length of diagonal stay as indicated

in Figure PFT-32, inches l = length of line drawn at right angles

to boiler head or surface supportedto center of palm of diagonal stay, asindicated in Figure PFT-32

Example: Given diameter of direct stay=1 in.a=0.7854 sq. in., L=60 in., l=48 in.; substitutingand solving:

Diameter=1.11 in. = 1-1/8 in.

32.2 For staying segments of tube sheets suchas in horizontal-return tubular boilers, whereL is not more than 1.15 times l for any stay, thestays may be calculated as direct stays allow-ing 90 percent of the allowable stress valuegiven in Table PG-23.1.

PFT-33 DESIGN OF STAYS AND STAYCONNECTIONS

All rivet holes and pinholes shall conform tothe requirements of PR-32 and the pins shall be made a neat fit. To determine the sizes thatshall be used, proceed as follows:

33.1 Determine the required cross-sectionalarea of the stay in accordance with PFT-29.

33.2 Design the body of the stay so that thecross-sectional area shall be at least equal tothe required cross-sectional area of the stayfor unwelded stays. Where the stays are forgewelded, the cross-sectional area at the weldshall be at least as great as that computed fora stress of 6,000 psi (see Table PG-23.3).

33.3 Make the area of pins to resist doubleshear at least three-quarters of the required

cross-sectional area of the stay.

33.4 Make the combined cross section of theeye at the side of the pin (in crowfoot stays)at least 25 percent greater than the requiredcross-sectional area of the stay.

33.5 Make the cross-sectional areas throughthe blades of diagonal stays where attachedto the shell of the boiler at least equal to therequired rivet section, that is, at least equal to1-1/4 times the required cross-sectional area

of the stay.

33.6 Design each branch of a crowfoot to carrytwo-thirds the total load on the stay.

33.7 Make the net sectional areas throughthe sides of the crowfoot, tee irons, or similarfastenings at the rivet holes at least equal tothe required rivet section, that is, at least equal

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not exceeding 100 psi, the segment of headsabove the tubes may be stayed by steel struc-tural shapes as specified in Table PFT-35 andFigure PFT-35 , except that structural shapesof equal thickness and greater depth of out-standing leg, or of greater thickness and the

same or greater depth of outstanding leg, may be substituted for those specified. The legsattached to heads may vary in depth 1/2 in.above or below the dimensions specified inTable PFT-35.

35.2 When this form of staying is to be placedon a boiler, the diameter of which is inter-mediate to or below the diameters given inTable PFT-35 , the tabular values for the nexthigher diameter shall govern. Rivets of thesame diameter as used in the longitudinal joints of the boiler shall be used to attach thestructural shapes to the head and to connectthe outstanding legs.

35.3 The rivets attaching structural shapesto heads shall be spaced not over 4 in. apart.The centers of the end rivets shall be not over3 in. from the ends of the structural shape. Therivets through the outstanding legs shall bespaced not over 8 in. apart; the centers of theend rivets shall be not more than 4 in. from

the ends of the structural shapes. The ends ofthe structural shapes shall be considered thoseof the outstanding legs and the lengths shall be such that their ends overlap a circle 3 in.inside the inner surface of the shell as shownin Figure PFT-35.

35.4 The distance from the center of the struc-tural shapes to the shell of the boiler, markedA in Figure PFT-35 , shall not exceed the valuesin Table PFT-35 , but in no case shall the legattached to the head of the lower angle come

closer than 2 in. from the top of the tubes.

35.5 When segments are beyond the rangespecification in Table PFT-35 , the heads shall be stayed in accordance with the requirementsin these rules.

PFT-36 CROWN BARS AND GIRDER STAYS

36.1 Crown bars and girder stays for tops ofcombustion chambers and back connectionsor wherever used, shall be proportional to

conform to the following formula:

� �

where, W = extreme distance between supports

of, in a scotch marine boiler, thedistance from the fireside of the tubesheet to the fireside of the back con-nection plate, inches


p = pitch of supporting bolts, inches D

1= distance between girders from cen-

ter to center, inches d = depth of girder, inches C = 7,000 when girder is fitted with one

supporting bolt C = 10,000 when the girder is fitted with

two or three supporting bolts C = 11,000 when the girder is fitted with

four or five supporting bolts C = 11,500 when the girder is fitted with

six or seven supporting bolts C = 12,000 when the girder is fitted witheight or more supporting bolts

Example: Given W=34 in., p=7.5 in., D1=7.75

in., d=7.5 in., t=2 in., three stays per girder,C=10,000; then substitute the formula:

�

�

Sling stays, if used between crown bars and boiler shell or wrapper sheet, shall be propor-tioned so as to carry the entire load withoutconsidering the strength of the crown bars.

36.2 In a form of reinforcement for crownsheets where the top sheet of the firebox is a

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semicircle and the top part of the circle notexceeding 120 degree in arc is reinforced byarch bars extending over the top and down below the top row of staybolts at the sides ofthe furnace beneath the semicircular crownsheet, these arch bars being riveted to the

waterside through thimbles, the maximumallowable working pressure shall be deter-mined by adding to the maximum allowableworking pressure for a plain circular furnaceof the same thickness, diameter, and lengthdetermined by the formula in PFT-14 , thepressure P

1 determined from the following

formula which is a modification of the firstformula in PFT-15:

��

where, b = net width of crown bar, inches d = depth of crown bar, inchesD

1= longitudinal spacing of crown bar

which shall not exceed twice themaximum allowable staybolt pitch,inches

D = two times the radius of the crownsheet, inches

provided that the maximum allowable work-

ing pressure must not exceed that determined by the formula for furnaces of the Adamsontype, in PFT-16 when L is made equal to D

1 ,

and also provided that the diameter of theholes for the staybolts in the crown bars doesnot exceed 1/3 b, and the cross-sectionalareas of the crown bars is not less than 4 sq.in. PG-46 governs the spacing of the staybolts,rivets, or bolts attaching the sheet to the bars,and PFT-23.4 , the size of the staybolts, rivetsor bolts.

For constructions in which the crown sheetis not semicircular, or in which other featuresdiffer from those specified above, a test shall be made in accordance with PG-101 and theworking pressure shall be based thereon.

36.3 Cast iron supporting lugs, legs, or endsshall not be used.

PFT-37 TRUNCATED CONE SHAPEDCOMBUSTION CHAMBERSOF VERTICAL TUBULARBOILERS

37.1 Upper combustion chambers of vertical

submerged tubular boilers made in the shapeof a frustum of a cone when not over 38 in. indiameter at the large end may be used withoutstays if computed by the rule of plain cylin-drical furnaces in PFT-14 , making D in theformula equal to the diameter at the large end,provided that the longitudinal joint conformsto the requirements of PFT-14.

37.2 When over 38 in. in diameter at the largeend, that portion which is over 30 in. in diam-eter shall be fully supported by staybolts orgussets. If supported by staybolts, PFT-23.4 shall apply. If supported by gussets the spac-ing of the rivets attaching the gussets to thecone sheet shall not exceed the staybolt spac-ing given in PFT-23.4. The top row of stayboltsor rivets shall be at a point where the cone topis 30 in. or less in diameter.

In calculating the pressure permissible on theunstayed portion of the cone, the vertical dis-tance between the horizontal planes passing

through the centers of the rivets at the conetop and through the center of the top row ofstaybolts shall be as L in PFT-14.4 and D in thatparagraph shall be the inside diameter at thecenter of the top row of staybolts.

PFT-38 STAY TUBES

38.1 When stay tubes are used in multitubu-lar boilers to give support to the tube plates,the sectional area of such stay tubes may be

determined as follows:

Total section of stay tubes, sq. in. =

� �

where, A = area of that portion of tube plate

containing the tubes, square inches a = aggregate area of holes in the tube

plate, square inches

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S = maximum allowable stress value inthe tubes, pounds per square inch(not to exceed 7,000 psi).

38.2 The pitch of stay tubes shall conform tothe formula in PG-46, using the values of Cas given in Table PFT-38.

When the ends of tubes are not shieldedfrom the action of flame or radiant heat, thevalues of C shall be reduced 20%. The tubesshall project about 1/4 in. at each end and

be slightly flared. Stay tubes when threadedshall be not less than 3/16 in. in thickness at bottom of thread; nuts on stay tubes are notadvised. For nest of tubes, C shall be takenas 2.5 and p as the mean pitch of stay tubes.For spaces between nests of tubes, p shall betaken as the horizontal distance from centerto center of the bounding rows of tubes andC as given in Table PFT-38.

DOORS AND OPENINGS

PFT-39 RIVETED DOOR OPENINGS

Doors in waterlegs may be attached by rivet-ing provided the rules for riveting in Part PRand the rules for stayed surfaces in this Partare complied with.

PFT-40 WELDED DOOR OPENINGS

Arc or gas welding may be used in the fabri-cation of door holes provided the sheets arestayed around the opening in accordance withthe requirements of PFT-26.7 and 26.8.

The fit-up of the several parts of an arc or gaswelded door opening shall be such that themaximum gap between the two plates to be joined by welding does not exceed 1/8 in.

PFT-41 OPENINGS IN WRAPPERSHEETS

Openings located in the curved portion ofthe wrapper sheet of a locomotive-type boilershall be designed in accordance with the rulesin PG-32.

PFT-42 ACCESS AND FIRINGDOORS

The minimum size of an access door to beplaced in a boiler setting shall be 12 in. x 16in., or equivalent area; 11 in. to be the leastdimension in any case. The minimum size ofa fire door opening in an internally fired boilerin which the minimum furnace dimension is24 in. or over shall be not less than 11 in. x 15in. or 10 in. x 16 in. in size. A circular openingshall be not less than 15 in. in diameter.

TABLE PFT-38 — Values of C For Determining Pitch of Stay Tubes

Pitch of Stay Tubes When Tubes Have No When Tubes Are Fitted Within the Bounding Rows Nuts Outside of Plates Nuts Outside of Plates

Where there are two plain

tubes between two stay tubes 2.2 2.4

Where there is one plaintube between two stay tubes 2.6 2.8

Where every tube in the bounding rows is a stay tubeand each alternate tube has a nut . . . 3.2

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the top row of tubes. Scotch marine boilers(wet-back type) shall also have an opening forinspection of the water space at the rear of thecombustion chamber.

PFT-44 OPENING BETWEEN BOILERAND SAFETY VALVE

The opening or connection between the boilerand the safety valve shall have at least thearea of the valve inlet. In the case of firetube boilers, the openings in the boilers for safetyvalves or safety relief valves shall be not lessthan given in Table PFT-44 , except firetube boilers used for waste heat purposes only,not equipped for direct firing, need not meetthe requirements of Table PFT-44 providedthe rated steaming capacity is stamped onthe boiler and safety valves or safety reliefvalves of the required relieving capacity aresupplied such that the provisions of PG-67.2are satisfied. No valve of any descriptionshall be placed between the required safetyvalve or safety relief valve or valves and the boiler, nor on the discharge pipe betweenthe safety valve or safety relief valve and theatmosphere. When a discharge pipe is used,the cross-sectional area shall be not less than

the full area of the valve outlet or of the totalof the areas of the valve outlets dischargingthereinto and shall be as short and straight aspossible and so arranged as to avoid unduestresses on the valve or valves.

DOMES

PFT-45 REQUIREMENTS FORDOMES

45.1 The longitudinal joint of a riveted dome24 in. or over in inside diameter shall be of butt- and double-strap construction, or thedome may be made without a seam of onepiece of steel pressed into shape; and its flangeshall be double-riveted to the shell. In thecase of a dome less than 24 in. in diameter, for

which the product of the inside diameter ininches and the maximum allowable workingpressure in pounds per square inch does notexceed 4,000, its flange may be single-rivetedto the shell and the longitudinal joint may beof the lap type, provided it is computed with

a factor of safety of not less than 8.

The longitudinal joint of a dome may be butt-welded and the dome flange may be doublefull fillet lap-welded to the shell, in place ofriveting if the welding complies fully with therequirements for welding in Part PW. Radio-graphic examination of the fillet welds may beomitted. The opening shall be reinforced inaccordance with PG-32 through PG-44.

45.2 The joints of a dome may be welded andthe dome welded to the shell if the weldingcomplies fully with the requirements forwelding in Part PW. The opening shall bereinforced in accordance with PG-32 throughPG-44.

45.3 When a dome is located on the barrel ofa locomotive-type boiler or on the shell of ahorizontal-return tubular boiler, the diameterof the dome shall not exceed six-tenths thediameter of the shell or barrel of the boiler un-

less the portion of the barrel or shell under thedome (the neutral sheet) is stayed to the heador shell of the dome by stays which conformin spacing and size to the requirements givenin PG-46 and Table PG-23.1. With such stayedconstruction the diameter of a dome locatedon the barrel or shell of a boiler is limited toeight-tenths of the barrel or shell diameter.

45.4 All domes shall be so arranged that anywater can drain back into the boiler.

45.5 Flanges of domes shall be formed witha corner radius, measured on the inside, of atleast twice the thickness of the plate for plates1 in. in thickness or less, and at least 3 timesthe thickness of the plate for plates over 1 in.in thickness.

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TABLE PFT-44 — Minimum Total Areas of Openings (Square Inches) in Firetube Boilers for Safety V

Gage Boiler Heating Surface, sq. ft.Pressure,psi 100 200 300 400 500 600 800 1000 1200 1400 1600 1800 2000

16 3.174 6.348 9.522 12.695 15.869 19.043 25.392 31.739 38.086 44.435 50.738 57.130 63.478 25 2.500 5.000 7.499 10.000 12.498 15.000 20.000 24.996 30.000 35.000 40.000 44.992 49.992 50 1.584 3.168 4.752 6.338 7.920 9.504 12.677 15.839 19.007 22.175 25.354 28.510 31.678

75 1.166 2.331 3.497 4.663 5.828 6.995 9.326 11.657 13.989 16.320 18.652 20.983 23.314 100 0.924 1.849 2.773 3.697 4.621 5.546 7.394 9.243 11.092 12.940 14.789 16.637 18.486 125 0.767 1.533 2.300 3.067 3.834 4.600 6.134 7.667 9.201 10.734 12.267 13.800 15.334

150 0.655 1.311 1.966 2.621 3.276 3.932 5.242 6.553 7.863 9.174 10.484 11.795 13.106 175 0.572 1.145 1.718 2.289 2.862 3.435 4.579 5.725 6.870 8.015 9.158 10.305 11.450 200 0.508 1.016 1.525 2.033 2.541 3.049 4.066 5.082 6.099 7.115 8.132 9.148 10.164

225 0.457 0.913 1.370 1.827 2.284 2.740 3.654 4.567 5.481 6.394 7.308 8.221 9.134 250 0.415 0.830 1.244 1.659 2.074 2.489 3.318 4.148 4.978 5.807 6.637 7.466 8.296

based on formula

�

where A = total area of openings, square inches NOTE: number and size of opening shall provide for H = boiler heating surface, square feet Intermediate values may be interpolated. With flangeV = specific volume of steam in cubic feet per pound area for determining diameter.

at maximum allowable working pressure

Nominal Pipe Internal Internal Nominal Pipe Internal Internal Nominal Pipe InternSize, in. Diameter Area, sq. in. Size, in. Diameter Area, sq., in. Size, in. Diam

1/2 0.622 0.304 2 2.067 3.355 4 4.026 3/4 0.824 0.533 2-1/2 2.469 4.788 5 5.047 1 1.049 0.864 3 3.068 7.393 6 6.065 1-1/4 1.380 1.495 3-1/2 3.548 9.886 8 8.071 1-1/2 1.610 2.036

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45.6 Domes and manhole frames attached toshells or heads of boilers shall be designed inaccordance with PG-32 through PG-44, withthe additional requirement that the maximumallowable stress value in tension of rivets inmanhole frames having a thickness of 7/8 in.

or less and of rivets in domed flanges shall notexceed 7,200 psi.

45.7 In a locomotive-type boiler with a domeon a tapered course, the maximum allowablediameter of the dome shall be based on thatdiameter of the tapered course which inter-sects the axis or centerline of the dome.

SETTING

PFT-46 METHOD OF SUPPORT

46.1 The design and attachment of lugs, hang-ers, saddles, and other supports shall meet therequirements of PG-22.1 and PG-55.

46.2 In applying the requirements of 46.1,localized stresses due to concentrated sup-port loads, temperature changes, and restraintagainst dilation of the boiler due to pressureshall be provided for. Lugs, brackets, saddles,and pads shall conform satisfactorily to the

shape of the shell or surface to which they areattached or with which they are in contact.

46.3 A horizontal-return tubular boiler over72 in. in diameter shall be supported fromsteel hangers by the outside-suspension-typeof setting, independent of the furnace sidewalls. The hangers shall be so designed thatthe load is properly distributed between therivets attaching them to the shell and so thatno more than two of these rivets come in thesame longitudinal line on each hanger. The

distance girthwise of the boiler from the cen-ters of the bottom rivets to the centers of thetop rivets attaching the hangers shall be notless than 12 in. The other rivets used shall bespaced evenly between these points.

46.4 The horizontal-return tubular boiler, 14ft. or more in length, or over 54 in. and up to

2" Maximum

FIGURE PFT-46.1 — Spacing ofSupporting Lugs in Pairs on Horizontal-Return Tubular Boiler

and including 72 in. in diameter, shall be sup-ported by the outside-suspension-type of set-ting as specified in PFT-46.3 , or at four points by not less than eight steel or cast-iron lugsset in pairs. A horizontal-return tubular boilerup to and including 54 in. in diameter shall be

supported by the outside-suspension-type ofsetting as specified in PFT-46.3 , or by not lessthan two steel or cast-iron lugs on each side.The distance girthwise of the boiler from thecenters of the bottom rivets to the centers ofthe top rivets attaching the hangers shall benot less than the square of the shell diameterdivided by 675. If more than four lugs are usedthey shall be set in four pairs, the lugs of each

Section B-B

T T T34

34

34

122

“T” “T”min.

Dimension “T” notless than 1% ofBoiler Diameter

2 0

m a x

.

2 0

m a x .

Dimension “R” not less than 1-1/2 x Diameter of Hole

“ R ”

B

B

FIGURE PFT-46.2 — Welded BracketConnection for Horizontal-ReturnTubular Boilers

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pair to be spaced not over 2 in. apart and theload to be equalized between them (see FigurePFT-46.1). If the boiler is supported on struc-tural steel work, the steel supporting membersshall be so located or insulated that heat fromthe furnace cannot impair their strength.

46.5 Figure PFT-46.2 illustrates an acceptabledesign of hanger bracket for welded attach-ment to welded horizontal-return tubular boilers with the additional requirement thatthe hanger pin be located at the vertical cen-ter line over the center of a welded contactsurface. The bracket plates shall be spaced atleast 2-1/2 in. apart, but this dimension shall be increased if necessary to permit access forthe welding operation.

46.6 Wet-bottom stationary boilers shall besupported so as to have a minimum clear-ance of 12 in. between the underside of thewet-bottom and the floor to facilitate in-spection. Other types of firetube boilers sethorizontally shall be supported so that theyhave a minimum clearance of 12 in. betweenthe metal surface of the shell and the floor.Boiler insulation, saddles, or other supportsshall be arranged so that inspection openingsare readily accessible.

PIPING, FITTINGS, AND APPLIANCES

PFT-47 WATER GLASSES

Boilers of the horizontal firetube type shall be so set that when the water is at the lowestreading in the water gage glass there shall beat least 3 in. of water over the highest pointof the tubes, flues, or crown sheet.

PFT-48 FEED PIPING

48.1 When a horizontal-return tubular boilerexceeds 40 in. in diameter, the feedwater shall

discharge at about three-fifths the length fromthe end of the boiler that is subjected to thehottest gases of the furnace (except a horizon-tal-return tubular boiler equipped with anauxiliary feedwater heating and circulatingdevice), above the central row of tubes. The

feed pipe shall be carried through the heador shell farthest from the point of dischargeof the feedwater in the manner specified for asurface blowoff in PG-59.3.2, and be securelyfastened inside the shell above the tubes. 48.2 In vertical tubular boilers having tubes4 ft. or less in length, the feedwater shall beintroduced at a point not less than 12 in. abovethe crown sheet. When the boiler is underpressure, feedwater shall not be introducedthrough the openings or connections used forthe water column, the water gage glass, or thegage cocks. In closed systems the water may be introduced through any opening when the boiler is not under pressure.

PFT-49 BLOWOFF PIPING

49.1 Blowoff piping of firetube boilers thatare exposed to products of combustion shall be attached by screwing into a tapped open-

ing with a screw fitting or valve at the otherend.

49.2 Blowoff piping of firetube boilers thatare not exposed to products of combustionmay be attached by any method provided inthis Section except by expanding into groovedholes.

49.3 The bottom blowoff pipes of traction andportable boilers shall have at least one slow orquick-opening blowoff valve or cock conform-

ing to the requirements of PG-59.5.3.3.

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APPENDIX — EXPLANATORY OF THE CODE AND CONTAINING MATTERWHICH IS NOT MANDATORY UNLESS SPECIFICALLY REFERRED

TO IN THE RULES OF THE CODE

A = strength of solid plate = P x t x TS B = strength of plate between rivet holes

(P - d) t x TS C = shearing strength of one rivet in

single shear = n x s x a D = crushing strength of plate in front of

a rivet = d x t x c

Divide B, C, or D (whichever is the least) byA, and the quotient will be the efficiency ofa single-riveted lap joint as shown in FigureA-1.

TS = 55,000 psi t = 1/4 in. = 0.25 in. P = 1-5/8 in. = 1.625 in. d = 11/16 in. = 0.6875 in. a = 0.3712 sq. in. s = 44,000 psi c = 95,000 psi A = 1.625 x 0.25 x 55,000 = 22,343 B = (1.625–0.6875)0.25 x 55,000 = 12,890 C = 1 x 44,000 x 0.3712 = 16,332 D = 0.6875 x 0.25 x 95,000 = 16,328

�

�

EFFICIENCY OF JOINTS

A-1 EFFICIENCY OF RIVETEDJOINTS

The ratio which the strength of a unit lengthof a riveted joint has to the same unit lengthof the solid plate is known as the efficiencyof the joint and shall be calculated by thegeneral method illustrated in the followingexamples:

TS = tensile strength stamped on plate,pounds per square inch

t = thickness of plate, inches b = thickness of buttstrap, inches P = pitch of rivets, inches, on row having

greatest pitch d = diameter of rivet after driving,

inches = diameter of rivet hole a = cross-sectional area of rivet after

driving, square inches s = shearing strength of rivet in single

shear, pounds per square inch, asgiven in PG-23.2 S = shearing strength of rivet in double

shear, pounds per square inch, asgiven in PG-23.2

c = crushing strength of mild steel,pounds per square inch, as given inPG-23.3

n = number of rivets in single shear in aunit length of joint

N = number of rivets in double shear ina unit length of joint

A-2 EXAMPLE

Lap joint, longitudinal or circumferential,single riveted.

P

FIGURE A-1 — Example of Lap Joint,Longitudinal or Circumferential, SingleRiveted

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A-3 EXAMPLE

Lap joint, longitudinal or circumferential,double riveted.

A = strength of solid plate = P x t x TS

B = strength of plate between rivet holes(P–d) t x TS

C = shearing strength of two rivets insingle shear = n x s x a

D = crushing strength of plate in front oftwo rivets = n x d x t x c

Divide B, C, or D (whichever is the least) byA, and the quotient will be the efficiency ofa double-riveted lap joint as shown in FigureA-2.

TS = 55,000 psi t = 5/16 in. = 0.3125 in. P = 2 7/8 in. = 2.875 in. d = 3/4 in. = 0.75 in. a = 0.4418 sq. in. s = 44,000 psi c = 95,000 psi A = 2.875 x 0.3125 x 55,000 = 49,414 B = (2. 875–0.75) 0.3125 x 55,0 00 =

36,523 C = 2 x 44,000 x 0.4418 = 38,878

D = 2 x 0.75 x 0.3125 x 95,000 = 44,531

�

�

A-4 EXAMPLE

Butt- and double-strap joint, double riveted.


in the outer row = (P–d) t x TS C = shearing strength of two rivets in

double shear, plus the shearingstrength of one rivet in single shear= N x S x a + n x s x a

D = strength of plate between rivet holesin the second row, plus the shearingstrength of one rivet in single shearin the outer row = (P–2d) t x TS + nx s x a

E = strength of plate between rivet holesin the second row, plus the crushingstrength of buttstrap in front of onerivet in the outer row = (P - 2d) t xTS + d x b x c

F = crushing strength of plate in frontof two rivets, plus the crushingstrength of buttstrap in front of onerivet = N x d x t x c + n x d x b x c

G = crushing strength of plate in frontof two rivets, plus the shearingstrength of one rivet in single shear= N x d x t x c + n x s x a

H = strength of buttstraps between rivetholes in the inner row = (P–2d) 2bx TS. This method of failure is notpossible for thicknesses of buttstrapsrequired by these rules and the

FIGURE A-2 — Example of Lap Joint,Longitudinal or Circumferential, DoubleRiveted

P

FIGURE A-3 — Example of Butt- andDouble-Strap Joint, Double Riveted

P

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computation need only be made forold boilers in which thin buttstrapshave been used. For this reason thismethod of failure will not be consid-ered in other joints.

Divide B, C, D, E, F, G, or H (whichever isthe least) by A, and the quotient will be theefficiency of a butt- and double-strap joint,double riveted, as shown in Figure A-3.

TS = 55,000 psi t = 3/8 in. = 0.375 in. b = 5/16 in. = 0.3125 in. P = 4-7/8 in. = 4.875 in. d = 7/8 in. = 0.875 in. a = 0.6013 sq. in. s = 44,000 psi S = 88,000 psi c = 95,000 psi

Number of rivets in single shear in a unitlength of joint = 1.

Number of rivets in double shear in a unitlength of joint = 2.

A = 4.875 x 0.375 x 55,000 = 100,547 B = (4.875– 0.875)0. 375 x 55,000 =

82,500 C = 2 x 88,000 x 0.6103 + 1 x 44,000 x0.6013 = 132,286

D = (4.875–2 x 0.857) 0.375 x 55,000 + 1 x44,000 x 0.6013 = 90,910

E = (4.875–2 x 0.875) 0.375 x 55,000 +0.875 x 0.3125 x 95,000 = 90,499

F = 2 x 0.875 x 0.375 x 95,000 + 1 x 0.875x 0.3125 x 95,000 = 88,320

G = 2 x 0.875 x 0.375 x 95,000 + 1 x 44,000x 0.6013 = 88,800

�

�

A-5 EXAMPLE

Butt- and double-strap joint, triple riveted.


in the outer row = (P–d)t x TS C = shearing strength of four rivets in

double shear, plus the shearingstrength of one rivet in single shear= N x S x a + n x s x a

D = strength of plate between rivet holesin the second row, plus the shearingstrength of one rivet in single shearin the outer row = (P–2d)t x TS + nx s x a

E = strength of plate between rivet holesin the second row, plus the crushingstrength of buttstrap in front of onerivet in the outer row = (P–2d)t x TS+ d x b x c

F = crushing strength of plate in frontof four rivets, plus the crushingstrength of buttstrap in front of onerivet = N x d x t x c + n x d x b x c

G = crushing strength of plate in frontof four rivets, plus the shearingstrength of one rivet in single shear= N x d x t x c + n x s x a

Divide B, C, D, E, F, or G (whichever is theleast) by A, and the quotient will be the effi-ciency of a butt- and double-strap joint, tripleriveted as shown in Figure A-4.

TS = 55,000 psi t = 3/8 in. = 0.375 in. b = 5/16 in. = 0.3125 in. P = 6-1/2 in. = 6.5 in. d = 13/16 in. = 0.8125 in. a = 0.5185 sq. in.

s = 44,000 psi S = 88,000 psi c = 95,000 psi

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A = 6.5 x 0.375 x 55,000 = 134,062 B = (6.5–0. 8125) 0.375 x 55 ,000 =

117,304 C = 4 x 88,000 x 0.5185 + 1 x 44,000 x

0.5185 = 205,326 D = (6.5–2 x 0.8125) 0.375 x 55,000 + 1 x

44,000 x 0.5185 = 123,360 E = (6.5–2 x 0.8125)0.375 x 55,000 +

0.8125 x 0.3125 x 95,000 = 124,667 F = 4 x 0.8125 x 0.375 x 95,000 + 1 x 0.8125

x 0.3125 x 95,000 = 139,902 G = 4 x 0.8125 x 0.375 x 95,000 + 1 x 44,000

x 0.5185 = 138,595

�

�

A-6 EXAMPLE

Butt- and double-strap joint, quadrupleriveted.

A = strength of solid plate = P x t x TS

B = strength of plate between rivet holesin the outer row = (P–d)t x TS

C = shearing strength of eight rivetsin double shear, plus the shearingstrength of three rivets in singleshear = N x S x a + n x s x a

D = strength of plate between rivet holesin the second row, plus the shearingstrength of one rivet in single shearin the outer row = (P–2d)t x TS + 1x s x a

E = strength of plate between rivet holesin the third row, plus the shearingstrength of two rivets in the secondrow in single shear and one rivetin single shear in the outer row =(P–4d)t x TS + n x s x a

FIGURE A-4 — Example of Butt- andDouble-Strap Joint, Triple Riveted

P

FIGURE A-5 — Example of Butt- andDouble-Strap Joint, Quadruple Riveted

P

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F = strength of plate between rivet holesin the second row, plus the crushingstrength of buttstrap in front of onerivet in the outer row = (P–2d)t x TS+ d x b x c

G = strength of plate between rivet holes

in the third row, plus the crushingstrength of buttstrap in front oftwo rivets in the second row andone rivet in the outer row = (P–4d)tx TS + n x d x b x c

H = crushing strength of plate in frontof eight rivets, plus the crushingstrength of buttstrap in front of threerivets = N x d x t x c + n x d x b xc

I = crushing strength of plate in frontof eight rivets, plus the shearingstrength of two rivets in the secondrow and one rivet in the outer row,in single shear = N x d x t x c + n x sx a

Divide B, C, D, E, F, G, H, or I (whichever isthe least) by A, and the quotient will be theefficiency of a butt- and double-strap joint, quadruple riveted, as shown in Figure A-5.

TS = 55,000 psi

t = 1/2 in. = 0.5 in. b = 7/16 in. = 0.4375 in. P = 15 in. d = 15/16 in. = 0.9375 in. a = 0.6903 sq. in. s = 44,000 psi S = 88,000 psi c = 95,000 psi



A = 15 x 0.5 x 55,000 = 412,500 B = (15–0.9375)0.5 x 55,000 = 386,718 C = 8 x 88,000 x 0.6903 + 3 x 44,000 x

0.6903 = 577,090

D = (15–2 x 0.9375)0.5 x 55,000 + 1 x44,000 x 0.6903 = 391,310

E = (15–4 x 0.9375)0.5 x 55,000 + 3 x44,000 x 0.6903 = 400,494

F = (15–2 x 0.9375)0.5 x 55,000 + 0.9375x 0.4375 x 95,000 = 399,902

G = (15–4 x 0.9375) 0.5 x 55,000 + 3 x0.9375 x 0.4375 x 95,000 = 426,269

H = 8 x 0.9375 x 0.5 x 95,000 + 3 x 0.9375x 0.4375 x 95,000 = 473,145

I = 8 x 0.9375 x 0.5 x 95,000 + 3 x 44,000x 0.6903 = 447,369

�

�

A-7

Figure A-6 and A-7 illustrate other joints thatmay be used in which eccentric stresses areavoided. The butt- and double-strap jointwith straps of equal width shown in FigureA-6 may be so designed that it will have anefficiency of from 82 to 84 percent, and thesawtooth joint shown in Figure A-7 so thatit will have an efficiency of from 92 to 94percent.

BRACED AND STAYED SURFACES

A-8

The allowable loads based on the net cross-sectional area of staybolts with V-threads arecomputed from the following formulas. Theuse of Whitworth threads with other pitchesis permissible.

The formula for the diameter of a staybolt atthe bottom of a V-thread is:

D–(P x 1.732) = d

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where, D = diameter of staybolt over the

threads, inches P = pitch of threads, inches =

1/number of threads per inch d = diameter of staybolt at bottom of

threads, inches 1.732= a constant

When ANSI Standard threads are used theformula becomes

D–(P x 1.732) = d

Tables A-1 and A-2 give the allowable loadson net cross-sectional areas for staybolts withV-threads having 12 and 10 threads per in.

FIGURE A-6 — Illustration of Butt- andDouble-Strap Joint with Straps of EqualWidth

FIGURE A-7 — Illustration of Butt- andDouble-Strap Joint of the Sawtooth Type

A-9

Table A-3 shows the allowable loads onnet cross-sectional areas of round stays or braces.

A-10

Table A-4 gives the net areas of segments ofheads for use in computing stays.

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TABLE A-1 — Allowable Loads on Staybolts with V Threads, 12 ThreadsPer Inch

Outside diameter Diameter at Net Cross-Sectional Allowable Loadof Staybolts, in. Bottom of Area (at Bottom at 7500 lb Thread, in. of Thread), sq. in. Stress per sq. in.

3/4 0.7500 0.6057 0.288 216013/16 0.8125 0.6682 0.351 26327/8 0.8750 0.7307 0.419 3142

15/16 0.9375 0.7932 0.494 37051 1.0000 0.8557 0.575 43121-1/16 1.0625 0.9182 0.662 4965

1-1/8 1.1250 0.9807 0.755 56621-3/16 1.1875 1.0432 0.855 61421-1/4 1.2500 1.1057 0.960 7200

1-5/16 1.3125 1.1682 1.072 80401-3/8 1.3750 1.2307 1.190 89251-7/16 1.4375 1.2932 1.313 98491-1/2 1.5000 1.3557 1.444 10830

TABLE A-2 — Allowable Loads on Staybolts with V Threads, 10 ThreadsPer Inch

Outside diameter Diameter at Net Cross-Sectional Allowable Loadof Staybolts, in. Bottom of Area (at Bottom at 7500 lb Thread, in. of Thread), sq. in. Stress per sq. in.

1-1/4 1.2500 1.0768 0.911 68321-5/16 1.3125 1.1393 1.019 76421-3/8 1.3750 1.2018 1.134 85051-7/16 1.4375 1.2643 1.255 94121-1/2 1.5000 1.3268 1.382 103651-9/16 1.5625 1.3893 1.515 113621-5/8 1.6250 1.4518 1.655 12412

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TABLE A-3 — Allowable Loads on Round Braces or Stay Rods

Allowable stress, in psi, on Net Cross-Sectional Area Minimum Diameter of Net Cross-Sectional 6000 8500 9500Circular Stay, in. Area of Stay, sq. in.

Allowable load, in lb., on Net Cross-Sectional Area

1 1.0000 0.7854 4712 6676 74621-1/16 1.0625 0.8866 5320 7536 84231-1/8 1.1250 0.9940 5964 8449 9443

1-3/16 1.1875 1.1075 6645 9414 105211-1/4 1.2500 1.2272 7363 10431 116581-5/16 1.3125 1.3530 8118 11501 12854

1-3/8 1.3750 1.4849 8909 12622 141071-7/16 1.4375 1.6230 9738 13796 154191-1/2 1.5000 1.7671 10603 15020 16787

1-9/16 1.5625 1.9175 11505 16298 182161-5/8 1.6250 2.0739 12443 17628 197021-11/16 1.6875 2.2365 13419 19010 21247

1-3/4 1.7500 2.4053 14432 20445 228521-13/16 1.8125 2.5802 15481 21932 245121-7/8 1.8750 2.7612 16567 23470 26231

1-15/16 1.9375 2.9483 17690 25061 280092 2.0000 3.1416 18850 26704 298452-1/8 2.1250 3.5466 21280 30147 33693

2-1/4 2.2500 3.9761 23857 33797 37773

2-3/8 2.3750 4.4301 26580 37656 420862-1/2 2.500 4.9087 29452 41724 46632

2-5/8 2.6250 5.4119 32471 46001 514132-3/4 2.7500 5.9396 35638 50487 564262-7/8 2.8750 6.4918 38951 55181 616733 3.0000 7.0686 42412 60083 67152

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TABLE A-4 — Net Areas of Segments of Heads Where d, as Given in PFT-31.1 andPFT-31.3 is Equal to 3 inches

Height From Diameter of Boiler, in.Tubes to Shell, 24 30 36 42 48 54 60 66 72 78 84 90 96in. Area to Be Stayed, sq. in.

8 28 33 37 40 43 47 51 53 55 58 60 63 658-1/2 35 41 46 51 55 59 63 66 70 74 76 80 829 42 49 56 62 67 72 76 82 86 90 92 95 989-1/2 50 58 66 70 80 86 91 96 101 105 111 116 11910 57 68 77 85 93 99 106 112 117 123 129 132 137

10-1/2 66 78 89 98 107 114 123 131 135 142 147 153 16011 74 88 100 111 121 130 138 147 155 161 169 174 18311-1/2 83 99 112 124 137 146 156 165 173 181 189 196 20412 91 109 125 139 151 163 174 184 194 203 213 219 23012-1/2 ... 120 138 153 167 180 193 204 216 224 234 243 252

13 ... 132 151 168 183 197 211 224 235 247 256 267 27913-1/2 ... 143 164 183 200 216 230 246 258 270 282 293 30214 ... 155 178 199 217 234 250 266 280 294 305 319 33114-1/2 ... 167 192 215 235 254 271 287 303 318 333 345 36015 ... 178 206 231 252 273 291 309 326 343 357 372 386

15-1/2 ... ... 220 247 271 291 312 332 350 368 382 400 41716 ... ... 235 263 289 312 334 355 374 394 411 423 44316-1/2 ... ... 249 281 308 332 357 380 399 420 436 457 47517 ... ... 264 297 326 353 378 402 425 447 467 486 50217-1/2 ... ... ... 314 345 374 400 426 449 471 494 516 536

18 ... ... ... 331 365 396 424 450 476 500 520 543 56418-1/2 ... ... ... 349 384 417 448 476 501 526 552 577 59819 ... ... ... 366 404 439 470 500 529 555 580 604 63119-1/2 ... ... ... 384 424 461 496 528 558 584 613 641 66320 ... ... ... 401 444 483 519 552 583 613 642 667 699

20-1/2 ... ... ... ... 464 505 543 578 613 643 675 706 72921 ... ... ... ... 485 528 568 604 640 673 705 733 76621-1/2 ... ... ... ... 505 551 594 632 669 703 739 766 79722 ... ... ... ... 526 574 618 658 697 734 769 800 83522-1/2 ... ... ... ... ... 597 643 687 726 765 800 835 867

23 ... ... ... ... ... 620 668 713 754 796 830 869 90623-1/2 ... ... ... ... ... 642 695 740 784 827 866 904 94524 ... ... ... ... ... 667 719 768 814 859 897 939 97824-1/2 ... ... ... ... ... 689 745 797 843 892 934 975 101825 ... ... ... ... ... 714 771 825 875 922 966 1010 1051

25-1/2 ... ... ... ... ... 737 798 855 907 956 1003 1047 109226 ... ... ... ... ... 761 824 882 936 987 1035 1083 112626-1/2 ... ... ... ... ... ... 850 909 968 1024 1073 1120 116727 ... ... ... ... ... ... 877 939 998 1053 1106 1157 120227-1/2 ... ... ... ... ... ... 904 968 1030 1089 1145 1195 1243

28 ... ... ... ... ... ... 930 997 1060 1120 1177 1232 127928-1/2 ... ... ... ... ... ... ... 1028 1092 1157 1211 1270 132129 ... . .. .. . ... ... . .. .. . 1056 1123 1187 1248 1305 136029-1/2 ... ... ... ... ... ... ... 1084 1155 1221 1284 1347 140030 ... . .. .. . ... ... . .. .. . 1115 1187 1255 1321 1382 1442

30-1/2 ... ... ... ... ... ... ... ... 1218 1290 1358 1424 148031 ... ... ... ... ... ... ... ... 1252 1324 1394 1459 152331-1/2 ... ... ... ... ... ... ... ... 1286 1359 1433 1496 156132 ... ... ... ... ... ... ... ... 1317 1394 1467 1538 165032-1/2 ... ... ... ... ... ... ... ... ... 1430 1508 1575 1650

33 ... ... ... ... ... ... ... ... ... 1465 1542 1617 168733-1/2 ... ... ... ... ... ... ... ... ... 1500 1578 1655 173334 ... ... ... ... ... ... ... ... ... 1536 1617 1695 177034-1/2 ... ... ... ... ... ... ... ... ... ... 1654 1735 181635 ... ... ... ... ... ... ... ... ... ... 1692 1775 1856

35-1/2 ... ... ... ... ... ... ... ... ... ... ... 1810 190036 ... ... ... ... ... ... ... ... ... ... ... 1857 194136-1/2 ... ... ... ... ... ... ... ... ... ... ... ... 198437 ... ... ... ... ... ... ... ... ... ... ... ... 2026

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APPENDIX D — RECOMMENDED GUIDE FOR THE DESIGN OFA TEST SYSTEM FOR PRESSURE RELIEF DEVICES IN

COMPRESSIBLE FLUID SERVICE

D-1000 INTRODUCTION

This nonmandatory appendix provides guid-ance for the design of a test system usingcompressible fluids (i.e., steam or air/gas)and permits the determination of pressurerelief valve set pressure and valve operatingcharacteristics such as blowdown. The sizeof the test vessel needed depends on the sizeof the valve, its set pressure, the design of thetest system, and whether blowdown must bedemonstrated. A repair organization may usethe information provided in this appendixto determine the minimum size test vesselneeded so that the measured performanceis characteristic of the valve and not the testsystem.

D-1010 GENERAL

The National Board administrative rulesand procedures for the “VR” Certificate ofAuthorization and symbol stamp requirethat pressure relief valves, after repair, be

tested in accordance with the manufacturer’srecommendations and the applicable ASMECode. The purpose of this testing is to pro-vide reasonable assurance that valves willperform according to design when they arereturned to service.

It is recognized that a full evaluation of theperformance of some pressure relief valve de-signs requires testing at maximum allowableoverpressure. However, it is beyond the scopeof this appendix to define test equipment or

facilities for such testing.

D-1020 provides a glossary, D-2000 describestypical test equipment, and D-3000 providesdata for estimating the size of test vesselsrequired.

D-1020 GLOSSARY

Accumulator: A vessel in which the test me-dium is stored or accumulated prior to its usefor testing.

Transient: A very short time, occurring over a brief time interval, maintained only for a shorttime interval as opposed to a steady state.

Velocity distortion: The pressure decrease thatoccurs when fluid flows past the opening ofa pressure sensing line. This is a distortion ofthe pressure that would be measured underthe same conditions for a non or slowly mov-ing fluid.

Intervening: Coming between or inserted between, as between the test vessel and thevalve being tested.

Water head: The pressure adjustment thatmust be taken into account due to the weightof test media (in this case, steam) that is 0.433psi per ft. (10 KPa per m.) added (subtracted)

from the gage pressure for each foot the gageis below (above) the point at which the pres-sure is to be measured.

D-2000 TEST SYSTEMDESCRIPTION

An optimum configuration, particularlywhen the test medium source is of smallcapacity, is shown in Figure D-2000. Thetest medium flows from the pressure

source, usually a compressor or boiler, to anaccumulator. It then flows through apressure-controlling valve into the testvessel, from which it is discharged,through the pressure relief valve mount-ed on the test vessel. The pressure-con-

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APPENDIX D — RECOMMENDED GUIDE FOR THE DESIGN OF A TEST SYSTEM FORPRESSURE RELIEF DEVICES IN COMPRESSIBLE FLUID SERVICE

trolling valve is usually a globe valve,although any throttling valve is acceptable. Ifthe pressure-controlling valve is of adequatesize and can open quickly, large transientflows can be generated, increasing the pres-sure above the pressure relief valve set pres-

sure, causing it to lift, and be sustained in itslifted condition.

Figure D-2000-a shows a simpler test sys-tem in which the test vessel is pressurizeddirectly from the pressure source withoutthe use of an accumulator. In this con-figuration, flow-rates through the pres-sure relief valve and any consequentover-pressure are dependent on the flowgenerating capacity of the pressure source.

In a test facility, the pressure relief valve isusually mounted on an isolating valve thatshould be of sufficient size that it will notchoke flow to the pressure relief valve. Thereshould be no intervening piping between thetwo valves to avoid any unnecessary pressuredrop between the test vessel and the pressurerelief valve.

The isolating valve and any adapter flanges orvalve test nozzles must be designed to sustain

pressure relief valve discharge forces, and sosecured that these forces cannot be transmit-ted to the test vessel. This is especially impor-tant for larger valves set at pressures greaterthan 100 psig (700 KPa).

The vessel should have a length-to-diameterratio as low as is practical, and should be suit-ably anchored.

Pressure sensing lines should be connectedto the test vessel well away from any inlet

or outlet connections where transient flowvelocity during testing could cause erroneouspressure readings. When testing with steam,any water head which develops in the gageline must be taken into consideration.

Any intervening piping between the test ves-sel and the pressure relief valve should be asshort and as straight as possible and be of ad-equate size to minimize inlet pressure drop.

In the case of steam, the equipment should be

insulated and steam traps should be installed,as appropriate, to ensure that the test steam isdry, saturated steam with a minimum qualityof 98%.

Safety valves should be used to protect thetest vessel and the accumulator.

D-3000 TEST VESSEL SIZING DATA

Recommended test vessel sizes are given in Fig-ures D-3000 and D-3000-a f or a configurationusing one vessel fed directly from the sourceof the test medium. Figure D-3000 gives thetest vessel size in cu. ft. vs. the valve orificearea in sq. in. for dry, saturated steam. Curvesare shown for set pressures up to 500 psig (3.5MPa) for three different blowdowns: 4%, 7%,and 10%. The source is assumed to be capableof feeding the test vessel at 2500 lbs/hr. (1140kg/hr) Figure D-3000-a gives similar curvesfor air with a source capable of feeding the

test vessel at 200 SCFM.

For smaller valves, with effective orifices lessthan 1.28 sq. in., the size of the test vesselneeded becomes less dependent on the flowcapacity of the source. For these valves, a 15cu. ft. (0.4 cu. m.) minimum size test vessel isrecommended. This should allow the accuratemeasurement and setting of blowdown forsmall valves. This minimum size should also be adequate for determining set pressuresof larger valves; however, larger test vessels

must be used if blowdown is to be set accu-rately. It is recognized that there are practicallimits on the size and maximum pressure of atest vessel used to demonstrate pressure reliefvalve operational characteristics. In suchcases, determination of valve set pressure

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remains the only viable production and repairtest option. The recommended minimum sizetest vessel [15 cu. ft. (0.4 cu. m.)] should beadequate for this purpose.

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APPENDIX D — RECOMMENDED GUIDE FOR THE DESIGN OF A TEST SYSTEM FORPRESSURE RELIEF DEVICES IN COMPRESSIBLE FLUID SERVICE

FIGURE D-2000-a — Schematic of Test Equipment without Accumulator

FIGURE D-2000 — Schematic of Test Equipment with Accumulator

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Recommended Procedures forRepairing Pressure Relief Valves

Appendix E

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APPENDIX E — RECOMMENDED PROCEDURES FOR REPAIRING


E-1000 INTRODUCTION

It is essential that the repair organizationestablish basic, specific procedures for therepair of pressure relief valves. The purposeof these recommended procedures is to pro-vide the repair organization with guidelinesfor this important aspect of valve repair. Itis realized that there are many various typesof valves and conditions under which theyare repaired and, for this reason, the specificitems in these recommended procedures maynot apply, or they may be inadequate foreach of those types or to the detailed repairs

which may be required for each valve. SeeRA-2255(i).

Part I contains recommended procedures forthe repair of spring loaded pressure reliefvalves, and Part II contains recommendedprocedures for the repair of pilot operatedtypes of safety relief valves.

E-2000 SPRING LOADED


Note 1: Prior to removal of a valve from asystem for a repair or any disassembly, ensurethat all sources of pressure have been removedfrom the valve.

1. Visual Inspection as Received This information is to be recorded:

a. Record user (customer) identificationnumber.

b. Complete nameplate data, plus anyimportant information received fromcustomer.

c. Check external adjustment seals forwarranty repair.

d. Check bonnet for venting on bellowtype valves.

e. Check appearance for any unusualdamage, missing, or misappliedparts.

Note 2: If sufficient damage or other unusualconditions are detected that may pose a safetyrisk during preliminary testing, then proceeddirectly to step three.

Note 3: Valves that are to be repaired in placeproceed to step 3, unless preliminary testing

has been authorized by the owner.

2. Preliminary Test as Received Information from the recommended pre-

liminary performance test and subsequentdisassembly and inspections will providea basis for any repair interval change thatshould be necessary to ensure that thevalve will function as intended.

a. Determine set pressure or Cold Dif-ferential Test Pressure (CDTP) inaccordance with manufacturer’srecommendations and appropriateASME Code Section. Do not allowtest pressure to exceed 116% of setpressure unless otherwise specified bythe owner. A minimum of three tests isusually required to obtain consistentresults.

Note 4: If results do not correlate with fieldperformance, then steps to duplicate field

conditions (fluid and temperature) may benecessary.

b. Record preliminary test results andtest bench identification data.

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APPENDIX E — RECOMMENDED PROCEDURES FOR REPAIRING PRESSURE RELIEF VALVES

3. Disassemblya. Remove cap and lever assembly, if

applicable.

b. Remove release nut assembly, ifapplicable.

c. Loosen jam nut on adjusting (com-pression) screw.

d. Record measurement and removeadjusting (compression) screw.

e. Remove bonnet or yoke.

f. Remove spring and washers, and tag(identify) including upper and lowerwashers, as appropriate.

g. Remove spindle and disk assembly.

h. Remove ring pins.

i. Record measurement and removeadjusting rings, nozzle, and guide, asapplicable.

4. Cleaninga. Wire all small parts together and clean

by means of an abrasive (caution: donot use a cleaning method that willdamage the parts.)

b. Do not clean in a chemical solution ex-cept under acceptable circumstances.

c. Protect seating surfaces and name-plates prior to cleaning.

5. Inspectiona. Check spring for damage such as

erosion, corrosion, cracking, breakage,or compression below free height.

b. Check nozzle for cracks (NDE asapplicable) or unusual wear.

c. Check disk assembly for cracks (NDEas applicable) or unusual wear.

d. Check spindle for trueness, bearingareas, and thread condition.

e. Check guide for wear and galling.

f. Check adjusting ring(s) for wornthreads and wear.

g. Check ring pins for bent or broken pinand thread condition.

h. Check bellows, if provided, for pin-holes and corrosion.

i. Check flange gasket facings for wearand cuts.

6. Machining Machine nozzle and disk as necessary

to the manufacturer’s critical dimensioncharts.

7. Lappinga. Machine or hand lap disk and nozzle

to be sure of flatness.

b. Lap bevel seats to a grey finish; thenremachine disk or plug to the manu-facturer’s critical dimension.

8. Adjusting Rings Install lower ring and guide ring to the

same position they were when removed,or to manufacturer’s specifications.

9. Bearing Points Grind all bearing areas with grinding

compound to make sure they are round

and true.

10. Testing All test data is to be recorded. Testing

will be done in accordance with manu-facturer’s recommendations and appro-

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priate ASME Code section. To precludeunsafe and unstable valve operations orerroneous performance test results, it isrecommended that low volume testingequipment (e.g., gas cylinders withouta test vessel, hand pumps, tubing, etc.)

should be avoided.

11. Sealing After final adjusting and acceptance by

quality control inspection, all externaladjustments will be sealed with a safetyseal providing a means of identification ofthe organization performing the repair.

12. Nameplate The repairer will place a repair nameplate

on each repaired valve. The nameplateshall, as a minimum, meet the require-ments of RE-1061.

13. Packaging, Shipping and Transportationa. Valves should be securely fastened to

pallets in the vertical position to avoidside loads on guiding surfaces.

b. Threaded and socket-weld valves upto 2 in. may be securely packaged andcushioned during transport.

c. Valve inlet and outlet connection,drain connections and bonnet ventsshould be protected during shipmentand storage to avoid internal contami-nation of the valve. Ensure all coversand/or plugs are removed prior toinstallation.

d. Lifting levers should be wired or se-cured so they cannot be moved whilethe valve is being shipped or stored.

e. Valves for special services, including but not limited to oxygen, chlorine,and hydrogren peroxide, should bepackaged in accordance with ap-propriate standards and/or ownerprocurement requirements.

E-3000 PILOT OPERATED SAFETY

RELIEF VALVES

1. Visual Inspection as Received This information is to be recorded:

a. Complete nameplate data, plus anyother important information receivedfrom the customer.

b. User identification number, ifapplicable.

c. Seals on external adjustment (yes/no).

d. Identification on seal.

e. Obvious damage and external condi-tion including missing or misappliedparts.

2. Disassemblya. Remove pilot and disassemble per

manufacturer’s maintenance instruc-tion.

b. Disassemble main valve. Where liftadjustments are provided, do not

remove the locking device or changethe lift unless it is required as part ofconversion.

c. Remove the nozzle if recommended by the manufacturer’s maintenanceinstructions and/or when required aspart of conversion.

3. Cleaninga. Pilot – Components of pilot are small

and must be handled carefully to pre-

vent damage or loss. Clean parts andnameplates with solvents that will notaffect the parent metal and/or polishwith 500 grit paper.

b. Main Valve – Clean by appropriatemeans such as abrasive blast. Finishes

A05

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of machined surfaces must not beaffected. (Caution: Do not use a clean-ing method that will damage the partsor nameplates.)

4. Inspection

a. Pilot

1. Check spring for damage such ascorrosion, cracks, out of squareends, etc.

2. Inspect all parts for damage. Small burrs or scratches may be removed by polishing. Severely damagedparts should be replaced. (Internalcomponents or pilots should not be repaired by machining as thefunctions of the pilot could easily be impaired.)

3. Check strainers on inlet and outletlines.

4. Replace all soft goods per manu-facturer’s recommendation.

b. Main Valve

1. Check nozzle seating surface fornicks. These can be removed by machining or lapping as re-quired.

2. Check the piston and liner (orother moving member) for gall-ing or excessive wear. The pistonshould move freely in the liner.

3. Replace soft goods or relap disk asrequired.

4. Where lift adjustments are pro-vided, measure the lift per themanufacturer’s specifications.

5. Testing All test data is to be recorded. Testing

will be done in accordance with themanufacturer’s recommendation and inaccordance with the applicable ASMECode section. To preclude unsafe and un-

stable valve operations or erroneous per-formance test results, it is recommendedthat low volume testing equipment (e.g.,gas cylinders without a test vessel, handpumps, tubing, etc.) should be avoided.

6. Sealing After final adjustment and acceptance by

quality control, all external adjustmentswill be sealed by means assuring positiveidentification of the organization perform-ing the repair.

7. Nameplate The repairer will place a repair nameplate

on each repaired valve. The nameplate, asa minimum, shall meet the requirementsof RE-1061.

8. Packaging, Shipping and Transportationa. Valves should be securely fastened to

pallets in the vertical position to avoidside loads on guiding surfaces.

b. Threaded and socket-weld valves upto 2 in. may be securely packaged andcushioned during transport.

c. Valve inlet and outlet connection anddrain connections should be protectedduring shipment and storage to avoidinternal contamination of the valve.Ensure all covers and/or plugs areremoved prior to installation.

d. Lifting levers should be wired or se-cured so they cannot be moved whilethe valve is being shipped or stored.

e. Tubing should be protected duringshipment and storage to avoid dam-age and/or breakage.

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f. Valves for special services, including but not limited to oxygen, chlorine,and hydrogen peroxide, should bepackaged in accordance with ap-propriate standards and/or ownerprocurement requirements.

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Appendix F

Pressure Differential Between Safety orSafety Relief Valve Setting and Boiler orPressure Vessel Operating Pressure

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APPENDIX F — PRESSURE DIFFERENTIAL BETWEEN SAFETY OR

SAFETY RELIEF VALVE SETTING AND BOILER OR

PRESSURE VESSEL OPERATING PRESSURE

F-1000 SCOPE

If a safety valve or safety relief valve issubjected to pressure at or near its set pres-sure, it will tend to weep or simmer, anddeposits may accumulate in the seat and diskarea. Eventually, this can cause the valve tofreeze close and thereafter the valve could failto open at the set pressure. Unless the sourceof pressure to the boiler or pressure vessel isinterrupted, the pressure could exceed therupture pressure of the vessel.

It is important that the pressure differential between the valve set pressure and the boileror pressure vessel operating pressure is suf-ficiently large to prevent the valve from weep-ing or simmering.

F-2000 HOT WATER HEATING

BOILERS

For hot water heating boilers, the recom-mended pressure differential between the

pressure relief valve set pressure and the boiler operating pressure should be at least10 psi (70 KPa), or 25% of the boiler operatingpressure, whichever is greater.

Two examples follow:a. If the safety relief valve of a hot-water-

heating boiler is set to open at 30 psi (210KPa), the boiler operating pressure shouldnot exceed 20 psi (140 KPa).

b. If the safety relief valve of a hot water

heating boiler is set to open at 100 psi (690

KPa), the boiler operating pressure shouldnot exceed 75 psi (520 KPa).

Section IV of the ASME Code does not requirethat safety relief valves used on hot waterheating boilers have a specified blowdown.Therefore, to help ensure that the safety re-lief valve will close tightly after opening andwhen the boiler pressure is reduced to thenormal operating pressure, the pressure atwhich the valve closes should be well abovethe operating pressure of the boiler.

F-3000 STEAM HEATING BOILERS

For steam heating boilers, the recommendedpressure differential between the safety valveset pressure and boiler operating pressureshould be at least 5 psi (35 KPa), i.e., the boileroperating pressure should not exceed 10 psi(70 KPa).

Since some absorption-type refrigerationsystems use the steam heating boiler for their

operation, the boiler operating pressure mayexceed 10 psi (70 KPa). If the boiler operatingpressure is greater than 10 psi (70 KPa), itshould not exceed 15 psi (100 KPa), minus the blowdown pressure of the safety valve.

This recommendation can be verified byincreasing the steam pressure in the boileruntil the safety valve pops, then slowlyreducing the pressure until it closes, to ensurethat this closing pressure is above the operat-ing pressure.

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APPENDIX F — PRESSURE DIFFERENTIAL BETWEEN SAFETY OR SAFETY RELIEF VALVE SETTINGAND BOILER OR PRESSURE VESSEL OPERATING PRESSURE

F-4000 POWER BOILERS

For power boilers (steam), the recommended pressure differentials between the safety valveset pressure and the boiler operating pressure are as follows:

MINIMUM PRESSURE DIFFERENTIAL AS

PERCENTAGE OF BOILER DESIGN PRESSURE

DESIGN PRESSURE: over 15 psi to 300 psi (100 KPa to 2100 KPa) 10% but not less than 7 psi (50 KPa)

over 300 psi to 1000 psi (2100 KPa to 6900 KPa) 7% but not less than 30 psi (210 KPa)

over 1000 psi to 2000 psi (6900 KPa to 13.8 MPa) 5% but not less than 70 psi (500 KPa)

over 2000 psi (13.8 MPa) per designer’s judgement

Notes: 1. Above 2000 psi (13.8 MPa) the pressure differential between operating pressureand the maximum allowable working pressure is a matter for the designer’s judge-ment, taking into consideration such factors as satisfactory operating experienceand the intended service conditions .

2. Safety relief valves in hot water service are more susceptible to damage and sub-sequent leakage, than safety valves relieving steam. It is recommended that themaximum allowable working pressure of the boiler and safety relief valve set-ting for high-temperature hot water boilers be selected substantially higher than

the desired operating pressure, so as to minimize the times the safety relief valvemust lift.

F-5000 PRESSURE VESSELS

Due to the variety of service conditions andthe various designs of pressure relief valves,only general guidelines can be given regard-ing differentials between the set pressure ofthe valve and the operating pressure of the

vessel. Operating difficulty will be minimized by providing an adequate differential for theapplication. The following is general advi-sory information on the characteristics of theintended service and of the pressure reliefvalves that may bear on the proper pressuredifferential selection for a given application.

These considerations should be reviewedearly in the system design since they maydictate the maximum allowable working pres-sure of the system.

To minimize operational problems it isimperative that the user consider not onlynormal operating conditions of the fluids

(liquids or gases), pressures, and tempera-tures, but also start-up and shutdown condi-tions, process upsets, anticipated ambientconditions, instrument response time, pres-sure surges due to quick-closing valves, etc.When such conditions are not considered, thepressure relief devices may become, in effect, a

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pressure controller, a duty for which it was notdesigned. Additional consideration should begiven to the hazard and pollution associatedwith the release of the fluid. Larger differen-tials may be appropriate for fluids which aretoxic, corrosive, or exceptionally valuable.

The blowdown characteristics and capabil-ity are the first consideration in selecting acompatible valve and operating margin.After a self-actuated release of pressure, thevalve must be capable of reclosing above thenormal operating pressure. For example: ifthe valve is set at 100 psi (690 KPa) with a 7% blowdown, it will close at 93 psi (640 KPa).The operating pressure must be maintained below 93 psi (640 KPa) in order to preventleakage or flow from a partially open valve.Users should exercise caution regarding the blowdown adjustment of large, spring-loadedvalves. Test facilities, whether owned by themanufacturer, repair house, or user, may nothave sufficient capacity to accurately verifythe blowdown setting. The setting cannot beconsidered accurate unless made in the fieldon an actual installation.

Pilot operated valves represent a special casefrom the standpoint of both blowdown and

tightness. The pilot portion of some pilotoperated valves can be set at blowdowns asshort as 2%. This characteristic is not, how-ever, reflected in the operation of the mainvalve in all cases. The main valve can varyconsiderably from the pilot depending on thelocation of the two components in the system.If the pilot is installed remotely from the mainvalve, significant time and pressure lags canoccur, but reseating of the pilot assures reseat-ing of the main valve. The pressure drop inconnecting piping between the pilot and the

main valve must not be excessive, otherwisethe operation of the main valve will be ad-versely affected.

Tightness capability is another factor affect-ing valve selection, whether spring-loadedor pilot operated. Tightness varies somewhatdepending on whether metal or resilient seats

are specified and also on such factors as corro-sion and temperature. The required tightnessand test method should be specified to complyat a pressure not lower than the normal op-erating pressure of the process. It should beremembered that any degree of tightness ob-

tained should not be considered permanent.Service operation of a valve almost invariablyreduces the degree of tightness.

The following minimum pressure differentialsare recommended unless the safety or safetyrelief valve has been designed or tested ina specific or similar service and a smallerdifferential has been recommended by themanufacturer:

a. for set pressures up to 70 psi (480 KPa),the recommended pressure differential is5 psi (35 KPa);

b. for set pressure between 70 and 1000psi (480 KPa and 6900 KPa), the recom-mended pressure differential is 10% of setpressure;

c. for set pressures above 1000 psi (6900KPa), the recommended pressure differ-ential is 7% of set pressure.

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Safety Valves on the Low-Pressure Sideof Steam Pressure-Reducing Valves

Appendix G

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APPENDIX G — SAFETY VALVES ON THE LOW-PRESSURE SIDEOF STEAM PRESSURE-REDUCING VALVES

G-1000 SCOPE

The subject of protection of vessels in steam

service connected to the low-pressure sideof a steam pressure-reducing valve is of con-siderable importance to proper operation ofauxiliary equipment such as pressure cookers,hot water heating systems, etc., operating atpressures below that which the primary boilergenerating unit is operating.

To automatically reduce the primary boilerpressure for such processing equipment,pressure-reducing valves are used. Themanufacturers of such equipment have dataavailable listing the volume of flow throughreducing valves manufactured by them, butsuch data are not compiled in a form that theresults can be deduced readily. To protect theequipment operating on the low pressure sideof a pressure-reducing valve, safety valves ofa relieving capacity sufficient to prevent anunsafe pressure rise in case of failure ofthe pressure-reducing valve, should be in-stalled.

The pressure-reducing valve is a throttlingdevice, the design of which is based oncertain diaphragm pressures opposed byspring pressure which, in turn, controls theopening through the valve. If the spring, thediaphragm, or any part of the pressure-re-ducing valve fails, steam will flow directlythrough the valve and the low pressure equip-ment will be subjected to the boiler pressure.To protect the equipment operating on thelow pressure side of the pressure-reducingvalve, safety valve(s) should be installed on

the low pressure side of the pressure-reducingvalve which will provide a relieving capacitysufficient to prevent the pressure from risingabove the system design pressure.

In most cases pressure-reducing valves usedfor the reduction of steam pressures have thesame pipe size on the inlet and outlet. In case

of failure of a pressure-reducing valve, thesafety valve on the low-pressure side musthave a capacity to take care of the volume of

steam determined by the high pressure sideand the area of the pipe.

G-2000 INSTALLATION OF SAFETYVALVES

In most cases it is necessary to install morethan one safety valve on the low-pressure sideof the pressure-reducing valve. It is advisable,if the safety valves are connected to the pipeattached to the pressure-reducing valve, thateach safety valve have a separate connectionto the pipe. It is not important that all thesafety valves be mounted on the pipelineconnecting the pressure-reducing valve tothe auxiliaries. Safety valves will be equallyeffective if they are attached to some of theauxiliaries provided the piping betweenthe pressure-reducing valve and the safetyvalve is of a size adequate for the maximumpressure, and there are no intervening stopvalves.

G-3000 SAFETY VALVE CAPACITY

The capacity of the safety valve(s) on thelow-pressure side of the pressure-reducingvalve should be based on the capacity of thepressure-reducing valve when wide open orunder maximum flow conditions or the flowcapacity through the bypass valve.

By using the formula in G-4000 below, In-

spectors may calculate the required relievingcapacities of the safety valve(s) installed onthe low-pressure side of the pressure-reduc-ing valve.

Usually a pressure-reducing valve has a by-pass arrangement so that in case of failure ofthe pressure-reducing valve the boiler pres-

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APPENDIX G — SAFETY VALVES ON THE LOW-PRESSURE SIDE OF STEAM PRESSURE-REDUCING VALVES

sure may be short circuited into the low-pres-sure line without passing through the pres-sure-reducing valve. When determining therequired relieving capacity of safety valves forthe low-pressure side of the pressure-reduc-ing valve, the steam flow through the bypass

must be taken into consideration.

G-4000 CALCULATION OF SAFETYVALVE RELIEVING

CAPACITY

When a pressure-reducing valve is installed,there are two possibilities of introducing boilerpressure into the low pressure system:

a. the failure of the pressure-reducing valveso that it remains wide open;

b. the possibility of the bypass valve beingopen.

It is necessary therefore, to determine theflow under both circumstances (a) and (b) andcheck that the size of the safety valve undereither condition will be adequate. The follow-ing formula should be used:

a. steam flow, W in lbs/hr through thepressure-reducing valve

W = AKCwhere, A = internal area in sq. in. of the inlet

pipe size of the pressure-reducingvalve (ref. Table 2)

K = flow coefficient for the pressurereducing valve (see G-5000)

C = flow of saturated steam through a1 sq. in. pipe at various pressure

differentials from Table G-4000.

b. steam flow, W in lbs/hr through the by-pass valve

W = A1 K

1 C

1

where, A

1 = internal area in sq. in. of the pipe size

of the bypass around the pressure-reducing valve

K1 = flow coefficient for the bypass valves

(see G-5000) C

1 = flow of saturated steam through a

1 sq. in. pipe at various pressuredifferentials from Table G-4000.

G-5000 STEAM FLOW WHEN FLOWCOEFFICIENTS ARE NOTKNOWN

It is possible that the flow coefficients K and K1

may not be known and in such instances forapproximating the flow, a factor of 1/3 may be substituted for K and 1/2 for K

1.

The formulas in G-4000 then become:

W = 1/3 AC for the capacity through thepressure-reducing valve and

W = 1/2 A1 C

1 for the capacity through

the bypass valve

Caution should be exercised when substitut-ing these factors for the actual coefficientssince this method will provide approximatevalues only and the capacities so obtainedmay in fact be lower than actual. It is recom-mended that the actual flow coefficient be

obtained from the pressure-reducing valvemanufacturer and reference books be con-sulted for the flow coefficient of the bypassvalve.

G-6000 TWO-STAGE PRESSURE-REDUCING VALVE

STATIONS

The safety relief valve for two-stage pressure-reducing valve stations shall be sized on the

basis of the high-side pressure and the inletsize of the first pressure-reducing valve in theline. If an intermediate pressure line is takenoff between the pressure-reducing valvesthen this line and the final low side shall beprotected by safety relief valves sized on the basis of the high-side pressure and the inletsize of the first pressure-reducing valve. SeeTable G-6000.

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TABLE G-4000 — Capacity of Saturated Steam, in lb./hr., per sq. in. of Pipe Area

850 800 750 700 650 600 550 500 450 400 350 300 250

1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 22550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

750 30600 21800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700 35730 29420 21020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

650 39200 34250 28260 20190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 41500 37470 32800 27090 19480 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

550 42840 39850 35730 31310 25940 18620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 43330 40530 37610 33880 29760 24630 17720 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

450 43330 40730 38150 35260 31980 28080 23290 16680 . . . . . . . . . . . . . . . . . . . . . . . . .

400 . . . . . 40760 38220 35680 33050 29980 26380 21870 15760 . . . . . . . . . . . . . . . . . . . .

350 . . . . . . . . . . . . . . . . . . . . 33120 30690 27910 24570 20460 14790 . . . . . . . . . . . . . . .

300 . . . . . . . . . . . . . . . . . . . . 33240 . . . . . 28140 25610 22620 18860 13630 . . . . . . . . . . 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28150 25650 23200 21000 17100 10800 . . . . .

200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21350 18250 15350 10900

175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18250 16000 12600

150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18250 16200 13400

125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18780 . . . . . 13600

110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13600

100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13600

85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13600

75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13600

60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13630

50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outletpres.,psi

Pressure-reducing valve inlet pressure, psi

Where capacities are not shown for inlet and outlet conditions, use the highest capacity shown under the applicable inlet pressure column.

Metric equivalents will appear in the 2005 Addendum.


1500 1450 1400 1350 1300 1250 1200 1150 1100 1050 1000 950 900

1000 76560 72970 69170 64950 60540 55570 49930 43930 35230 25500 . . . . . . . . . . . . . . .

950 77430 74180 70760 67000 63100 58770 53920 48610 42380 34890 24910 . . . . . . . . . .

900 77750 74810 71720 68340 64870 61040 56820 52260 47050 41050 33490 23960 . . . . .

850 77830 74950 72160 69130 66020 62610 58900 54930 50480 45470 39660 29080 23190

800 . . . . . 75070 72330 69490 66700 63680 60390 56910 53060 48800 43980 38340 31610 750 . . . . . . . . . . . . . . . 69610 66880 64270 61260 58200 54840 51170 47080 42420 37110

700 . . . . . . . . . . . . . . . . . . . . 66900 64270 61520 58820 55870 52670 49170 45230 40860

650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61550 58860 56260 53480 50440 47070 43400

600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58980 56270 53660 51020 48470 45010 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53810 51040 48470 45800

500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45850

450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45870

400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outletpres.,psi




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APPENDIX G — SAFETY VALVES ON THE LOW-PRESSURE SIDE OF STEAM PRESSURE-REDUCING VALVES

TABLE G-6000 — Pipe Data

Nominal Approx. pipe size, Actual external Approx. internal internal area in. (DN) diameter, in. (mm) diameter, in. (mm) sq. in. (sq. mm)

3/8 (10) 0.675 (17) 0.49 (12) 0.19 (123) 1/2 (15) 0.840 (21) 0.62 (16) 0.30 (194) 3/4 (20) 1.050 (27) 0.82 (21) 0.53 (342) 1 (25) 1.315 (33) 1.05 (27) 0.86 (555) 1-1/4 (32) 1.660 (42) 1.38 (35) 1.50 (968) 1-1/2 (40) 1.900 (48) 1.61 (41) 2.04 (1,316) 2 (50) 2.375 (60) 2.07 (53) 3.36 (2,168) 2-1/2 (65) 2.875 (73) 2.47 (63) 4.78 (3,084) 3 (80) 3.500 (89) 3.07 (78) 7.39 (4,768)

3-1/3 (90) 4.000 (102) 3.55 (90) 9.89 (6,381) 4 (100) 4.500 (114) 4.03 (102) 12.73 (8,213) 5 (125) 5.563 (141) 5.05 (128) 19.99 (12,897) 6 (150) 6.625 (168) 6.07 (154) 28.89 (18,639) 8 (200) 8.625 (219) 8.07 (205) 51.15 (33,000) 10 (250) 10.750 (273) 10.19 (259) 81.55 (52,613) 12 (300) 12.750 (324) 12.09 (307) 114.80 (74,064)

Note: In applying these rules, the area of the pipe is always based upon standard weightpipe and the inlet size of the pressure-reducing valve.

200 175 150 125 100 85 75 60 50 40 30 25

1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

950 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

850 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 7250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 9540 6750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

125 10800 8780 6220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

110 11000 9460 7420 4550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 11000 9760 7970 5630 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 11000 . . . . . 8480 6640 4070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 11000 . . . . . . . . . . 7050 4980 3150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 11000 . . . . . . . . . . 7200 5750 4540 3520 . . . . . . . . . . . . . . . . . . . . . . . . .

50 11000 . . . . . . . . . . . . . . . 5920 5000 4230 2680 . . . . . . . . . . . . . . . . . . . .

40 11000 . . . . . . . . . . . . . . . . . . . . 5140 4630 3480 2470 . . . . . . . . . . . . . . .

30 11050 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3860 3140 2210 . . . . . . . . . .

25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3340 2580 1485 . . . . .

15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2830 2320 1800

10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2060

5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outletpres.,psi





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Recommended Guide for the Inspection ofPressure Vessels in LP Gas Service

Appendix H

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APPENDIX H — RECOMMENDED GUIDE FOR THE INSPECTION OF

PRESSURE VESSELS IN LP GAS SERVICE

H-1000 GENERAL CONDITIONS

Pressure vessels designed for storing LP

gas can be stationary or can be mounted onskids. LP gases are generally considered to be noncorrosive to the interior of the vessel.This part is provided for guidance of a generalnature for the owner, user, or jurisdictionalauthority. There may be occasions wheremore detailed procedures will be required.

The application of this section to undergroundvessels will only be necessary when evidenceof structural damage to the vessel has beenobserved, leakage has been determined,or the tank has been dug up and is to bereinstalled.

H-2000 PRE-INSPECTION

ACTIVITIES

A review of the known history of the pressurevessel should be performed. This shouldinclude a review of information, such as:

a. Operating conditions

b. Normal contents of the vessel

c. Results of any previous inspection

d. Current jurisdictional inspection certificate,if required

e. ASME Code symbol stamping or mark ofcode of construction, if required

f. National Board and/or jurisdictionalregistration number, if required

The vessel should be sufficiently cleaned toallow for visual inspection.

H-3000 ASSESSMENT OF

INSTALLATION

The type of inspection given to pressurevessels should take into consideration thecondition of the vessel and the environmentin which it operates. The inspection may be external or internal, and use a varietyof nondestructive examination methods.Where there is no reason to suspect an unsafecondition or where there are no inspectionopenings, internal inspections need not beperformed. The external inspection may beperformed when the vessel is pressurized ordepressurized, but shall provide the necessaryinformation that the essential sections of thevessel are of a condition to operate.

H-3100 DEFINITIONS

Dents — Deformations caused by a bluntobject coming in contact with the vessel insuch a way that the thickness of the metal isnot materially reduced.

Cuts or Gouges — Deformations caused bya sharp object coming in contact with thevessel in such a way as to cut into or upsetthe metal reducing the thickness of the metalat that point.

Corrosion or Pitting — The loss of wall thickness by corrosive media, for example.

Isolated Pitting — Small diameter voidsseparated from other pits or corrosion that donot effectively weaken the vessel.

Line Corrosion — A loss of wall thickness(corrosion) in a continuous pattern or pittingconnected in a narrow band or line.

Crevice Corrosion — A loss of metal in thearea of the intersection of skirts (footrings),collars (headrings), saddle bands and otherattachments with the vessel.

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APPENDIX H — RECOMMENDED GUIDE FOR THE INSPECTION OF PRESSURE VESSELS IN LP GAS SERVICE

General Corrosion — A loss of metal over aconsiderable surface area of the vessel.

Crack — Any surface or subsurface separationof base metal or weld material whose extentmust be determined by nondestructive

examination methods. See H-3510.

Distortion — Any change in the original shapeof the vessel, for example.

Bulges — Permanent deformations caused by excessive internal pressure that results inthe pressure vessel’s surface being outside itsoriginal symmetry.

H-3200 EXTERNAL INSPECTION

All parts of the vessel shall be inspectedfor corrosion, distortion, cracking, or otherconditions as described in this section. Inaddition, the following should be reviewed,where applicable:

a. Insulation If the insulation is in good condition and

there is no reason to suspect an unsafecondition behind it, then it is not necessary

to remove the insulation in order to inspectthe vessel. However, it may be advisableto remove a small portion of the insulationin order to determine its condition and thecondition of the vessel surface.

b. Evidence of Leakage Any leakage of vapor or liquid shall be

investigated. Leakage coming from behindinsulation, supports, or evidence of pastleakage shall be thoroughly investigated by removing any insulation necessary

until the source is established.

c. Structural Attachments The pressure vessel mountings should

be ch ecked for ad eq uate al lo wanc efor expansion and contraction, suchas provided by slotted bolt holesor unobstructed saddle mountings.Attachments of legs, saddles, skirts, or

other supports should be examined fordistortion or cracks at welds.

d. Vessel Connections Components which are exterior to

the vessel and are accessible without

disassembly shall be inspected asdescribed in this paragraph. Manholes,reinforcing plates, nozzles, or otherconnections shall be examined for cracks,deformation, or other defects. Bolts ornuts should be examined for corrosionor defects. Weep holes in reinforcingplates shall remain open to provide visualevidence of leakage as well as to preventpressure build up between the vessel andthe reinforcing plate. Accessible flangefaces should be examined for distortion.It is not intended that flanges or otherconnections be opened unless there isevidence of corrosion to justify openingthe connection.

e. Fire Damage Pressure vessels shall be carefully inspected

for evidence of fire damage. The extent offire damage determines the repair that isnecessary, if any.

H-3300 INTERNAL INSPECTION

When there is a reason to suspect an unsafecondition, the suspect parts of the vessel shall be inspected and evaluated. See RB-6230.

H-3400 NONDESTRUCTIVE

EXAMINATION (NDE)

Listed below are a variety of methods that may

be employed to assess the condition of thepressure vessel. These examination methodsshould be implemented by experienced andqualified individuals. Generally, some formof surface preparation will be required priorto the use of these examination methods:visual, magnetic particle, liquid penetrant,ultrasonic, radiography, radioscopy, eddycurrent, metallographic examination, and

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acoustic emission. When there is doubt as tothe extent of a defect or detrimental conditionfound in a pressure vessel, additional NDEmay be required.

H-3500 ACCEPTANCE CRITERIA

H-3510 CRACKS

Cracks in the pressure boundary (heads,shells, nozzles, welds joining parts, andattachment welds) are unacceptable. When acrack is identified, the vessel shall be removedfrom service until the crack is repaired by aqualified repair organization or permanentlyretired from service. See Part RC.

H-3520 DENTS

Dents may be evaluated as follows:

a. Shells The maximum mean dent diameter in

shells shall not exceed 10% of the shelldiameter, and the maximum depth of thedent shall not exceed 10% of the mean

dent diameter. The mean dent diameteris defined as the average of the maximumdent diameter and the minimum dentdiameter. If any portion of the dent iscloser to a weld than 5% of the shelldiameter, the dent shall be treated as adent in a weld area, see paragraph H-3520(b).

b. Welds The maximum mean dent diameter

on welds (i.e., part of the deformation

includes a weld) shall not exceed 10% ofthe shell diameter. The maximum depthshall not exceed one twentieth of the meandent diameter.

c. Heads The maximum mean dent diameter on

heads shall not exceed 10% of the shell

diameter. The maximum depth shall notexceed one twentieth of the mean dentdiameter. The use of a template may berequired to measure dents on heads.

When dents are identified that exceed the

limits set forth in these paragraphs, the vesselshall be removed from service until the dentsare repaired by a qualified repair organizationor permanently retired from service.

H-3530 BULGES

Bulges may be evaluated as follows:

a. Shells If a bulge is suspected, the circumference

shall be measured at the suspect locationand several places remote from thesuspect location. The variation betweenmeasurements shall not exceed 1%.

b. Heads If a bulge is suspected, the radius of

curvature shall be measured by the useof templates. At any point the radius ofcurvature shall not exceed 1.25% of thediameter for the specified shape of the

head.

When bulges are identified that exceed thelimits set forth in these paragraphs, the vesselshall be removed from service until the bulgesare repaired by a qualified repair organizationor permanently retired from service.

H-3540 CUTS OR GOUGES

When a cut or a gouge exceeds 1/4 of the

thickness of the vessel, the vessel shall beremoved from service until it is repaired by aqualified repair organization or permanentlyretired from service.

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APPENDIX H — RECOMMENDED GUIDE FOR THE INSPECTION OF PRESSURE VESSELS IN LP GAS SERVICE

H-3550 CORROSION

Corrosion may be evaluated as follows:

a. Line and Crevice Corrosion For line and crevice corrosion, the depth

of the corrosion shall not exceed 1/4 ofthe original wall thickness.

b. Isolated Pitting Isolated pits may be disregarded provided

that:

1. Their depth is not more than one-halfthe required thickness of the pressurevessel wall (exclusive of corrosionallowance);

2. The total area of the pits does notexceed 7 sq. in. (4500 sq. mm) withinany 8 in. (200 mm) diameter circle;and

3. The sum of their dimensions along anystraight line within this circle does notexceed 2 in. (50 mm).

c. General Corrosion For a corroded area of considerable size

the thickness along the most criticalplane of such area should be averagedover a length not exceeding 20 in. (500mm). The thickness at the thinnest pointshall not be less than 50% of the requiredwall thickness and the average shall not be less than 75% of the required wallthickness. When general corrosion isidentified that exceeds the limits set forthin this paragraph, the pressure vesselshall be removed from service until it isrepaired by a qualified organization or

permanently retired from service.

H-3560 LEAKS

Leakage is unacceptable. When leaks areidentified, the vessel shall be removed from

service until repaired by a qualified repairorganization or permanently retired fromservice.

H-3570 FIRE DAMAGE

Fire damage may be evaluated as follows:

a. Vessels in which bulging exceeds the limitsof H-3530(a) or distortion that exceeds thelimits of the original code of construction(e.g., Section VIII, Div. 1 of the ASMECode) shall be removed from service untilrepaired by a qualified organization orpermanently retired from service.

b. Common evidence of exposure to fire is:

1. charring or burning of the paint orother protective coat,

2. burning or scarring of the metal,

3. distortion, or

4. burning or melting of the valves.

c. A pressure vessel that has been subjected

to the action of fire shall be removedfrom service until it has been properlyevaluated. The general intent of thisrequirement is to remove from servicepressure vessels which have been subjectto the action of fire which has changedthe metallurgical structure or the strengthproperties of the steel. This is normallydetermined by visual examination asdescribed above with particular emphasisgiven to the condition of the protectivecoating. If there is evidence that the

protective coating has been burnedoff any portion of the pressure vesselsurface, or if the pressure vessel is burned,warped, or distorted, it is assumed thatthe pressure vessel has been overheated.If, however, the protective coating isonly smudged, discolored, or blistered

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and is found by examination to be intactunderneath, the pressure vessel shall not be considered affected within the scope ofthis requirement. Vessels that have beeninvolved in a fire and show no distortionshall be requalified for continued service

by retesting using the hydrostatic testprocedure applicable at the time oforiginal fabrication.

H-4000 RECORDS

A permanent record shall be maintainedfor each vessel repaired by a qualifiedorganization. The record shall include thefollowing:

a. An ASME Manufacturer’s Data Report or,if the vessel is not ASME Code stamped,other equivalent specifications.

b. Form R-1 , Report of Welded Repair , or otherequivalent document describing theextent of all repairs to the vessel.

H-5000 CONCLUSIONS

Any defect or deficiency in the condition,operating, and maintenance practices of thepressure vessel should be evaluated at thetime of inspection and decision made for thecorrection of such defect or deficiency.

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APPENDIX I — INSTALLATION REQUIREMENTS

I-1300 APPLICATION OFTHESE RULES

a. As referenced in lower case letters, theterms “owner”, “user”, or “owner/user” means any person, firm, or cor-poration legally responsible for the safeoperation of the boiler, pressure vessel,piping, or other pressure-retaining item.Further, where the term owner is used,it shall mean the owner, or user, or theowner’s or user’s designee, except forI-1300(b).

b. Where the owner is required to perform

an activity, it is intended that the owneror the owner’s designee may performthe activity; however, the owner retainsresponsibility for compliance with theserules.

c. These rules refer to documentationobtained from the jurisdiction (installa-tion permit, operating permit). It is notintended to require the jurisdiction to is-sue such permits but rather a caution toowners and installers that such permitsmay be required.

I-2000 POWER BOILERS

I-2100 INTRODUCTION

I-2110 SCOPE

This section provides requirements for theinstallation of power boilers as defined inI-2120. For installation of items that do notfall within the scope of this section, refer tothe following as applicable:

I-3000 Heating Boilers and Potable Water HeatersI-4000 Pressure VesselsI-5000 Piping

I-1000 INSTALLATIONREQUIREMENTS

I-1100 INTRODUCTION

The proper installation of boilers, pressurevessels, piping, and other pressure-retainingitems is essential for safe and satisfactoryoperation. The owner-user is responsiblefor ensuring that installations meet all therequirements of the jurisdiction at the pointof installation including licensing, registra-tion or certification of those performinginstallations. The following are minimum

requirements and users of this documentare cautioned that it is not a substitute forsound engineering evaluations of a particu-lar installation. Where mandated by a juris-diction, these requirements are mandatory.Where a jurisdiction establishes differentrequirements or where a conflict exists, therules of the jurisdiction prevail.

I-1200 PURPOSE

a. The purpose of these rules is to establishminimum requirements, which, if fol-lowed, will ensure that pressure-retain-ing items, when installed, may be safelyoperated, inspected, and maintained.

b. It should be recognized that many ofthe requirements included in theserules must be considered in the designof the pressure-retaining item by themanufacturer. However, the owner-

user is responsible for ensuring that theinstallation complies with all the appli-cable requirements contained herein.Further, the installer is responsible forcomplying with the applicable sectionswhen performing work on behalf of theowner-user.

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I-2120 POWER BOILERS

A power boiler is a closed vessel in whichwater or other liquid is heated, steam orvapor generated, steam or vapor is super-heated, or any combination thereof, under

pressure for use external to itself, by thedirect application of energy from the combustion of fuels or from electricity or solarenergy. The term boiler includes fired unitsfor heating or vaporizing liquids other thanwater but does not include fired processheaters and systems. The term boiler alsoshall include the apparatus used to generateheat and all controls and safety devices as-sociated with such apparatus or the closedvessel.

a. Power Boiler – a boiler in which steam orother vapor is generated at a pressurein excess of 15 psig (100 kPa) for useexternal to itself.

b. High Temperature Boiler – a boiler inwhich water or other fluid is heated andoperates at a pressure in excess of 160psig (1.1 MPa) and/or temperature inexcess of 250°F (120°C).

c. Electric Boiler – a power boiler as de-scribed above in which the source ofheat is electricity.

I-2200 CERTIFICATION, INSPECTION, AND JURISDICTIONAL

REQUIREMENTS

I-2210 RESPONSIBILITY

The owner is responsible for satisfying ju-risdictional requirements for certificationand documentation. When required by jurisdictional rules applicable to the loca-tion of installation, the boiler shall not beoperated until the required documentationhas been provided to the owner and the jurisdiction.

I-2220 EQUIPMENT CERTIFICATION

All boilers shall have documented certifica-tion from the manufacturer indicating thatthe boiler complies with the requirements

of the code of construction. The certifica-tion shall identify the revision level of thecode of construction to which the boiler wasfabricated.

I-2230 JURISDICTIONAL REVIEW

a. The owner shall determine jurisdictionalrequirements (i.e., certificates, permits,licenses, etc.) before installing the equip-ment. The organization responsiblefor installation shall obtain all permitsrequired by the jurisdiction prior tocommencing installation.

b. The owner shall determine jurisdictionalrequirements (i.e., certificates, permits,licenses, etc.) before operating the equip-ment. The owner shall obtain operatingcertificates, permits, etc. required by the jurisdiction prior to commencing opera-tion.

I-2240 INSPECTION

All boilers shall be inspected after installa-tion and prior to commencing operation.

I-2300 GENERAL REQUIREMENTS

I-2310 SUPPORTS,

FOUNDATIONS, AND SETTINGS

Each boiler and its associated piping must be safely supported. Design of supports,foundations, and settings shall considervibration, movement (including thermalmovement), and loadings (includingflooded conditions) in accordance with ju-

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risdictional requirements, manufacturer’srecommendations, and/or other industrystandards, as applicable.

I-2320 STRUCTURAL STEEL

a. If the boiler is supported by structuralsteel work, the steel supporting members shall be so located or insulated thatthe heat from the furnace will not affecttheir strength.

b. Structural steel shall be installed inaccordance with jurisdictional require-ments, manufacturer’s recommenda-tions, and/or other industry standards,as applicable.

I-2330 CLEARANCES

a. Boiler installations shall allow for nor-mal operation, maintenance, and inspec-tions. There shall be at least 36 in. (900mm) of clearance on each side of the boiler to enable access for maintenanceand/or inspection activities. Boilersoperated in battery shall not be installed

closer than 48 in. (1200 mm) from eachother. The front or rear of any boilershall not be located nearer than 36 in.(900 mm) from any wall or structure.Alternative clearance in accordance withthe manufacturer’s recommendationsare subject to acceptance by the jurisdic-tion.

b. Boilers shall be installed to allow forremoval and installation of tubes.

c. Boilers with a top-opening manhole,shall have at least 84 in. (2100 mm) ofclearance from the manhole to the ceil-ing of the boiler room.

d. Boilers without top-opening manholesshall have at least 36 in. (90 mm) ofclearance from the top of the boiler oras recommended by the manufacturer.

e. Boilers with a bottom opening shall haveat least 12 in. (300 mm) of unobstructedclearance.

I-2340 BOILER ROOM

REQUIREMENTS

I-2341 EXIT AND EGRESS

Two means of exit shall be provided for boiler rooms exceeding 500 sq. ft. (46.5 sq.m) floor area and containing one or more boilers having a fuel capacity of 1,000,000Btu/hr. (293 W/hr.) or more (or equivalentelectrical heat input). Each elevation shall beprovided with at least two means of egress,each to be remotely located from the other.A platform at the top of a single boiler is notconsidered an elevation.

I-2342 LADDERS AND RUNWAYS

a. All walkways, runways, and platformsshall:

1. be of metal construction;

2. be provided between or over the topof boilers which are more than 8 ft.(2.8 m) above the operating floorto afford accessibility for normaloperation, maintenance and inspec-tion;

3. be constructed of safety treads,standard grating, or similar materialand have a minimum width of 30 in.(750 mm);

4. be of bolted, welded, or riveted con-struction;

5. be equipped with handrails 42 in.(1050 mm) high with an interme-diate rail and 4 in. (100 mm) toeboard.

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b. Stairways which serve as a means of ac-cess to walkways, runways, or platformsshall not exceed an angle of 45 degreesfrom the horizontal and be equippedwith handrails 42 in. (1050 mm) highwith an intermediate grid.

c. Ladders which serve as a means of ac-cess to walkways, runways, or platformsshall:

1. be of metal construction and not lessthan 18 in. (450 mm) wide;

2. have rungs that extend through theside members and are permanentlysecured;

3. have a clearance of not less than30 in. (750 mm) from the front ofrungs to the nearest permanentobject on the climbing side of theladder;

4. have a clearance of not less than6-1/2 in. (165 mm) from the backof rungs to the nearest permanentobject;

5. have a clearance width of at least15 in. (390 mm) from the center ofthe ladder on either side across thefront of the ladder.

d. There shall be at least two permanentlyinstalled means of egress from walk-ways, runways, or platforms that exceed6 ft. (2 cm) in length.

I-2343 DRAINS

At least one floor drain shall be installed inthe boiler room.

I-2344 WATER

A convenient water supply shall be pro-vided for flushing out the boiler and its

appurtenances, adding water to the boilerwhile it is not under pressure and cleaningthe boiler room floor.

I-2400 SOURCE REQUIREMENTS

I-2410 FEEDWATER

I-2411 VOLUME

The source of feedwater shall be capable ofsupplying a sufficient volume of water asdetermined by the boiler manufacturer inorder to prevent damage to the boiler whenall the safety relief valves are discharging atfull capacity.

I-2412 CONNECTION

a. To prevent thermal shock, feedwatershall be introduced into a boiler insuch a manner that the water will not be discharged directly against surfacesexposed to gases of high temperature orto direct radiation from the flame.

b. For boiler operating pressures of 400 psi(2700 kPa) or higher, the feedwater inletthrough the drum shall be fitted withshields, sleeves, or other suitable meansto reduce the effects of temperature dif-ferentials in the shell or head.

c. Feedwater other than condensate returnshall not be introduced through the blowoff.

d. Boilers having more than 500 sq. ft.(46.5 sq. m.) of water heating surfaceshall have at least two means of sup-plying feedwater. For boilers that arefired with solid fuel not in suspension,and boilers whose setting or heat sourcecan continue to supply sufficient heat tocause damage to the boiler if the feed-water supply is interrupted, one such

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Boiler Pressure, Boiler Feedwater Pumppsi (MPa) Discharge Pressure,* psi (MPa)

200 (1.5) 250 (1.7) 400 (3.0) 475 (3.3) 800 (5.5) 925 (6.4)

1,200 (8.0) 1,350 (9.3)*based on 34.5 lbs. (15.5 kg) of evaporation perhour @ 212°F (100°C)

For forced-flow steam generators with nofixed steam or water line, each source offeedwater shall be capable of supplying feed-water to the boiler at a minimum pressureequal to the expected maximum sustainedpressure at the boiler inlet corresponding tooperation at maximum designed steaming

capacity with maximum allowable pressureat the superheater outlet.

Control devices may be installed on feed-water piping to protect the pump againstoverpressure.

I-2414 VALVES

a. The feedwater piping shall be providedwith a check valve and a stop valve. Thestop valve shall be located between thecheck valve and the boiler.

b. When two or more boilers are fed froma common source, there shall also be aglobe or regulating valve on the branchto each boiler located between the checkvalve and the feedwater source.

c. When the feedwater piping is dividedinto branch connections and all such

connections are equipped with stop andcheck valves, the stop and check valve inthe common source may be omitted.

d. On single boiler-turbine unit installa-tions, the boiler feedwater stop valvemay be located upstream from the boilerfeedwater check valve.

means of supplying feedwater shall not be subject to the same interruption as thefirst method. Boilers fired by gaseous,liquid, or solid fuel in suspension may be equipped with a single means of sup-plying feedwater provided means are

furnished for the immediate removal ofheat input if the supply of feedwater isinterrupted.

e. For boilers having a water heating sur-face of not more than 100 sq. ft. (9 sq. m.),the feedwater piping and connectionto the boiler shall not be smaller thanNPS 1/2 (DN 15). For boilers having awater heating surface more than 100 sq.ft. (9 sq. m.), the feedwater piping andconnection to the boiler shall not be lessthan NPS 3/4 (DN 20).

Electric boiler feedwater connectionsshall not be smaller than NPS 1/2(DN 15).

f. High temperature water boilers shall beprovided with means of adding water tothe boiler or system while under pres-sure.

I-2413 PUMPS

Boiler feedwater pumps shall have dis-charge pressure in excess of the boiler ratedpressure (MAWP) in order to compensatefor frictional losses, entrance losses, regulat-ing valve losses, and normal static head, etc.Each source of feedwater shall be capableof supplying feedwater to the boiler at aminimum pressure of three percent higherthan the highest setting of any safety valve

on the boiler plus the expected pressuredrop across the boiler. The following tableis a guideline for estimating feed pumpdifferential:

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e. If a boiler is equipped with duplicatefeedwater supply arrangements, eachsuch arrangement shall be equipped asrequired by these rules.

f. A check valve shall not be a substitute

for a stop valve.

g. A combination feedwater stop-and-check valve in which there is only oneseat and disk and a valve stem is pro-vided to close the valve when the stem isscrewed down shall be considered onlyas a stop valve, a separate check valveshall be installed.

h. Whenever globe valves are used onfeedwater piping, the inlet shall be un-der the disk of the valve.

i. Stop valves and check valves shall beplaced on the inlet of economizers orfeedwater-heating devices.

j. The recirculating return line for a hightemperature water boiler shall be pro-vided with the stop valve, or valves,required for the main discharge outleton the boiler.

I-2420 FUEL

Fuel systems, whether coal, oil, gas, or othersubstance shall be installed in accordancewith jurisdictional and environmentalrequirements, manufacturer’s recommen-dations and/or industry standards, asapplicable.

I-2430 ELECTRICAL

a. All wiring for controls, heat generatingapparatus, and other appurtenancesnecessary for the operation of the boileror boilers should be installed in accor-dance with the provisions of national

or international standards and complywith the applicable local electricalcodes.

b. A manually operated remote shutdownswitch or circuit breaker should be lo-

cated just outside the boiler room doorand marked for easy identification.Consideration should also be givento the type and location of the switchto safeguard against tampering. If the boiler room door is on the building ex-terior, the switch should be located justinside the door. If there is more than onedoor to the boiler room, there should bea switch located at each door.

1. For atmospheric-gas burners, and oil burners where a fan is on a commonshaft with the oil pump, the com-plete burner and controls should beshut off.

2. For power burners with detachedauxiliaries, only the fuel input sup-ply to the firebox need be shut off.

c. Controls and Heat Generating Appara-tus

1. Oil and gas-fired and electricallyheated boilers and water heatersshall be equipped with suitableprimary (flame safeguard) safetycontrols, safety limit switches, and burners or electr ic elements asrequired by a nationally or interna-tionally recognized standard.

2. The symbol of the certifying organi-zation16 that has investigated such

equipment as having complied witha nationally recognized standardshall be affixed to the equipmentand shall be considered as evidence

16 Organizations – A certifying organization is onethat provides uniform testing, examination, andlisting procedures under established, nationallyrecognized standards, and that is acceptable tothe authorities having jurisdiction.

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that the unit was manufactured inaccordance with that standard.

3. These devices shall be installed inaccordance with jurisdictional andenvironmental requirements, manu-

facturer’s recommendations and/orindustry standards as applicable.

I-2440 VENTILATION ANDCOMBUSTION AIR

a. The boiler room shall have an adequateair supply to permit clean, safe combus-tion, minimize soot formation and main-tain a minimum of 19.5% oxygen in theair of the boiler room. The combustionand ventilation air should be supplied by either an unobstructed air openingor by power ventilation or fans.17

b. Unobstructed air openings shall be sizedon the basis of 1 sq. in. (650 sq. mm)free area per 2000 Btu/hr. (586 W/hr.)maximum fuel input of the combined burners located in the boiler room, oras specified in the National Fire Protec-tion Association (NFPA) standards for

oil and gas burning installations for theparticular job conditions. The boilerroom air supply openings shall be keptclear at all times.

c. Power ventilators or fans shall be sizedon the basis of 0.2 cfm (0.0057 cu metersper minute) for each 1000 Btu/hr. (293W/hr.) of maximum fuel input for thecombined burners of all boilers and wa-ter heaters located in the boiler room.

d. When power ventilators or fans are usedto supply combustion air they shall beinstalled with interlock devices so thatthe burners will not operate without anadequate number of ventilators/fans inoperation.

e. The size of openings specified in I-2440(b) may be reduced when specialengineered air supply systems ap-proved by the jurisdiction are used.

I-2450 LIGHTING

The boiler room should be well lighted andit should have an emergency light source foruse in case of power failure.

I-2460 EMERGENCY VALVES ANDCONTROLS

All emergency shut-off valves and controlsshall be accessible from a floor, platform,walkway, or runway. Accessibility shallmean within a 6 ft. (2 m) elevation of thestanding space and not more than 12 in.(300 mm) horizontally from the standing

space edge.

I-2500 DISCHARGEREQUIREMENTS

I-2510 CHIMNEY OR STACK

Chimneys or stacks shall be installed inaccordance with jurisdictional and envi-ronmental requirements, manufacturer’s

recommendations, and/or industry stan-dards, as applicable.

17 Fans – When combustion air is supplied to the boiler by an independent duct, with or withoutthe employment of power ventilators or fans, theduct shall be sized and installed in accordancewith the manufacturer’s recommendations.However, ventilation for the boiler room muststill be considered.

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I-2520 ASH REMOVAL

Ash removal systems shall be installed inaccordance with jurisdictional and envi-ronmental requirements, manufacturer’srecommendations, and/or industry stan-

dards, as applicable.

I-2530 DRAINS

I-2531 CONNECTION

a. Each boiler shall have at least one drainpipe fitted with a stop valve at the low-est point of the boiler. If the connectionis not intended for blowoff purposes,a single valve is acceptable if it can belocked in the closed position or a blankflange can be installed downstream ofthe valve. If the connection is intendedfor blowoff purposes, requirements ofI-2650 shall be followed.

b. For high temperature water boilers, theminimum size of the drain pipe shall beNPS 1 (DN 25).

c. Drain pipes, valves, and fittings withinthe same drain line shall be the samesize.

d. The discharge from the drain shall bepiped to a safe location.

I-2532 PRESSURE RATING

a. When the maximum allowable work-ing pressure of the boiler is equal to or

less than 100 psi (700 kPa), the drainpipe, valve, and fittings shall be ratedfor at least 100 psi (700 kPa) and 220°F(105°C).

b. When the maximum allowable work-ing pressure of the boiler exceeds 100psi (700 kPa), the drain pipe, valve, and

fittings shall be rated for at least themaximum allowable working pressureand temperature of the boiler.

I-2533 PARTS

a. When parts (economizers, etc.) are in-stalled with a stop valve between thepart and the boiler or the part cannot becompletely drained through the drainon the boiler, a separate drain shall beinstalled on each such part. These drainsshall meet the requirements of this para-graph.

b. Each water column shall have a drainpipe fitted with a stop valve at the low-est point of the water column. The stopvalve shall have the capability of beinglocked in the closed position while the boiler is under pressure. The mini-mum size of the drain shall be NPS 3/4(DN 20) and all other requirements ofthis paragraph shall be met.

I-2600 OPERATING SYSTEMS

I-2610 BREECHING ANDDAMPERS

Breeching and dampers shall be installedin accordance with jurisdictional and en-vironmental requirements, manufacturer’srecommendations, and/or industry stan-dards, as applicable.

I-2620 BURNERS AND STOKERS

Burners and stokers shall be installed inaccordance with jurisdictional and envi-ronmental requirements, manufacturer’srecommendations, and/or industry stan-dards, as applicable.

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I-2630 STEAM SUPPLY

a. Provisions shall be made for the expan-sion and contraction of steam mainsconnected to boiler(s) so that thereshall be no undue strain transmitted to

the boiler(s). Steam reservoirs shall beinstalled on steam mains when heavypulsations of the steam currents causevibration of the boiler shell plates.

b. Each discharge outlet of the boilerdrum or superheater outlet, shall befitted with a stop valve located at anaccessible point in the steam-deliveryline and as near the boiler nozzle as isconvenient and practicable. The valveshall be equipped to indicate from a dis-tance whether it is closed or open, andshall be equipped with a slow-openingmechanism. When such outlets are overNPS 2 (DN 50), the valve or valvesused on the connection shall be of theoutside screw-and-yoke-rising spindletype, so as to indicate from a distance by the position of its spindle whether itis closed or open, and the wheel should be carried either on the yoke or attachedto the spindle. In the case of a single

boiler and prime mover installation, thestop valve may be omitted provided theprime mover throttle valve is equippedwith an indicator to show whether thevalve is open or closed and is designedto withstand the required hydrostatictest pressure of the boiler.

c. Stop valves and fittings shall complywith the appropriate national standardexcept that austenitic stainless steel isnot permitted for water wetted ser-

vice.

d. Stop valves and fittings shall be ratedfor the maximum allowable workingpressure of the boiler and shall be atleast rated for 100 psi (700 kPa) at theexpected steam temperature at the valveor fitting, in accordance with the appro-priate national standard.

e. The nearest stop valve or valves to thesuperheater outlet shall have a pressurerating at least equal to the minimumset pressure of any safety valve on thesuperheater and at the expected super-heated steam temperature; or at least

equal to 85% of the lowest set pressureof any safety valve on the boiler drumat the expected steam temperature ofthe superheater outlet, whichever isgreater.

f. Ample provision for gravity drain shall be provided when a stop valve is solocated that water or condensation mayaccumulate. The gravity drain(s) shall be located such that the entire steamsupply system can be drained.

g. When boilers are connected to a com-mon header, the connection from each boiler having a manhole opening shall be fitted with two stop valves havingan ample freeblow drain between them.The discharge of this drain shall bevisible to the operator while operatingthe valve. The stop valves shall consistof one stop check valve (set next to the boiler) and a second valve of the outside

screw-and-yoke type; or two valves ofthe outside screw-and-yoke type.

h. The second steam stop valve shall havea pressure rating at least equal to thatrequired for the expected steam tem-perature and pressure at the valve, orthe pressure rating shall be not less than85% of the lowest set pressure of anysafety valve on the boiler drum and forthe expected temperature of the steamat the valve, whichever is greater.

i. Pressure-red ucing valves may beinstalled in the steam supply pipingdownstream from the required stopvalve or valves.

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I-2640 CONDENSATE ANDRETURN

Each condensate return pump where prac-ticable, shall be provided with an automaticwater level control set to maintain an ad-

equate water level. Condensate tanks shall be vented to the atmosphere.

I-2650 BLOWOFF

a. Except for forced-flow steam generatorswith no fixed steam or water line, each boiler shall have a blowoff pipe, fittedwith a stop valve, in direct connectionwith the lowest water space practicable.When the maximum allowable work-ing pressure of the boiler exceeds 100psi (700 kPa) there shall be two valvesinstalled.

The blowoff piping for each electric boiler pressure vessel having a nominalwater content not exceeding 100 gal.(380 l) is required to extend through onlyone valve.

b. One of the blowoff valves shall be a slow-

opening valve. When a second valve isrequired, the second valve should be aquick-opening or slow-opening valve.

c. Two independent slow-opening valvesor a slow-opening valve and quick-opening valve should be combined inone body and should be used providedthe combined fitting is the equivalent oftwo independent slow-opening valvesor a slow-opening valve and a quick-opening valve, and provided further

that the failure of one to operate cannotaffect the operation of the other.

d. Straight-run globe valves or valveswhere dams or pockets can exist forthe collection of sediment shall not beused.

e. The blowoff valve or valves and the pipeand fittings between them and the boilershall be of the same size. The minimumsize of pipe and fittings shall be NPS 1(DN 25), except boilers with 100 sq. ft. (9sq. m.) of heating surface or less should

be NPS 3/4 (DN 20). The maximum sizeof pipe and fittings shall not exceed NPS2-1/2 (DN 65).

For electric boilers, the minimum size of blowoff pipes and fittings shall be NPS1 (DN 25), except for boilers of 100 kWinput or less the minimum size should be NPS 3/4 (DN 20).

f. Fittings and valves shall comply withthe appropriate national standard ex-cept that austenitic stainless steel andmalleable iron are not permitted.

g. When the maximum allowable work-ing pressure exceeds 100 psi (700 kPa), blowoff piping shall be at least Schedule80 and the required valves and fittingsshall be rated for at least 1.25 times themaximum allowable working pressureof the boiler. When the maximum allow-able working pressure exceeds 900 psi

(6 MPa), blowoff piping shall be at leastSchedule 80 and the required valvesand fittings shall be rated for at least themaximum allowable working pressureof the boiler plus 225 psi (1.6 MPa).

h. All blowoff piping, when exposed tofurnace heat, shall be protected by fire brick or other heat resisting material soconstructed that the piping should bereadily inspected.

i. On a boiler having multiple blowoffpipes, a single master stop valve should be placed on the common blowoff pipefrom the boiler and one stop valve oneach individual blowoff. Either the mas-ter valve or the valves on the individual blowoff lines shall be of the slow-open-ing type.

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j. The discharge of blowoff pipes shall belocated so as to prevent injury to person-nel.

k. All waterwalls or water screens thatdo not drain back into the boiler and

integral economizers forming part ofa boiler shall be equipped with blowoffpiping and valves conforming to therequirements of this paragraph.

l. Blowoff piping from a boiler should notdischarge directly into a sewer. A blow-off tank, constructed to the provisions ofa code of construction acceptable to the jurisdiction, shall be used where condi-tions do not provide an adequate andsafe open discharge.

m. Galvanized pipe shall not be used.

n. Boiler blowoff systems shall be con-structed in accordance with the Guide for Blowoff Vessels. 18

o. Where necessary to install a blowofftank underground, it shall be enclosedin a concrete or brick pit with a remov-able cover so that inspection of the en-

tire shell and heads of the tank can bemade.

p. Piping connections used primarily forcontinuous operation, such as decon-centrators on continuous blowdownsystems, are not classed as blowoffs butthe pipe connections and all fittings upto and including the first shutoff valveshall be equal at least to the pressure re-quirements for the lowest set pressure ofany safety valve on the boiler drum and

with the corresponding saturated-steamtemperature. Further, such connectionsshall not exceed NPS 2-1/2 (DN 65).

I-2700 CONTROLS AND GAGES

I-2710 WATER

a. Each automatically steam-fired boiler

shall be equipped with at least two low-water fuel cutoffs. The water inlet shallnot feed water into the boiler through afloat chamber.

Each electric steam boiler of the resis-tance element type shall be equippedwith an automatic low-water cutoff oneach boiler pressure vessel, so locatedas to automatically cut off the powersupply to the heating elements beforethe surface of the water falls below thevisible part of the glass. No low-watercutoff is required for electrode-type boil-ers.

b. Designs embodying a float and float bowl shall have a vertical straightawaydrainpipe at the lowest point in thewater equalizing pipe connections, bywhich the bowl and the equalizing pipecan be flushed and the device tested.

c. The water column shall be directly con-nected to the boiler. Outlet connections(except for damper regulator, feedwaterregulator, low-water fuel cutoff, drains,steam gages, or such apparatus that doesnot permit the escape of an appreciableamount of steam or water) should not be placed on the piping that connectsthe water column to the boiler.

d. Straight-run globe valves of the ordi-nary type shall not be used on piping

that connects the water column to the boiler. Where water columns are sevenfeet or more above the floor level, ad-equate means for operating gage cocksor blowing out the water glass shall beprovided.

18 The Guide for Blowoff Vessels can be found on theNational Board Web site, nationalboard.org , underthe Publications menu button.

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e. When automatic shutoff valves areused on piping that connects the watercolumn to the boiler, they shall conformto the requirements of the code of con-struction for the boiler.

f. When shutoff valves are used on theconnections to a water column, theyshall be either outside-screw-and-yokeor lever-lifting-type gate valves or stopcocks with levers permanently fastenedthereto and marked in line with theirpassage, or of such other through-flowconstructions to prevent stoppage bydeposits of sediment and to indicate bythe position of the operating mechanismwhether they are in open or closed posi-tion; and such valves or cocks shall belocked or sealed open.

g. Each steam boiler having a fixed water-line shall have at least one water-gageglass except that boilers operated atpressures over 400 psi (3 MPa) shall beprovided with two water-gage glasseswhich may be connected to a single wa-ter column or connected directly to thedrum. The gage glass connections andpipe connection shall be not less than

NPS 1/2 (DN 15). Each water-gage glassshall be equipped with a valved drain.

Electric steam boilers shall have at leastone water-gage glass. On electrode-typeelectric boilers the gage glass shall belocated as to indicate the water levels both at startup and maximum steamload conditions, as established by the boiler manufacturer. On resistance el-ement type electric steam boilers thelowest visible part of the gage glass

shall be located at least 1 in. (25 mm)above the lowest permissible water levelestablished by the manufacturer.

h. The lowest visible part of the water-gageglass shall be at least 2 in. (50 mm) abovethe lowest permissible water level which

shall be that level at which there will beno danger of overheating any part of the boiler when in operation.

i. For all installations where the water-gage glass or glasses are more than

thirty feet (9 m.) from the boiler operat-ing floor, it is recommended that waterlevel indicating or recording gages beinstalled at eye height from the operat-ing floor.

j. Boilers of the horizontal firetube typeshall be so set that when the water isat the lowest reading in the water-gageglass there shall be at least 3 in. (75 mm)of water over the highest point of thetubes, flues, or crown sheet.

k. Each water-gage glass shall be equippedwith a top and a bottom shutoff valveof such through-flow construction as toprevent blockage by deposits of sedi-ment and to indicate by the position ofthe operating mechanism whether theyare in the open or closed position. Thepressure-temperature rating shall be atleast equal to that of the lowest set pres-sure of any safety valve on the boiler

drum and the corresponding saturatedsteam temperature.

I-2720 PRESSURE

I-2721 GAGE REQUIREMENTS

a. Each steam boiler shall have a pressuregage connected to the steam space or tothe steam connection to the water col-

umn. When a pressure-reducing valveis installed in the steam supply piping,a pressure gage shall be installed on thelow pressure side of the pressure-reduc-ing valve.

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b. The dial range shall not be less than 1.5times the pressure at which the lowestsafety relief valve is set.

c. The dial range should be no greater thantwo times the pressure at which the low-

est safety relief valve is set.

I-2722 CONNECTION

a. For a steam boiler the gage or connec-tion shall contain a syphon or equivalentdevice which will develop and maintaina water seal that will prevent steam fromentering the gage tube. A valve or cockshall be placed in the gage connectionadjacent to the gage. An additional valveor cock should be located near the boilerproviding it is locked or sealed in theopen position. No other shut-off valvesshall be located between the gage andthe boiler.

b. Pressure gage connections shall be suit-able for the maximum allowable work-ing pressure and temperature, but ifthe temperature exceeds 406°F (208°C) brass or copper pipe or tubing shall not

be used. The connections to the boiler,except for the syphon, if used, shall not be less than NPS 1/4 (DN 8). Where steelor wrought iron pipe or tubing is used,it shall not be less than 1/2 in. (13 mm)inside diameter. The minimum size of asyphon, if used, shall be 1/4 in. (6 mm)inside diameter.

I-2730 TEMPERATURE

Each high temperature water boiler shallhave a temperature gage or other report-ing device located to provide an accuraterepresentation of the temperature at or nearthe boiler outlet.

I-2800 PRESSURE RELIEF VALVES

I-2810 VALVE REQUIREMENTS

a. Safety valves are designed to relieve

steam.

b. Safety relief valves are valves designedto relieve either steam or water, depend-ing on the application.

c. Safety and safety relief valves are to be manufactured in accordance with anational or international standard.

d. Deadweight or weighted-lever pressure-relieving valves shall not be used.

e. For high temperature water boilers,safety relief valves shall have a closed bonnet, and safety relief valve bodiesshall not be constructed of cast iron.

f. Safety and safety relief valves with aninlet connection greater than NPS 3(DN 80) used for pressure greater than15 psig (100 kPa), shall have a flangeinlet connection or a welding-end inlet

connection. The dimensions of flangessubjected to boiler pressure shall con-form to the applicable standards.

g. When a safety or safety relief valveis exposed to outdoor elements thatshould affect operation of the valve, itis permissible to shield the valve witha cover. The cover shall be properlyvented and arranged to permit servicingand normal operation of the valve.

I-2820 NUMBER

At least one National Board capacity certi-fied safety or safety relief valve shall beinstalled on the boiler. If the boiler has more

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than 500 sq. ft. (46 sq. m.) of heating surface,or if an electric boiler has a power input ofmore than 1,100 kw, two or more NationalBoard capacity certified safety or safetyrelief valves shall be installed.

I-2830 LOCATION

a. Safety or safety relief valves shall beplaced on, or as close as physically pos-sible, to the boiler proper.

b. Safety or safety relief valves shall not beplaced on the feedline.

c. Safety or safety relief valves shall be con-nected to the boiler independent of anyother connection without any unneces-

sary intervening pipe or fittings. Suchintervening pipe or fittings shall not belonger than the face-to-face dimensionof the corresponding tee fitting of thesame diameter and pressure rating aslisted in the applicable standards.

TABLE I-2840-1 — Minimum Pounds of Steam per Hour per Square Foot of HeatingSurface (kg/hr/ sq m)

Firetube Boilers Watertube BoilersBoiler heating surface Hand-fired 5 (2107) 6 (2528) Stoker-fired 7 (2950) 8 (3371) Oil-, gas-, or pulverized-fuel-fired 8 (3371) 10 (4214)

Waterwall heating surface Hand-fired 8 (3371) 8 (3378)

Stoker-Fired 10 (4214) 12 (5057) Oil-, gas-, or pulverized-fuel-fired 14 (5900) 16 (6742)

Copper finned water tubes

Hand-fired 4 (1686) 4 (1686) Stoker-Fired 5 (2107) 5 (2107) Oil-, gas-, or pulverized-fuel-fired 5 (2107) 6 (2528)

NOTES:When a boiler is fired only by a gas having a heat value not in excess of 200 Btu/cu. ft. (7.5 J/cu. cm.), theminimum relieving capacity should be based on the values given for hand-fired boilers above.

For firetube boiler units exceeding 8000 Btu/sq. ft. (9120 J/sq. cm.) (total Fuel Btu (J) Input divided by totalheating surface), the factor from the table will be increased by 1 (422.3) for every 1000 Btu/sq. ft. (1140 J/sq. cm.) above 8000 (9120 J/sq. cm.). For units less than 7000 Btu/sq. ft. (7980 J/sq. cm.), the factor from thetable will be decreased by 1 (422.3) for every 1000 Btu/sq. ft. (1140 J/sq. cm.) below 7000 (7980 J/sq. cm.).

For watertube boiler units exceeding 16000 Btu/sq. ft. (18240 J/sq. cm.) (total fuel Btu input divided bythe total heating surface), the factor from the table will be incresed by 1 (422.3) for every 1000 Btu/sq. ft.(1140 J/sq. cm.) above 16000 (18240 J/sq. cm.). For units with less than 15000 Btu/sq. ft. (17100 J/sq. cm.),the factor in the table will be decreased by 1 (422.3) for every 1000 Btu/sq. ft. (1140 J/sq. cm.) below 15000(17100 J/sq. cm.).

The heating surface shall be computed for that side of the boiler surface exposed to the products of combustion, exclusive of the superheating surface. In computing the heating surface for this purpose, only thetubes, fireboxes, shells, tube sheets, and the projected area of headers need to be considered, except thatfor vertical firetube steam boilers, only that portion of the tube surface up to the middle gage cock is to becomputed.

A05

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I-2840 CAPACITY

a. The pressure-relieving valve capacity foreach boiler shall be such that the valve orvalves will discharge all the steam thatcan be generated by the boiler without

allowing the pressure to rise more than6% above the highest pressure at whichany valve is set and in no case to morethan 6% above the maximum allowableworking pressure of the boiler.

b. The minimum relieving capacity for oth-er than electric boilers and forced-flowsteam generators with no fixed steamline and waterline, shall be estimatedfor the boiler and waterwall heatingsurfaces as given in Table I-2840-1 , but inno case should the minimum relievingcapacity be less than the maximum de-signed steaming capacity as determined by the manufacturer.

c. The required relieving capacity inpounds per hour of the safety or safetyrelief valves on a high temperature wa-ter boiler shall be determined by divid-ing the maximum output in Btu at the boiler nozzle obtained by the firing of

any fuel for which the unit is designed by one thousand.

d. The minimum safety or safety reliefvalve relieving capacity for electric boil-ers is 3.5 lbs./hr./kW. (1.6 kg./hr./kW.)input.

e. If the safety or safety relief valve ca-pacity cannot be computed, or if it isdesirable to prove the computations,it should be checked by any one of the

following methods; and if found insuffi-cient, additional relieving capacity shall be provided:

1. By performing an accumulation test,that is, by shutting off all other steamdischarge outlets from the boiler andforcing the fires to the maximum.

This method should not be usedon a boiler with a superheater orreheater or on a high temperaturewater boiler.

2. By measuring the maximum amount

of fuel that can be burned and com-puting the corresponding evapora-tive capacity upon the basis of theheating value of the fuel.

3. By determinin g the maximumevaporative capacity by measur-ing the feedwater. The sum of thesafety valve capacities marked onthe valves shall be equal to or greaterthan the maximum evaporativecapacity of the boiler. This methodshould not be used on high tempera-ture water boilers.

I-2850 SET PRESSURE

One or more safety or safety relief valves onthe boiler proper shall be set at or below themaximum allowable working pressure. Ifadditional valves are used, the highest pres-sure setting shall not exceed the maximum

allowable working pressure by more than3%. The complete range of pressure settingsof all the safety relief valves on a boiler shallnot exceed 10% of the highest pressure towhich any valve is set. Pressure setting ofsafety relief valves on high temperaturewater boilers may exceed this 10% range.

I-2860 FORCED-FLOW STEAMGENERATOR

For a forced-flow steam generator with nofixed steamline and waterline, equippedwith automatic controls and protective in-terlocks responsive to steam pressure, safetyvalves should be installed in accordancewith the following, as an alternative:

a. One or more power-actuated pressure-relieving valves shall be provided in

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direct communication with the boilerwhen the boiler is under pressure andshall receive a control impulse to openwhen the maximum allowable workingpressure at the superheater outlet isexceeded. The total combined relieving

capacity of the power-actuated pres-sure-relieving valves should be notless than 10% of the maximum designsteaming capacity of the boiler underany operating condition as determined by the manufacturer. The valves shall be located in the pressure part systemwhere they will relieve the overpressure.An isolating stop valve of the outside-screw-and-yoke type should be installed between the power-actuating pressure-relieving valve and the boiler to permitrepairs provided an alternate power-actuated pressure-relieving valve of thesame capacity is so installed as to be indirect communication with the boiler.

b. Spring-loaded safety valves shall be pro-vided having a total combined relievingcapacity, including that of the power-actuated pressure-relieving valve, ofnot less than one hundred percent ofthe maximum designed steaming ca-

pacity of the boiler, as determined bythe manufacturer. In this total, creditin excess of 30% of the total relievingcapacity should not be allowed forthe power-actuated pressure-relievingvalves actually installed. Any or all ofthe spring-loaded safety valves should be set above the maximum allowableworking pressure of the parts to whichthey are connected, but the set pressuresshall be such that when all these valves(together with the power-actuated pres-

sure-relieving valves) are in operationthe pressure will not rise more than 20%above the maximum allowable workingpressure of any part of the boiler, exceptfor the steam piping between the boilerand the prime mover.

c. When stop valves are installed in thewater-steam flow path between any twosections of a forced-flow steam generatorwith no fixed steamline and waterline:

1. The power-actuated pressure-reliev-

ing valve shall also receive a controlimpulse to open when the maximumallowable working pressure of thecomponent, having the lowest pres-sure level upstream to the stop valve,is exceeded.

2. The spring-loaded safety valve shall be located to provide overpressureprotection for the component havingthe lowest working pressure.

3. A reliable pressure-recording de-vice shall always be in service andrecords kept to provide evidenceof conformity to the above require-ments.

I-2870 SUPERHEATERS

a. Every attached superheater shall haveone or more safety valves. The location

shall be suitable for the service intendedand shall provide the overpressureprotection required. The pressure dropupstream of each safety valve shall beconsidered in determining the set pres-sure and relieving capacity of that valve.If the superheater outlet header has afull, free steam passage from end toend and is so constructed that steam issupplied to it at practically equal inter-vals throughout its length so that thereis a uniform flow of steam through the

superheater tubes and the header, thesafety valve or valves may be locatedanywhere in the length of header.

b. The pressure-relieving capacity of thesafety valve or valves on an attachedsuperheater should be included in deter-mining the number and size of the safetyvalves for the boiler provided there are

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no intervening valves between the su-perheater safety valve and the boiler andthe discharge capacity of the safety reliefvalve or valves, on the boiler, as distinctfrom the superheater, is at least 75% ofthe aggregate capacity required.

c. Every independently fired superheaterthat may be shut off from the boilerand permit the superheater to becomea fired pressure vessel shall have one ormore safety valves having a dischargecapacity equal to six pounds of steamper/hr./sq. ft. (29 kg. per sq. m.) of su-perheater surface measured on the sideexposed to the hot gases.

d. Every safety valve used on a superheaterdischarging superheated steam at atemperature over 450°F (230°C) shallhave a casing, including the base, body, bonnet, and spindle constructed of steel,steel alloy, or equivalent heat-resistantmaterial. The valve shall have a flangedinlet connection or a welding-end inletconnection. The seat and disk shall beconstructed of suitable heat-erosiveand corrosive-resistant material, andthe spring fully exposed outside of the

valve casing so that it is protected fromcontact with the escaping steam.

I-2871 ECONOMIZERS

An economizer that may not be isolatedfrom a boiler does not require a safety reliefvalve. Economizers that should be isolatedfrom a boiler or other heat transfer device,allowing the economizer to become a firedpressure vessel, shall have a minimum of

one safety relief valve. Discharge capacity,rated in lbs./hr (kg/hr), of the safety reliefvalve or valves shall be calculated from themaximum expected heat absorbtion ratein BTU/hr (Joules/hr) of the economizer,and will be determined from manufacturer

date, divided by 1000. The safety relief valveshall be located as close as possible to theeconomizer outlet.

I-2880 PRESSURE-REDUCING

VALVES

a. Where pressure-reducing valves areused, one or more safety or safety reliefvalves shall be installed on the lowpressure side of the reducing valve inthose installations where the pipingor equipment on the low pressure sidedoes not meet the requirements for thesteam supply piping.

b. The safety or safety relief valves shall belocated as close as possible to the pres-sure-reducing valve.

c. Capacity of the safety or safety reliefvalves shall not be less than the totalamount of steam that can pass from thehigh pressure side to the low pressureside and be such that the pressure ratingof the lower pressure piping or equip-ment shall not be exceeded.

d. The use of hand-controlled bypassesaround reducing valves is permissible.The bypass around a reducing valvemay not be greater in capacity than thereducing valve unless the piping orequipment is adequately protected bysafety or safety relief valves or meetsthe requirements of the high pressuresystem.

I-2890 MOUNTING AND

DISCHARGE REQUIREMENTS

a. Every boiler shall have outlet connec-tions for the safety or safety relief valve,or valves, independent of any otheroutside steam connection, the area of

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I-2900 TESTING AND ACCEPTANCE

I-2910 GENERAL

a. Care shall be exercised during instal-lation to prevent loose weld material,welding rods, small tools, and miscella-neous scrap metal from getting into the boiler. Where possible, an inspection ofthe interior of the boiler and its appurte-nances shall be made for the presence offoreign debris prior to making the finalclosure.

b. The Inspector shall inspect for safeoperation all boilers and connectedappurtenances and all pressure pipingconnecting them to the appurtenancesand all piping up to and including thefirst stop valve, or the second stop valvewhen two are required.

c. The wall thickness of all pipe connec-tions shall comply with the require-ments of the code of construction for the boiler.

d. All threaded pipe connections shallengage at least five full threads of thepipe or fitting.

e. In bolted connections, the bolts, studs,and nuts shall be marked as required bythe original code of construction and befully engaged (i.e., the end of the bolt orstud shall protrude through the nut).

f. Washers shall only be used when speci-fied by the manufacturer of the part

being installed.

I-2920 PRESSURE TEST

Prior to initial operation, the completed boiler, including pressure piping, watercolumns, super heaters, economizers, stopvalves, etc., shall be pressure tested in ac-

cordance with the original code of construc-tion. Any pressure piping and fittings suchas water column, blowoff valve, feedwaterregulator, super heater, economizer, stopvalves, etc., which are shipped connected tothe boiler as a unit, shall be hydrostaticallytested with the boiler and witnessed by anInspector.

I-2930 NONDESTRUCTIVEEXAMINATION

Boiler components and subcomponents shall be nondestructively examined as required by the governing code of construction.

I-2940 SYSTEMS TESTING

Prior to final acceptance, an operational testshall be performed on the complete instal-lation. The test data shall be recorded and

the data made available to the jurisdictionalauthorities as evidence that the installationcomplies with the provisions of the govern-ing code(s) of construction. This operationaltest may be used as the final acceptance ofthe unit.

I-2950 FINAL ACCEPTANCE

A boiler may not be placed into serviceuntil its installation has been inspected and

accepted by the appropriate jurisdictionalauthorities.

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I-2960 BOILER INSTALLATIONREPORT

a. Upon completion, inspection, and ac-ceptance of the installation, the installershall complete and certify the Boiler

Installation Report (Report I-1).

b. The I-1 Boiler Installation report shall besubmitted as follows:

1. One copy to the owner;

2. One copy to the jurisdiction, ifrequired.

I-3000 HEATING BOILERS ANDPOTABLE WATER HEATERS

I-3100 INTRODUCTION

I-3110 SCOPE

The scope of this section shall apply to thosesteam boilers, hot water boilers, and potablewater heaters as defined in I-3120. For in-

stallation of items that do not fall within thescope of this section, refer to the followingas applicable:

I-2000 Power BoilersI-4000 Pressure VesselsI-5000 Piping (ASME B31 Series)

I-3120 DEFINITIONS

I-3121 STEAM HEATING BOILERS

Steam heating boilers are steam boilers in-stalled to operate at pressures not exceeding15 psi (100 kPa).

I-3122 HOT-WATER HEATINGAND HOT-WATER SUPPLYBOILERS

Hot-water heating and hot-water supply boilers are hot water boilers installed to

operate at pressures not exceeding 160 psi(1100 kPa) and/or temperatures not ex-ceeding 250°F (120°C), at or near the boileroutlet.

I-3123 POTABLE WATER HEATERS

a. Potable water heaters are corrosion re-sistant water heaters supplying potablehot water at pressures not exceeding 160psi (1100 kPa) and temperatures not inexcess of 210°F (100°C).

b. Water heaters are exempted from I-3000when none of the following limitationsis exceeded:

1. Heat input of 200,000 Btu/hr(60 kW/hr)

2. Water tem pera ture of 210°F(100°C)

3. Nominal water containing capacityof 120 gallons (454 l), except thatthey shall be equipped with safetydevices in accordance with the re-quirements of I-3837.

I-3200 CERTIFICATION, INSPECTION AND JURISDICTIONAL

REQUIREMENTS


The owner is responsible for satisfying ju-risdictional requirements for certificationand documentation. When required by

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jurisdictional rules applicable to the loca-tion of installation, the boiler shall not beoperated until the required documentationhas been provided to the owner and the jurisdiction.


All boilers shall have documented certifica-tion from the manufacturer indicating thatthe boiler complies with the requirementsof the code of construction. The certifica-tion shall identify the revision level of thecode of construction to which the boiler wasfabricated.


a. The owner shall determine jurisdictionalrequirements (i.e., certificates, permits,licenses, etc.) before installing the equip-ment. The organization responsiblefor installation shall obtain all permitsrequired by the jurisdiction prior tocommencing installation.

b. The owner shall determine jurisdic-tional requirements (i.e., certificates,permits, licenses, etc.) before operatingthe equipment. The owner shall obtainoperating certificates, permits, etc., re-quired by the jurisdiction prior to com-mencing operation.

I-3240 INSPECTION

All boilers shall be inspected after installa-

tion and prior to commencing operation.


I-3310 SUPPORTS

Each heating boiler shall be supported by

masonry and/or structural supports ofsufficient strength and rigidity to safelysupport the heating boiler and its contentswithout vibration in the heating boiler or itsconnecting piping and to allow for expan-sion and contraction.

I-3311 METHODS OF SUPPORTFOR STEAM HEATING,HOT-WATER HEATING,AND HOT-WATER SUPPLYBOILERS

a. Loadings

1. The design and attachment of lugs,hangers, saddles, and other supportsshall take into account the stressesdue to hydrostatic head of fullyflooded equipment in determiningthe minimum thicknesses required.Additional stresses imposed by ef-fects other than working pressureor static head that increase the aver-age stress by more than 10% of theallowable working stress shall also be taken into account. These effectsinclude the weight of the component

and its contents, and the method ofsupport.

2. In applying the requirements of (1)above, provision shall be made forlocalized stresses due to concen-trated support loads, temperaturechanges, and restraint against move-ment of the boiler due to pressure.Lugs, hangers, brackets, saddles,and pads shall conform satisfac-torily to the shape of the shell or

surface to which they are attachedor are in contact.

b. Horizontal Return Firetube Boilers

1. Boilers over 72 in. (1800 mm) indiameter

A horizontal-return tubular boilerover 72 in. (1800 mm) in diameter

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shall be supported from steel hang-ers by the outside-suspension typeof setting, independent of the fur-nace wall. The hangers shall be sodesigned that the load is properlydistributed.

2. Boilers over 54 in. (1350 mm) up to 72in. (1800 mm) in diameter

A horizontal-return tubular boilerover 54 in. (1350 mm) and up toand including 72 in. (1800 mm) indiameter shall be supported by theoutside-suspension type of setting,or at four points by not less than

eight steel brackets set in pairs, the brackets of each pair to be spacednot over 2 in. (5 cm) apart and theload to be equalized between them.See Fig. I-3311-a.

3. Boilers up to 54 in. (1350 mm) indiameter

A horizontal-return boiler up to andincluding 54 in. (137 cm) in diametershall be supported by the outside-suspension type of setting, or by notless than two steel brackets on eachside.

FIGURE I-3311-a — Spacing and weld details for supporting lugs in pairs on hori-zontal-return tubular boiler

FIGURE I-3311-b — Welded bracket connection for horizontal-return tubular boiler

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c. Supporting Members If the boiler is supported by structural

steel work, the steel supporting members shall be so located or insulated thatthe heat from the furnace will not impairtheir strength.

d. Lugs or Hangers Lugs, hangers, or brackets made of ma-

terials in accordance with the require-ments of the code of construction should be attached by fusion welding providedthey are attached by fillet welds alongthe entire periphery or contact edges.Figure I-3311-b illustrates an accept-able design of hanger bracket with theadditional requirement that the centerpin be located at the vertical center lineover the center of the welded contactsurface. The bracket plates shall bespaced at least 2-1/2 in. (64 mm) apart, but this dimension shall be increased ifnecessary to permit access for the weld-ing operation. The stresses computed by dividing the total load on each lug,hanger, or bracket, by the minimumcross-sectional area of the weld shallnot exceed 2800 psi (19 MPa). Whereit is impractical to attach lugs, hang-

ers, or brackets by welding, studs withnot less than 10 threads/in. (approx. 4threads/cm) may be used. In computingthe shearing stresses, the root area at the bottom of the thread shall be used. Theshearing and crushing stresses on studsshall not exceed that permitted by thecode of construction.

I-3320 SETTINGS

Steam heating, hot-water heating, and hot-water supply boilers of wrought materialsof the wet-bottom type having an externalwidth of over 36 in. (900 mm) shall be sup-ported so as to have a minimum clearanceof 12 in. (300 mm) between the bottom ofthe boiler and the floor to facilitate inspec-tion. When the width is 36 in. (900 mm) or

less, the clearance between the bottom ofthe boiler and the floor line shall be not lessthan 6 in. (150 mm), except when any part ofthe wet bottom is not farther from the outeredge than 12 in. (300 mm), this clearanceshall be not less than 4 in. (100 mm). Boiler

insulation, saddles, or other supports shall be arranged so that inspection openings arereadily accessible.

I-3330 STRUCTURAL STEEL

a. If the boiler is supported by structuralsteel work, the steel supporting members shall be so located or insulated thatthe heat from the furnace will not affecttheir strength.

b. Structural steel shall be installed inaccordance with jurisdictional require-ments, manufacturer’s recommenda-tions, and/or industry standards asappropriate.

I-3340 CLEARANCES

a. Heating boilers shall have a minimum

distance of at least 36 in. (900 mm) between the top of the heating boilerand any overhead structure and at least36 in. (900 mm) between all sides ofthe heating boiler and adjacent walls,structures, or other equipment. Heat-ing boilers having manholes shall haveat least 60 in. (150 mm) of clearance between the manhole opening and anywall, ceiling, piping, or other equipmentthat may prevent a person from enteringthe heating boiler. Alternative clearance

in accordance with the manufacturer’srecommendations are subject to accep-tance by the jurisdiction.

b. Modular heating boilers that requireindividual units to be set side by side,front to back or by stacking shall pro-vide clearances in accordance with the

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manufacturer’s recommendations, subject to acceptance by the jurisdiction.

c. Heating boilers shall be located so thatadequate space is provided for properoperation, maintenance19 , and inspec-

tion of equipment and appurtenances.

I-3350 BOILER ROOMREQUIREMENTS

I-3351 EXIT AND EGRESS

Two means of exit shall be provided for boiler rooms exceeding 500 sq. ft. (46 sq.m) of floor area and containing one or more boilers having a fuel capacity of 1,000,000Btu/hr. (293 kW/hr.) or more (or equivalentelectrical heat input). Each elevation shall beprovided with at least two means of egress,each to be remotely located from the other.A platform at the top of a single boiler is notconsidered an elevation.

I-3352 LADDERS AND RUNWAYS

a. All walkways, runways, and platformsshall:

1. Be of metal construction

2. Be provided between or over thetop of boilers which are more than8 ft. (2.8 m.) high from the operat-ing floor to afford accessibility forthe operation and servicing of the boilers

3. Be constructed of safety treads, stan-dard grating, or similar material andhave a minimum width of 30 in. (775mm)

4. Be of bolted, welded, or rivetedconstruction

5. Be equipped with handrails 42 in.(107 cm) high with an intermediaterail and 4 in. (10 cm) toeboard.

b. Stairways which serve as a means of ac-cess to walkways, runways, or platforms

shall not exceed an angle of 45 degreesfrom the horizontal and be equippedwith handrails 42 in. (1000 mm) highwith an intermediate grid.

c. Ladders which serve as a means of ac-cess to walkways, runways, or platformsshall:

1. Be of metal construction and not lessthan 18 in. (450 mm) wide

2. Have rungs that extend through theside members and are permanentlysecured

3. Have a clearance of not less than 30in. (775 mm) from the front of rungsto the nearest permanent object onthe climbing side of the ladder

4. Have a clearance of not less than6-1/2 in. (170 mm) from the back

of rungs to the nearest permanentobject

5. Have a clearance width of at least 15in. (400 mm) from the center of theladder on either side across the frontof the ladder.

d. There shall be at least two permanentlyinstalled means of egress from walk-ways, runways, or platforms that exceed6 ft (1800 mm) in length

I-3353 VENTILATION AND COMBUSTION AIR

The boiler room shall have an adequate airsupply to permit clean, safe combustion,

19 Maintenance – This includes the removal of tubes.

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minimize soot formation and maintaina minimum of 19.5% oxygen in the airof the boiler room. The combustion andventilation air may be supplied by eitheran unobstructed air opening or by powerventilators or fans.

a. Unobstructed air openings shall besized on the basis of 1 sq. in. (6.5 sq. cm)free area per 2000 Btu/hr. (586 W/hr.)maximum fuel input of the combined burners located in the boiler room, oras specified in the National Fire Protec-tion Association (NFPA) standards foroil and gas burning installations for theparticular job conditions. The boilerroom air supply openings shall be keptclear at all times.

b. Power ventilators or fans shall be sizedon the basis of 0.2 cfm (.0057 cm/m.)for each 1,000 Btu/hr. (293 W/hr.) ofmaximum fuel input for the combined burners of all boilers and/or water heat-ers located in the boiler room.

c. When power ventilators or fans are usedto supply combustion air, they shall beinstalled with interlock devices so that

the burners will not operate without anadequate number of ventilators/fans inoperation.

d. When combustion air is supplied to theheating boiler by an independent duct,with or without the employment ofpower ventilators or fans, the duct shall be sized and installed in accordancewith the manufacturer’s recommenda-tions. However, ventilation for the boilerroom must still be considered.

I-3354 LIGHTING

The boiler room should be well lighted, andit should have an emergency light source foruse in case of power failure.

I-3355 EMERGENCY VALVES ANDCONTROLS

All emergency shut-off valves and controlsshall be accessible from a floor, platform,walkway or runway. Accessibility shall

mean within a six foot elevation of thestanding space and not more than 12 in.(300 mm) horizontally from the standingspace edge.

I-3400 SOURCE REQUIREMENTS

I-3410 WATER

a. A means to add water to or fill the boiler,while not under pressure, shall be pro-vided. A valve or threaded plug may beused to shut off the fill connection whenthe boiler is in service.

b. Water fill connections shall be installedand provisions should be made to pre-vent boiler water from back-feeding intothe service water supply.

c. Provision should also be made in ev-ery boiler room for a convenient water

supply that can be used to flush outthe boiler and to clean the boiler roomfloor.

I-3420 FUEL

Fuel systems, whether coal, oil, gas, or othersubstance shall be installed in accordancewith jurisdictional and environmentalrequirements, manufacturer’s recommen-dations, and/or industry standards, as

applicable.

I-3430 ELECTRICAL

a. All wiring for controls, heat generatingapparatus, and other appurtenancesnecessary for the operation of the boiler

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or boilers shall be installed in accordancewith the provisions of national or inter-national standards and comply with theapplicable local electrical codes.

b. A manually operated remote shutdown

switch or circuit breaker should be lo-cated just outside the boiler room doorand marked for easy identification.Consideration should also be givento the type and location of the switchto safeguard against tampering. If the boiler room door is on the building ex-terior, the switch should be located justinside the door. If there is more than onedoor to the boiler room, there should bea switch located at each door.

1. For atmospheric-gas burners, and oil burners where a fan is on a commonshaft with the oil pump, the com-plete burner and controls should beshut off.

2. For power burners with detachedauxiliaries, only the fuel input sup-ply to the firebox need be shut off.

c. Controls and Heat Generating Appara-

tus

1. Oil and gas-fired and electricallyheated boilers and water heatersshall be equipped with suitableprimary (flame safeguard) safetycontrols, safety limit switches, and burners or electr ic elements asrequired by a nationally or interna-tionally recognized standard.

2. The sym bol of the certifying organi-

zation20 that has investigated suchequipment as having complied witha nationally recognized standardshall be affixed to the equipment

and shall be considered as evidencethat the unit was manufactured inaccordance with that standard.

3. These devices shall be installedin accordance with jurisdictional

and environmental requirements,manufacturer’s recommendations,and/or industry standards, as ap-plicable.

I-3500 DISCHARGE REQUIREMENTS

I-3510 CHIMNEY OR STACK

Chimneys or stacks shall be installed inaccordance with jurisdictional and envi-ronmental requirements, manufacturer’srecommendations, and/or industry stan-dards, as applicable.

I-3520 ASH REMOVAL

Ash removal systems shall be installed inaccordance with jurisdictional and envi-

ronmental requirements, manufacturer’srecommendations, and/or industry stan-dards, as applicable.

I-3530 DRAINS

Unobstructed floor drains, properly locatedin the boiler room, will facilitate propercleaning of the boiler room. Floor drainswhich are used infrequently should havewater poured into them periodically to pre-

vent the entrance of sewer gasses and odors.If there is a possibility of freezing, an envi-ronmentally safe antifreeze mixture should be used in the drain traps. Drains receiving blowdown water should be connected to

20 Organization – A certifying organization is onethat provides uniform testing, examination, andlisting procedures under established, nationallyrecognized standards, and that is acceptable tothe authorities having jurisdiction.

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the sanitary sewer by way of an acceptable blowdown tank or separator or an air gapthat will allow the blowdown water to coolto at least 140°F (60°C) and reduce the pres-sure to 5 psig (35 kPa) or less.

I-3600 OPERATING SYSTEMS

I-3610 OIL HEATERS

a. A heater for oil or other liquid harmfulto boiler operation shall not be installeddirectly in the steam or water spacewithin a boiler.

b. Where an external-type heater for suchservice is used, means shall be providedto prevent the introduction into the boiler of oil or other liquid harmful to boiler operation.

I-3620 BREECHING ANDDAMPERS

Breeching and dampers shall be installedin accordance with jurisdictional and en-vironmental requirements, manufacturer’s

recommendations, and/or industry stan-dards, as applicable.

I-3630 BURNERS AND STOKERS

Burners and stokers shall be installed inaccordance with jurisdictional and envi-ronmental requirements, manufacturer’srecommendations, and/or industry stan-dards, as applicable.

I-3640 FEEDWATER, MAKEUPWATER, AND WATER

SUPPLY

a. Steam Boilers Feedwater or water treatment shall be

introduced into a boiler through the

return piping system. Alternatively,feedwater or water treatment should be introduced through an independentconnection. The water flow from theindependent connection shall not dis-charge directly against parts of the boiler

exposed to direct radiant heat from thefire. Feedwater or water treatment shallnot be introduced through openings orconnections provided for inspection orcleaning, safety valve, water column,water gage glass, or pressure gage. Thefeedwater pipe shall be provided witha check valve near the boiler and a stopvalve or cock between the check valveand the boiler, or between the checkvalve and the return pipe system.

b. Hot Water Boilers Makeup water may be introduced into

a boiler through the piping system orthrough an independent connection.The water flow from the independentconnection shall not discharge directlyagainst parts of the boiler exposed to di-rect radiant heat from the fire. Makeupwater shall not be introduced throughopenings or connections providedexclusively for inspection or cleaning,

safety relief valve, pressure gage, ortemperature gage. The makeup waterpipe shall be provided with a checkvalve near the boiler and a stop valveor cock between the check valve and the boiler, or between the check valve andthe piping system.

c. Potable Water Heaters

1. Water supply shall be introducedinto a water heater through an in-

dependent water supply connection.Feedwater shall not be introducedthrough openings or connectionsprovided for cleaning, safety reliefvalves, drain, pressure gage, ortemperature gage.

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2. If the water supply pressure to awater heater exceeds 75% of the setpressure of the safety relief valve,a pressure reducing valve is re-quired.

I-3650 STOP VALVES

I-3651 STEAM HEATING, HOTWATER HEATING, ANDHOT-WATER SUPPLY

BOILERS

a. For Single Installations Stop valves shall be located at an ac-

cessible point in the supply and returnpipe connections, as near the boiler asis convenient and practicable.

b. For Multiple Boiler Installations A stop valve shall be used in each sup-

ply and return pipe connection of twoor more boilers connected to a commonsystem. See Figures I-3651-a , I-3651-b , and I-3651-c.

c. Type of Stop Valve(s)

1. All valves or cocks shall conformwith the applicable portions of anacceptable code of construction andmay be ferrous or nonferrous.

2. The minimum pressure rating of allvalves or cocks shall be at least equalto the pressure stamped upon the boiler, and the temperature ratingof such valves or cocks, includingall internal components, shall be not

less than 250°F (120°C).

3. Valves or cocks shall be flanged,threaded or have ends suitable forwelding or brazing.

4. All valves or cocks with stems orspindles shall have adjustable pres-sure-type packing glands and, in

addition, all plug-type cocks shall beequipped with a guard or gland. Theplug or other operating mechanismshall be distinctly marked in linewith the passage to indicate whetherit is opened or closed.

5. All valves or cocks shall have tightclosure when under boiler hydro-static test pressure.


Stop valves shall be installed in the supplyand discharge pipe connections of a waterheater installation to permit draining thewater heater without emptying the sys-tem.

I-3660 RETURN PIPE CONNECTIONS

a. The return pipe connections of each boiler supplying a gravity return steamheating system shall be so arranged asto form a loop substantially as shownin Figure I-3651-b so that the water in

each boiler cannot be forced out belowthe safe water level.

b. For hand-fired boilers with a normalgrate line, the recommended pipe sizesdetailed as “A” in Fig. I-3651-a andI-3651-b are NPS 1-1/2 (DN 40) for 4 sq.ft. (0.37 sq. m.) or less firebox area at thenormal grate line, NPS 2-1/2 (DN 65)for areas more than 4 sq. ft. (0.37 sq m)up to 14.9 sq. ft. (1.38 sq. m.), and NPS4 (DN 100) for 15 sq. ft. (1.39 sq. m.) or

more.

c. For automatically fired boilers whichdo not have a normal grate line, therecommended pipe sizes detailed as“A” in Figures I-3651-a and I-3651-b are NPS 1-1/2 (DN 40) for boilers withminimum safety valve relieving capac-ity 250 lb./hr. (113 kg./hr.) or less, NPS

A05

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General Note:Return connections shown for a multiple boiler installation may not alwaysinsure that the system will operate properly. In order to maintain proper water levels in multipleboiler installations, it may be necessary to install supplementary controls or suitable devices.

Note:(1) Recommended for 1 in. and larger safety valve discharge.

From receiver tank

Solenoidvalve

Check valve

Stop valve

Stop valve

Check valveBlowoffvalve/drain

Blowoffvalve/drain

From receiver tank

Solenoidvalve

Single ReturnShown

To receivertank

Safety valvedischarge piping(with union)


To receivertank

F & T traphigh level“spill”

F & T traphigh level“spill”

Multiple ReturnsShown

Safetyvalve

Safetyvalve

Low-waterfuel cutoff

Pump controland gage glass

Pressurecontrols

Steam gageHeatingsupply

Stop valve

Pressurecontrols

Steam gage

Low-water fuelcutoff pump controland gage glass

Steam main

Stop valve

Drippanelbow

Alternativesafety valvedischargepiping[Note (1)]

“A”

FIGURE I-3651-a — Steam boilers in battery – pumped return – acceptable pipinginstallation

2-1/2 (DN 65) for boilers with minimumsafety valve relieving capacity from 251lb./hr. (114 kg./hr.) to 2000 lb./hr. (987kg./hr.), inclusive, and NPS 4 (DN 100)for boilers with more than 2000 lb./hr.(987 kg./hr.) minimum safety valverelieving capacity.

d. Provision shall be made for cleaning theinterior of the return piping at or close tothe boiler. Washout openings should beused for return pipe connections and thewashout plug placed in a tee or a crossso that the plug is directly opposite andas close as possible to the opening in the boiler.

I-3670 BOTTOM BLOWOFF ANDDRAIN VALVES

I-3671 STEAM HEATING, HOTWATER HEATING, ANDHOT-WATER SUPPLY

BOILERS

a. Bottom Blowoffs Each steam boiler shall have a bottom

blowoff connection fitted with a valveor cock connected to the lowest waterspace practicable with a minimum sizeas shown in Table I-3671-a. The dis-

A05

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FIGURE I-3651-b — Steam boilers in battery – gravity return – acceptable pipinginstallation

charge piping shall be full size to thepoint of discharge.

b. Boilers having a capacity of 25 gallons(95 l) or less are exempt from the above

requirements, except that they shallhave a NPS 3/4 (DN 20) minimum drainvalve.

c. Drains Each steam or hot-water boiler shall

have one or more drain connections,fitted with valves or cocks connecting

to the lowest water containing spaces.All parts of the boiler must be capableof being drained (the boiler design willdictate the number and size of drains).The minimum size of the drain piping,

valves, and cocks shall be NPS 3/4 (DN20). The discharge piping shall be fullsize to the point of discharge.

When the blowoff connection is locatedat the lowest water containing space,a separate drain connection is not re-quired.

General Note:Return connections shown for a multiple boiler installation may not alwaysinsure that the system will operate properly. In order to maintain proper water levels in multipleboiler installations, it may be necessary to install supplementary controls or suitable devices.

Note:(1) Recommended for 1 in. and larger safety valve discharge.

Check valve

Stop valve

Stop valve

Blowoffvalve/drain

Blowoffvalve/drain

Single ReturnShown



F & T trap

Multiple ReturnsShown

Safetyvalve

Safetyvalve

Low-waterfuel cutoff

Water columnand gage glass

Pressurecontrols

Steam gage

HeatingsupplyStop valve

Pressurecontrols

Steam gage

Low-water fuelcutoff andgage glass

Steam main

Stop valve

Drippanelbow

Alternativesatety valvedischargepiping[Note (1)]

“A”

Heating return

Check valve

Return loopconnection

LowestPermissiblewaterline

Toreturnheader

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FIGURE I-3651-d — A typical acceptable piping installation for storage water heat-ers in battery

Note:(1) Recirculation system may be gravity or pump actuated.

Water Heater with TopRelief Opening

Water Heater with SideRelief Opening

PressureReducing Valveif Required

Expansion Tankif Required Drain Valve with

Suitable Drain

Water Heaterwith VerticalTop SafetyRelief Opening

To Open Drain

Point of Use

To Open Drain

Water Heaterwith SideSafety ReliefOpening & within4 in. of the topof the shell

Drain Valve

Cold Water Supply

Drain Valve

OpticalRecirculation Line[Note (1)]

FIGURE I-3651-e — A typical acceptable piping installation for flow through waterheater with provisions for piping expansion

Opticalrecirculationline

Drain valve

Flow switch onflow throughwater heater

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TABLE I-3671-a — Size of BottomBlowoff Piping, Valves, and Cocks

Minimum Required Blowoff Piping, Valves,Safety Valve and Cocks Size,

Capacity, lb of in. (mm) (min.)steam/hr (Note 1)

up to 500 3/4 (19)501 to 1,250 1 (25)1,251 to 2,500 1-1/4 (32)2,501 to 6,000 1-1/2 (38)6,001 and larger 2 (50)

Note 1: To determine the discharge capacity ofsafety relief valves in terms of Btu, the relievingcapacity in lb of steam/hr is multiplied by 1,000.

TABLE I-3692 — Expansion TankCapacities for a Water Heater (Note 1)

Tank Capacities, gal System Prepressurized NonpressurizedVolume, Diaphragm Type Typegal (l)

50 (190) 1 3

100 (380) 2 6200 (760) 3 12300 (1150) 4 18400 (1520) 5 24500 (1900) 6 301,000 (3800) 12 602,000 (7600) 24 120

Note 1: Capacities in this table are given as a guideto reduce or eliminate relief valve weeping underconditions of partial water system demands or oc-casional water draw during recovery.

System volume includes water heater capacity plusall piping capacity for a recirculation system or

water heater capacity only for a nonrecirculationsystem.

The capacities are based upon a water temperaturerise from 40°F to 180°F (4°C to 80°C), 60 psi fill pres-sure, maximum operating pressure of 125 psi, 20%water recovery, and an acceptance factor of 0.465for prepressurized types, and 0.09156 for nonpre-pressurized types. A procedure for estimating tanksizes for other design conditions may be found inChapter 12 of the 1996 HVAC Systems and Equip-ment volume of the ASHRAE Handbook.

2. Any discharge piping connected tothe bottom drain connection shall befull size to the point of discharge.

I-3680 MODULAR STEAM

HEATING AND HOT WATER HEATING BOILERS

I-3681 INDIVIDUAL MODULES

a. The individual modules shall complywith all the requirements of the code ofconstruction and this paragraph. Theindividual modules shall be limited to a

maximum input of 400,000 Btu/hr. (gas)(117 kW/hr.), 3 gal./hr. (oil) (11.4 l/hr.),or 117 kW (electricity).

b. Each module of a modular steam heat-ing boiler shall be equipped with:

1. Safety valve, see I-3810

2. Blowoff valve, see I-3671(a)

3. Drain valve, see I-3671(c).

c. Each module of a modular hot-waterheating boiler shall be equipped with:

1. Safety relief valve, see I-3820

2. Drain valve, see I-3671(c).

I-3682 ASSEMBLED MODULARBOILERS

a. The individual modules shall be mani-folded together at the job-site withoutany intervening valves.

b. The assembled modular steam heating

boiler shall also be equipped with:

1. Feedwater connection, see I-3640

2. Return pipe connection, see I-3660.

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c. The assembled modular hot water boilershall also be equipped with:

1. Makeup water connection, seeI-3640

2. Provision for thermal expansion, seeI-3690

3. Stop valves, see I-3651(a) (treatingthe assembled modular boiler as asingle unit).

I-3690 PROVISIONS FOR THERMAL EXPANSION IN

HEATING BOILERS

I-3691 EXPANSION TANKS ANDPIPING FOR STEAM

HEATING, HOT-WATERHEATING, AND HOT-

WATER SUPPLY BOILERS

a. Expansion Tanks for Hot-Water Heatingand Hot-Water Supply Boilers

All hot-water heating systems incor-porating hot-water tanks or fluid relief

columns shall be so installed as to pre-vent freezing under normal operatingconditions.

1. Heating Systems With Open ExpansionTank

An indoor overflow from the upperportion of the expansion tank shall be provided in addition to an openvent, the indoor overflow shall becarried within the building to a suit-able plumbing fixture or drain.

2. Closed Heating Systems An expansion tank shall be installed

that will be consistent with the vol-ume and capacity of the system. Ifthe system is designed for a workingpressure of 30 psi (200 kPa) or less,the tank shall be suitably designedfor a minimum hydrostatic test

pressure of 75 psi (525 kPa). Expan-sion tanks for systems designed tooperate above 30 psi (200 kPa) shall be constructed in accordance withan acceptable code of construction.Provisions shall be made for drain-

ing the tank without emptying thesystem, except for prepressurizedtanks. The minimum capacity of theclosed-type expansion tank should be determined from Tables I-3691-a and I-3691-b or from the followingformula where the necessary infor-mation is available:

Vt = [(0.00041T-0.0466)Vs]/

[(Pa/Pf) - (Pa/Po)] where,

Vt = minimum volume of tanks,

gallons (l) V

s = volume of system, not

including tanks, gallons (l) T = average operating temperature, °F (°C)

Pa = atmospheric pressure,

psia (kPa) P

f = fill pressure, psia (kPa)

Po = maximum operating

pressure, psia (kPa)

3. Hot-Water Supply Systems If a system is equipped with a check

valve or pressure reducing valve inthe cold water inlet line, consider-ation should be given to the instal-lation of an airtight expansion tankor other suitable air cushion. Other-wise due to the thermal expansion ofthe water, the safety relief valve maylift periodically. If an expansion tank

is provided, it shall be constructedin accordance with an acceptablecode of construction. Except forpre-pressurized tanks, which should be installed on the cold water side,provisions shall be made for drain-ing the tank without emptying thesystem. See Fig. I-3651-d f or a typicalacceptable installation.

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TABLE I-3691-a — Expansion Tank Ca-pacities for Gravity Hot Water Systems(Based on two-pipe system with average operat-ing water temperature 170°F (77°C), using cast- iron column radiation with heat emission rate150 Btu/hr sq. ft. (44 W/hr sq. 0.3 m) equivalentdirection radiation.)

Installed Equivalent Tank Capacity,Direct Radiation, sq. ft. gallon(Note 1)

up to 350 18up to 450 21up to 650 24up to 900 30up to 1,100 35up to 1,400 40up to 1,600 2- 30up to 1,800 2- 30up to 2,000 2- 35up to 2,400 2- 40

Note 1: For systems with more than 2,400 sq. ft.of installed equivalent direct water radiation, therequired capacity of the cushion tank shall be in-creased on the basis of 1 gal tank capacity/33 sq. ft.of additional equivalent direct radiation.

b. Piping for Steam Heating, Hot-WaterHeating and Hot-Water Supply Boilers

Provisions shall be made for the expan-sion and contraction of steam and hotwater mains connected to boiler(s) sothere will be no undue strain transmit-

ted to the boiler(s). See Figs. I-3651-a , I-3651-b , and I-3651-c for typical sche-matic arrangements of piping incorpo-rating strain absorbing joints for steamand hot-water heating boilers.

I-3692 EXPANSION TANKS AND PIPING FOR POTABLE

WATER HEATERS

a. Expansion Tanks If a system is equipped with a check

valve or pressure-reducing valve inthe cold water inlet line, considerationshould be given to the installation of anairtight expansion tank or other suitableair cushion. Otherwise, due to the ther-mal expansion of the water, the safetyrelief valve may lift periodically. If anexpansion tank is provided, it shall beconstructed in accordance with an ac-ceptable code of construction. The mini-

mum capacity of the expansion tankmay be determined from Table I-3692.See Fig. I-3651-d f or a typical acceptableinstallation. Except for prepressurizeddiaphragm-type tanks, which should beinstalled on the cold water side, provi-sions shall be made for draining the tankwithout emptying the system.

b. Piping Provisions shall be made for the expan-

sion and contraction of hot water mains

connected to water heater(s) so thatthere will be no undue strain transmit-ted to the water heater(s). See FiguresI-3651-d and I-3651-e for typical sche-matic arrangements of piping incorpo-rating strain absorbing joints.

I-3700 INSTRUMENTS, FITTINGS,AND CONTROLS

I-3710 STEAM HEATING BOILERS

I-3711 STEAM GAGES

a. Each steam boiler shall have a steamgage or a compound steam gage con-nected to its steam space or to its watercolumn or to its steam connection. Thegage or connection shall contain a si-phon or equivalent device which willdevelop and maintain a water seal thatwill prevent steam from entering thegage tube. The connection shall be soarranged that the gage cannot be shut offfrom the boiler except by a cock placedin the pipe at the gage and provided

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with a tee- or lever- handle arrangedto be parallel to the pipe in which itis located when the cock is open. Theconnections to the boiler shall be notless than NPS 1/4 (DN 8). Where steelor wrought iron pipe or tubing is used,

the connection and external siphon shall be not less than NPS 1/2(DN 15). Theminimum size of a siphon, if used, shall be NPS 1/4 (DN 8). Ferrous and nonfer-rous tubing having inside diametersat least equal to that of standard pipesizes listed above may be substitutedfor pipe.

b. The scale on the dial of a steam boilergage shall be graduated to not less than30 psi (200 kPa) nor more than 60 psi(400 kPa). The travel of the pointer from0 psi (0 kPa) to 30 psi (200 kPa) pressureshall be at least 3 in. (75 mm).

I-3712 WATER GAGE GLASSES

a. Each steam boiler shall have one ormore water gage glasses attached tothe water column or boiler by meansof valved fittings not less than NPS 1/2

(DN 15), with the lower fitting providedwith a drain valve of a type having anunrestricted drain opening not less thanNPS 1/4 (DN 8) to facilitate cleaning.Gage glass replacement shall be possibleunder pressure. Water glass fittings may be attached directly to a boiler. Boilershaving an internal vertical height of lessthan 10 in. (250 mm) should be equippedwith a water level indicator of the glass bulls-eye type provided the indicatoris of sufficient size to show the water at both normal operating and low-watercutoff levels.

b. The lowest visible part of the water gageglass shall be at least 1 in. (25 mm) abovethe lowest permissible water level rec-ommended by the boiler manufacturer.With the boiler operating at this lowestpermissible water level, there shall beno danger of overheating any part ofthe boiler.

c. In electric boilers of the submerged elec-trode type, the water gage glass shall beso located to indicate the water levels both at startup and under maximumsteam load conditions as established bythe manufacturer.

d. In electric boilers of the resistance ele-ment type, the lowest visible part of thewater gage shall be located at least 1 in.(25 mm) above the lowest permissible

water level specified by the manufactur-er. Each electric boiler of this type shallalso be equipped with an automaticlow-water cutoff on each boiler pressurevessel so located as to automaticallycut off the power supply to the heatingelements before the surface of the waterfalls below the visible part of the glass.

TABLE I-3691-b — Expansion TankCapacities for Forced Hot WaterSystems (Note 1)(Based on average operating water temperature195°F [91°C], fill pressure 12 psig [80 kPa], andmaximum operating pressure 30 psig [200 kPa])

Tank Capacities, gal (l) System Prepressurized NonpressurizedVolume, Diaphragm Type Typegal (l)

100 (380) 9 (34) 15 (57) 200 (760) 17 (65) 30 (114) 300 (1150) 25 (95) 45 (170) 400 (1500) 33 (125) 60 (230) 500 (1900) 42 (160) 75 (285) 1000 (3800) 83 (315) 150 (570) 2000 (7600) 165 (625) 300 (1150)

Note 1: System volume includes volume of waterin boiler, radiation, and piping, not including theexpansion tank. Expansion tank capacities are

based on an acceptance factor of 0.4027 for pre-pressurized types and 0.222 for nonpressurizedtypes. A procedure for estimating system volumeand determining expansion tank sized for otherdesign conditions may be found in Chapter 12 ofthe 1996 HVAC Systems and Equipment Volume ofthe ASHRAE Handbook.

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e. Tubular water glasses on electric boil-ers having a normal water content notexceeding 100 gallons (380 l) shall beequipped with a protective shield.

NOTE: Transparent material other than

glass may be used for the water gageprovided that the material will remaintransparent and has proved suitable forthe pressure, temperature, and corrosiveconditions expected in service.

I-3713 WATER COLUMN ANDWATER LEVEL CONTROLPIPES

a. The minimum size of ferrous or nonfer-rous pipes connecting a water columnto a steam boiler shall be NPS 1 (DN25). No outlet connections, except fordamper regulator, feedwater regulator,steam gages, or apparatus which doesnot permit the escape of any steam orwater except for manually operated blowdown, shall be attached to a watercolumn or the piping connecting a watercolumn to a boiler (see I-3640[a]) for in-troduction of feedwater into a boiler). If

the water column, gage glass, low-waterfuel cutoff, or other water level controldevice is connected to the boiler by pipeand fittings, no shutoff valves of anytype shall be placed in such pipe anda cross or equivalent fitting to which adrain valve and piping may be attachedshall be placed in the water pipingconnection at every right angle turn tofacilitate cleaning. The water columndrain pipe and valve shall be not lessthan NPS 3/4 (DN 20).

b. The steam connections to the watercolumn of a horizontal firetube wrought boiler shall be taken from the top of theshell or the upper part of the head, andthe water connection shall be taken froma point not above the center line of the

shell. For a cast-iron boiler, the steamconnection to the water column shall be taken from the top of an end sectionor the top of the steam header, and thewater connection shall be made on anend section not less than 6 in. (150 mm)

below the bottom connection to thewater gage glass.

I-3714 PRESSURE CONTROL

Each automatically fired steam boiler shall be protected from overpressure by two pres-sure-operated controls.

a. Each individual automatically firedsteam boiler shall have a safety limitcontrol that will cut off the fuel supply toprevent steam pressure from exceedingthe 15 psi (100 kPa) maximum allowableworking pressure of the boiler. Eachcontrol shall be constructed to preventa pressure setting above 15 psi (100kPa).

b. Each individual steam boiler or eachsystem of commonly connected steam boilers shall have a control that will cut

off the fuel supply when the pressurereaches an operating limit, which shall be less than the maximum allowablepressure.

c. Shutoff valves of any type shall not beplaced in the steam pressure connec-tion between the boiler and the controlsdescribed in (a) and (b) above. Thesecontrols shall be protected with a siphonor equivalent means of maintaining awater seal that will prevent steam from

entering the control. The connectionsto the boiler shall not be less than NPS1/4 (DN 8), but where steel or wroughtiron pipe or tubing is used, they shallnot be less than NPS 1/2 (DN 15). Theminimum size of an external siphonshall be NPS 1/4 (DN 8) or 3/8 in.

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(10 mm) outside diameter nonferroustubing. For manifold connections, theminimum size shall be as specified inthe original code of construction.

I-3715 AUTOMATIC LOW-WATERFUEL CUTOFF AND/ORWATER FEEDING DEVICE

a. Each automatica lly fired steam- orvapor-system boiler shall have an au-tomatic low-water fuel cutoff so locatedas to automatically cut off the fuel sup-ply when the surface of the water fallsto the lowest visible part of the watergage glass. If a water feeding device isinstalled, it shall be so constructed thatthe water inlet valve cannot feed waterinto the boiler through the float chamberand so located as to supply requisitefeedwater.

b. Such a fuel cutoff or water feedingdevice may be attached directly to a boiler. A fuel cutoff or water feedingdevice may also be installed in thetapped openings available for attachinga water glass direct to a boiler, provided

the connections are made to the boilerwith nonferrous tees or Y’s not less thanNPS 1/2 (DN 15) between the boiler andwater glass so that the water glass is at-tached directly and as close as possibleto the boiler; the run of the tee or Y shalltake the water glass fittings, and the sideoutlet or branch of the tee or Y shall takethe fuel cutoff or water feeding device.The ends of all nipples shall be reamedto full-size diameter.

c. Fuel cutoffs and water feeding devicesembodying a separate chamber shallhave a vertical drain pipe and a blowoffvalve not less than NPS 3/4 (DN 20),located at the lowest point in the waterequalizing pipe connections so that thechamber and the equalizing pipe can beflushed and the device tested.

I-3716 MODULAR STEAM HEATING BOILERS

a. Each module of a modular steam boilershall be equipped with:

1. Steam gage, see I-3711

2. Water-gage glass, see I-3712

3. Pressure control, see I-3714(a)

4. Low water cutoff, see I-3715.

b. The assembled modular steam heating boiler shall also be equipped with apressure control. See I-3714(b).

I-3717 INSTRUMENTS, FITTINGS,AND CONTROLSMOUNTED INSIDE BOILERJACKETS

Any or all instruments, fittings, and controlsrequired by these rules may be installedinside of boiler jackets provided the watergage and pressure gage on a steam boilerare visible through an opening or openings

at all times.

I-3720 HOT-WATER HEATING ORHOT-WATER SUPPLY

BOILERS

I-3721 PRESSURE OR ALTITUDEGAGES

a. Each hot-water heating or hot-water

supply boiler shall have a pressure oraltitude gage connected to it or to itsflow connection in such a manner thatit cannot be shut off from the boiler ex-cept by a cock with tee or lever handle,placed on the pipe near the gage. Thehandle of the cock shall be parallel tothe pipe in which it is located when thecock is open.

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b. The scale on the dial of the pressure oraltitude gage shall be graduated ap-proximately to not less than 1-1/2 normore than 3-1/2 times the pressure atwhich the safety relief valve is set.

c. Piping or tubing for pressure or altitudegage connections shall be of nonferrousmetal when smaller than NPS 1 (DN25).

I-3722 THERMOMETERS

Each hot-water heating or hot-water sup-ply boiler shall have a thermometer solocated and connected that it shall be eas-ily readable. The thermometer shall be solocated that it shall at all times indicate thetemperature of the water in the boiler at ornear the outlet.

I-3723 TEMPERATURE CONTROL

Each automatically fired hot-water heatingor hot-water supply boiler shall be protectedfrom over-temperature by two temperature-operated controls.

a. Each individual automatically firedhot-water heating or hot-water supply boiler shall have a safety limit controlthat will cut off the fuel supply to pre-vent water temperature from exceedingthe maximum allowable temperature atthe boiler outlet. This water temperaturesafety control shall be constructed toprevent a temperature setting above themaximum allowable temperature.

b. Each individual hot-water heating orhot-water supply boiler or each systemof commonly connected boilers withoutintervening valves shall have a controlthat will cut off the fuel supply whenthe water temperature reaches an oper-ating limit, which shall be less than themaximum allowable temperature.

I-3724 LOW-WATER FUEL CUTOFF

a. Each automatically fired hot-water boil-er with heat input greater than 400,000Btu/hr (117 kW/hr.) shall have an au-tomatic low-water fuel cutoff that has

been designed for hot-water service, andit shall be so located as to automaticallycut off the fuel supply when the surfaceof the water falls to the level establishedin (b) below.

b. As there is no normal waterline to bemaintained in a hot-water boiler, any lo-cation of the low-water fuel cutoff abovethe lowest safe permissible water levelestablished by the boiler manufactureris satisfactory.

c. A coil-type boiler or a watertube boilerwith heat input greater than 400,000Btu/hr. (117 kW/hr.) requiring forcedcirculation to prevent overheating of thecoils or tubes shall have a flow-sensingdevice installed in lieu of the low-waterfuel cutoff required in (a) above to auto-matically cut off the fuel supply whenthe circulating flow is interrupted.

d. A means shall be provided for testingthe operation of the external low-waterfuel cutoff without resorting to drainingthe entire system. Such means shall notrender the device inoperable except asfollows. If the means temporarily iso-lates the device from the boiler duringthis testing, it shall automatically returnto its normal position. The connectionshould be so arranged that the devicecannot be shut off from the boiler ex-cept by a cock placed at the device and

provided with a tee or lever-handle ar-ranged to be parallel to the pipe in whichit is located when the cock is open.

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I-3725 MODULAR HOT-WATERHEATING BOILERS

a. Each module of a modular hot-waterheating boiler shall be equipped with:

1. Pressure/altitude gage, see I-3721

2. Thermometer, see I-3722

3. Temperature control, see I-3723(a).

b. The assembled modular hot-water heat-ing boiler shall be equipped with:

1. Temperature control, see I-3723(b)

2. Low-water fuel cutoff, see I-3724.

I-3726 INSTRUMENTS, FITTINGS,AND CONTROLSMOUNTED INSIDE BOILERJACKETS

Any or all instruments, fittings, and con-trols required by these rules should beinstalled inside of boiler jackets providedthe thermometer and pressure gage are

visible through an opening or openings atall times.


I-3731 TEMPERATURE CONTROLS

Each individual automatically fired waterheater, in addition to the operating controlused for normal water heater operation shall

have a separate high limit temperature actu-ated combustion control that will automati-cally cut off the fuel supply. The temperaturerange of the high limit temperature actuatedcontrol shall not allow a setting over 210°F(100°C).

a. On gas-fired water heaters, the highlimit temperature control when actu-

ated shall shut off the fuel supply witha shutoff means other than the operatingcontrol valve. Separate valves may havea common body.

b. On electrically heated water heaters, the

high limit temperature control whenactuated shall cut off all power to theoperating controls.

c. On oil-fired water heaters, the high limittemperature control when actuated shallcut off all current flow to the burnermechanism.

d. On indirect water heating systems, thehigh limit temperature control when ac-tivated shall cut off the source of heat.

I-3732 THERMOMETER

Each installed water heater shall have athermometer so located and connected thatit shall be easily readable. The thermometershall be so located that it shall at all timesindicate the temperature of the water in thewater heater at or near the outlet.

I-3800 PRESSURE-RELIEVINGVALVES

I-3810 SAFETY VALVE REQUIREMENTS FOR

STEAM BOILERS

a. Safety valves are to be manufactured inaccordance with a national or interna-tional standard.

b. Each steam boiler shall have one or moreNational Board capacity certified safetyvalves of the spring pop type adjustedand sealed to discharge at a pressure notto exceed 15 psi (100 kPa).

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c. No safety valve for a steam boiler shall be smaller than NPS 1/2 (DN 15). Nosafety valve shall be larger than NPS4-1/2 (DN 115). The inlet opening shallhave an inside diameter equal to, orgreater than, the seat diameter.

d. The minimum valve capacity in pounds(kilograms) per hour shall be the greaterof that determined by dividing themaximum Btu (Watts) output at the boiler nozzle obtained by the firing ofany fuel for which the unit is installed by 1000, or shall be determined on the basis of the pounds (kilograms) of steamgenerated per hour per square foot(square meter) of boiler heating surfaceas given in Table I-3820. For cast-iron boilers, the minimum valve capacityshall be determined by the maximumoutput method. In many cases a greaterrelieving capacity of valves will have to be provided than the minimum speci-fied by these rules. In every case, therequirement of I-3810(e) shall be met.

e. The safety valve capacity for each steam boiler shall be such that with the fuel burning equipment installed, and oper-

ated at maximum capacity, the pressurecannot rise more than 5 psi (35 kPa)above the maximum allowable workingpressure.

f. When operating conditions are changed,or additional boiler heating surfaceis installed, the valve capacity shall be increased, if necessary, to meet thenew conditions and be in accordancewith I-3810(e). The additional valvesrequired, on account of changed condi-

tions, should be installed on the outletpiping provided there is no interveningvalve.

I-3820 SAFETY RELIEF VALVEREQUIREMENTS FORHOT-WATER HEATING ORSUPPLY BOILERS

a. Safety relief valves are to be manufac-

tured in accordance with a national orinternational standard.

b. Each hot-water heating or hot-watersupply boiler shall have at least oneNational Board capacity certified safetyrelief valve, of the automatic reseatingtype set to relieve at or below the maxi-mum allowable working pressure of the boiler.

c. Hot-water heating or hot-water supply boilers limited to a water temperaturenot in excess of 210°F (100°C) mayhave, in lieu of the valve(s) specified in(b) above, one or more National Boardcapacity certified temperature and pres-sure safety relief valves of the automaticreseating type set to relieve at or belowthe maximum allowable working pres-sure of the boiler.

d. When more than one safety relief valve

is used on either hot-water heating orhot-water supply boilers, the additionalvalves shall be National Board capacitycertified and may have a set pressurewithin a range not to exceed 6 psi (40kPa) above the maximum allowableworking pressure of the boiler up toand including 60 psi (400 kPa), and 5%for those having a maximum allowableworking pressure exceeding 60 psi (400kPa).

e. No safety relief valve shall be smallerthan NPS 3/4 (DN 20) nor larger thanNPS 4-1/2 (DN 115), except that boil-ers having a heat input not greaterthan15,000 Btu/hr. (15.8 4.4 W/hr.)should be equipped with a rated safetyrelief valve of NPS 1/2 (DN 15).

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fied by these rules. In every case, therequirements of I-3820(h) shall be met.

g. When operating conditions are changed,or additional boiler heating surface isinstalled, the valve capacity shall be

increased, if necessary, to meet the newconditions and shall be in accordancewith I-3820(h). The additional valvesrequired, on account of changed condi-tions, should be installed on the outletpiping provided there is no interveningvalve.

h. Safety relief valve capacity for each boiler with a single safety relief valveshall be such that, with the fuel burning

f. The required relieving capacity, inpounds per hour, of the pressure reliev-ing device or devices on a boiler shall bethe greater of that determined by divid-ing the maximum output in Btu (Watts)at the boiler nozzle obtained by the firing

of any fuel for which the unit is installed by 1,000, or shall be determined on the basis of pounds (kilograms) of steamgenerated per hour per square foot(square meter) of boiler heating surfaceas given in Table I-3820. For cast-iron boilers, the minimum valve capacityshall be determined by the maximumoutput method. In many cases a greaterrelieving capacity of valves will have to be provided than the minimum speci-

TABLE I-3820 — Minimum Pounds of Steam per Hour per Square Foot of HeatingSurface

Firetube Boilers Watertube BoilersBoiler heating surface Hand-fired 5 (2107) 6 (2528) Stoker-fired 7 (2950) 8 (3371) Oil-, gas-, or pulverized-fuel-fired 8 (3371) 10 (4214)

Waterwall heating surface Hand-fired 8 (3371) 8 (3378)

Stoker-Fired 10 (4214) 12 (5057) Oil-, gas-, or pulverized-fuel-fired 14 (5900) 16 (6742)

Copper finned water tubes Hand-fired 4 (1686) 4 (1686) Stoker-Fired 5 (2107) 5 (2107) Oil-, gas-, or pulverized-fuel-fired 5 (2107) 6 (2528)

NOTES:When a boiler is fired only by a gas having a heat value not in excess of 200 Btu per cubic foot, the minimumrelieving capacity should be based on the values given for hand-fired boilers above.

For firetube boiler units exceeding 8000 Btu/sq. ft. (total Fuel Btu Input divided by total heating surface), thefactor from the table will be increased by 1 for every 1000 Btu./sq. ft. above 8000. For units with less than

7000 Btu/sq. ft., the factor from the table will be decreased by 1 for every 1000 Btu/sq. ft. below 7000.

For watertube boiler units exceeding 16000 Btu/sq. ft. (total fuel Btu input divided by the total heating surface),the factor from the table will be increased by 1 for every 1000 Btu/sq. ft. above 16000. For units with less than15000 Btu/sq. ft., the factor in the table will be decreased by 1 for every 1000 Btu/sq. ft. below 15000.

The heating surface shall be computed for that side of the boiler surface exposed to the products of combus-tion, exclusive of the superheating surface. In computing the heating surface for this purpose, only the tubes,fireboxes, shells, tube sheets, and the projected area of headers need be considered, except that for verticalfiretube steam boilers, only that portion of the tube surface up to the middle gage cock is to be computed.

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equipment installed and operated atmaximum capacity, the pressure cannotrise more than 10% above the maximumallowable working pressure. Whenmore than one safety relief valve is used,the over pressure shall be limited to 10%

above the set pressure of the highest setvalve allowed by I-3820(b).

I-3830 MOUNTING SAFETY ANDSAFETY RELIEF VALVESFOR STEAM HEATING,HOT-WATER HEATING,AND HOT-WATER SUPPLYBOILERS

I-3831 PERMISSIBLE MOUNTING

Safety valves and safety relief valves shall be located at the top side21 of the boiler. Theyshall be connected directly to a tapped orflanged opening in the boiler, to a fittingconnected to the boiler by a short nipple,to a Y-base, or to a valveless header con-necting steam or water outlets on the same boiler. Coil- or header-type boilers shallhave the safety valve or safety relief valve

located on the steam or hot water outletend. Safety valves and safety relief valvesshall be installed with their spindles verti-cal. The opening or connection betweenthe boiler and any safety valve or safetyrelief valve shall have at least the area ofthe valve inlet.

I-3832 REQUIREMENTS FORCOMMON CONNECTIONSFOR TWO OR MOREVALVES

a. When a boiler is fitted with two or more

safety valves on one connection, thisconnection shall have a cross-sectionalarea not less than the combined areas ofinlet connections of all the safety valveswith which it connects.

b. When a Y-base is used, the inlet areashall be not less than the combinedoutlet areas. When the size of the boilerrequires a safety valve or safety reliefvalve larger than NPS 4-1/2 (DN 115),two or more valves having the requiredcombined capacity shall be used. Whentwo or more valves are used on a boiler,they may be single, directly attached ormounted on a Y-base.

I-3833 THREADED CONNECTIONS

A threaded connection may be used for at-taching a valve.

I-3834 PROHIBITED MOUNTINGS

Safety and safety relief valves shall not beconnected to an internal pipe in the boiler.

I-3835 USE OF SHUTOFF VALVESPROHIBITED

No shutoff of any description shall be placed

between the safety or safety relief valve andthe boiler, or on discharge pipes betweensuch valves and the atmosphere.

21Side – The top side of the boiler shall mean the high-est practicable part of the boiler proper but in nocase shall the safety valve be located below thenormal operating level and in no case shall thesafety relief valve be located below the lowestpermissible water level.

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I-3836 SAFETY AND SAFETYRELIEF VALVE DISCHARGEPIPING

a. A discharge pipe shall be used. Its inter-nal cross-sectional area shall be not less

than the full area of the valve outlet orof the total of the valve outlets discharg-ing therein to and shall be as short andstraight as possible and so arranged asto avoid undue stress on the valve orvalves. A union may be installed in thedischarge piping close to the valve out-let. When an elbow is placed on a safetyor a safety relief valve discharge pipe, itshall be located close to the valve outletdownstream of the union.

b. The discharge from safety or safetyrelief valves shall be so arranged thatthere will be no danger of scalding at-tendants. The safety or safety relief valvedischarge shall be piped away from the boiler to the point of discharge, andthere shall be provisions made for prop-erly draining the piping. The size andarrangement of discharge piping shall be such that any pressure that may existor develop will not reduce the relieving

capacity of the relieving devices belowthat required to protect the boiler.

I-3837 TEMPERATURE AND PRESSURE SAFETY RELIEF

VALVES

Hot-water heating or supply boilers limitedto a water temperature of 210°F (100°C)should have one or more National Boardcapacity certified temperature and pressure

safety relief valves installed. The require-ments of I-3831 through I-3836 shall be met,except as follows:

a. A Y-type fitting shall not be used.

b. If additional valves are used, they shall be temperature and pressure safety re-lief valves.

c. When the temperature and pressuresafety relief valve is mounted directlyon the boiler with no more than 4 in.(100 mm) maximum interconnectingpiping, the valve should be installed inthe horizontal position with the outlet

pointed down.

I-3840 SAFETY AND SAFETYRELIEF VALVES FORTANKS AND HEATEXCHANGERS

I-3841 STEAM TO HOT-WATERSUPPLY

When a hot-water supply is heated indi-rectly by steam in a coil or pipe within theservice limitations set forth in I-3100 , thepressure of the steam used shall not exceedthe safe working pressure of the hot watertank, and a safety relief valve at least NPS1 (DN 25), set to relieve at or below themaximum allowable working pressure ofthe tank, shall be applied on the tank.

I-3842 HIGH TEMPERATUREWATER TO WATER HEATEXCHANGER22

When high temperature water is circulatedthrough the coils or tubes of a heat exchangerto warm water for space heating or hot-wa-ter supply, within the service limitations setforth in I-3100 , the heat exchanger shall beequipped with one or more National Boardcapacity certified safety relief valves set torelieve at or below the maximum allowable

working pressure of the heat exchanger, andof sufficient rated capacity to prevent theheat exchanger pressure from rising morethan 10% above the maximum allowableworking pressure of the vessel.

22Exchanger – Suggested installation practices for thesecondary side of heat exchangers.

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I-3843 HIGH TEMPERATUREWATER TO STEAM HEATEXCHANGER

When high temperature water is circulatedthrough the coils or tubes of a heat exchang-

er to generate low pressure steam, withinthe service limitations set forth in I-3100 , theheat exchanger shall be equipped with oneor more National Board capacity certifiedsafety valves set to relieve at a pressure notto exceed 15 psi (100 kPa), and of sufficientrated capacity to prevent the heat exchangerpressure from rising more than 5 psi (35 kPa)above the maximum allowable workingpressure of the vessel. For heat exchangersrequiring steam pressures greater than 15psi (100 kPa), refer to I-2000 or I-4000.

I-3850 SAFETY RELIEF VALVEREQUIREMENTS FORPOTABLE WATER HEATERS

a. Each water heater shall have at leastone National Board capacity certifiedtemperature and pressure safety reliefvalve. No safety relief valve shall besmaller than NPS 3/4 (DN 20).

b. The pressure setting shall be less thanor equal to the maximum allowableworking pressure of the water heater.However, if any of the other componentsin the hot-water supply system (suchas valves, pumps, expansion or storagetanks, or piping) have a lesser workingpressure rating than the water heater,the pressure setting for the relief valve(s)shall be based upon the component withthe lowest maximum allowable work-

ing pressure rating. If more than onesafety relief valve is used, the additionalvalve(s) may be set within a range notto exceed 10% over the set pressure ofthe first valve.

c. The required relieving capacity in Btu/hr. (Watts/hr.) of the safety relief valve

shall not be less than the maximum al-lowable input unless the water heateris marked with the rated burner inputcapacity of the water heater on the cas-ing in a readily visible location, in whichcase the rated burner input capacity may

be used as a basis for sizing the safetyrelief valves. The relieving capacity forelectric water heaters shall be 3500 Btu/hr. per kW. (Watts/hr./kW.) of input. Inevery case, the following requirementsshall be met. Safety relief valve capac-ity for each water heater shall be suchthat with the fuel burning equipmentinstalled and operated at maximumcapacity the pressure cannot rise morethan 10% above the maximum allowableworking pressure.

d. If operating conditions are changed oradditional heating surface is installed,the safety relief valve capacity shall beincreased, if necessary, to meet the newconditions and shall be in accordancewith the above provisions. In no caseshall the increased input capacity exceedthe maximum allowable input capacity.The additional valves required, on ac-count of changed conditions, should be

installed on the outlet piping providingthere is no intervening valve.

I-3851 INSTALLATION

Safety relief valves shall be installed by ei-ther the installer or the manufacturer beforea water heater is placed in operation.

I-3852 PERMISSIBLE

MOUNTINGS

Safety relief valves shall be connected di-rectly to a tapped or flanged opening in thetop of the water heater, to a fitting connectedto the water heater by a short nipple, to aY-base, or to a valveless header connectingwater outlets on the same heater. Safety

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relief valves shall be installed with theirspindles upright and vertical with no hori-zontal connecting pipe, except that, whenthe safety relief valve is mounted directly onthe water heater vessel with no more than4 in. (100 mm) maximum interconnecting

piping, the valve may be installed in thehorizontal position with the outlet pointeddown. The center line of the safety reliefvalve connection shall be no lower than 4in. (100 mm) from the top of the shell. Nopiping or fitting used to mount the safetyvalve shall be of nominal pipe size less thanthat of the valve inlet.

I-3853 REQUIREMENTS FORCOMMON CONNECTIONFOR TWO OR MOREVALVES

a. When a water heater is fitted with twoor more safety relief valves on one con-nection, this connection shall have across-sectional area not less than thecombined areas of inlet connections ofall the safety release valves with whichit connects.

b. When a Y-base is used, the inlet areashall be not less than the combinedoutlet areas.

c. When the size of the water heater re-quires a safety relief valve larger thanNPS 4-1/2 (DN 115), two or more valveshaving the required combined capacityshall be used. When two or more valvesare used on a water heater, they may besingle, directly attached, or mounted ona Y-base.

I-3854 THREADED CONNECTIONS

A threaded connection should be used forattaching a valve.

I-3855 PROHIBITED MOUNTINGS

Safety relief valves shall not be connectedto an internal pipe in the water heater or acold water feed line connected to the waterheater.

I-3856 USE OF SHUTOFF VALVESPROHIBITED

No shutoff of any description shall be placed between the safety relief valve and the waterheater, or on discharge pipes between suchvalves and the atmosphere.

I-3857 SAFETY RELIEF VALVEDISCHARGE PIPING

a. When a discharge pipe is used, its inter-nal cross-sectional area shall be not lessthan the full area of the valve outlet orof the total of the valve outlets discharg-ing therein to, and shall be as short andstraight as possible and so arranged asto avoid undue stress on the valve orvalves. When an elbow is placed on asafety relief discharge pipe, it shall be

located close to the valve outlet.

b. The discharge from safety relief valvesshall be so arranged that there will beno danger of scalding attendants. Whenthe safety relief valve discharge is pipedaway from the water heater to the pointof discharge, there shall be provisionsfor properly draining the piping andvalve body. The size and arrangement ofdischarge piping shall be such that anypressure that may exist or develop will

not reduce the relieving capacity of therelieving devices below that required toprotect the water heater.

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I-3910 PRESSURE TEST

Prior to initial operation, the completed boiler, individual module, or assembledmodule, shall be subject to a pressure testin accordance with the requirements of theoriginal code of construction.

I-3920 FINAL ACCEPTANCE

a. In addition to determining that allequipment called for is furnished andinstalled in accordance with the plansand specifications, all controls shall betested by a person familiar with thecontrol system.

b. Before any new heating plant (or boiler)is accepted for operation, a final (or ac-ceptance) inspection shall be completedand all items of exception corrected.

I-3930 BOILER INSTALLATION

REPORT

a. Upon completion, inspection, and ac-ceptance of the installation, the installershall complete and certify the (I-1) BoilerInstallation Report.

b. The I-1 Boiler Installation report shall besubmitted as follows:

1. One copy to the Owner.

2. One copy to the jurisdiction, if re-quired.

I-3940 TABLES AND FIGURES

a. Table I-3691-a Expansion Tank Capaci-ties for Gravity Hot-Water Systems

b. Table I-3691-b Expansion Tank Capaci-

ties for Forced Hot-Water Systems

c. Table I-3692 Expansion Tank Capacitiesfor a Hot-Water Heater

d. Table I-3671-a Size of Bottom BlowoffPiping, Valves, and Cocks

e. Table I-3820 Minimum Pounds of SteamPer Hour Per Square Foot of HeatingSurface

f. Figure I-3311-a Spacing and Weld De-tails for Supporting Lugs in Pairs onHorizontal Return Tubular Boilers

g. Figure I-3311-b Welded Bracket Con-nection for Horizontal Return TubularBoilers

h. Figure I-3651-a Steam Boilers in BatteryPumped Return Acceptable Piping In-stallation

i. Figure I-3651-b Steam Boilers in Bat-tery Gravity Return Acceptable PipingInstallation

j. Figure I-3651-c Hot-Water Boilers inBattery Acceptable Piping Installation

k. Figure I-3651-d Storage Water Heaters inBattery Acceptable Piping Installation

l. Figure I-3651-e Flow Through Water

Heater Without Provision for PipingExpansion Acceptable Piping Installa-tion

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I-4000 PRESSURE VESSELS

I-4100 INTRODUCTION

I-4110 SCOPE

This section provides requirements for theinstallation of pressure vessels as defined inI-4120. For installation of items that do notfall within the scope of this section, refer tothe following as applicable:

I-2000 Power BoilersI-3000 Heating Boilers and Potable Water HeatersI-5000 Piping

I-4120 PRESSURE VESSELS

Pressure vessels are containers other than boilers or piping used for the containmentof pressure.

I-4200 CERTIFICATION, INSPECTION, AND

JURISDICTIONALREQUIREMENTS


The owner is responsible for satisfying ju-risdictional requirements for certificationand documentation. When required by ju-risdictional rules applicable to the locationof installation, the pressure vessel shall not be operated until the required documenta-

tion has been provided to the owner andthe jurisdiction.


All pressure vessels shall have documentedcertification from the manufacturer indicat-ing that the pressure vessel complies with

all requirements of the code of construction.The certification shall identify the revisionlevel of the code of construction to whichthe pressure vessel was fabricated.


a. The owner shall determine jurisdictionalrequirements, (i.e., certificates, permits,licenses, etc.) before installing the equip-ment. The organization responsiblefor installation shall obtain all permitsrequired by the jurisdiction prior tocommencing installation.

b. The owner shall determine jurisdictionalrequirements, (i.e., certificates, permits,licenses, etc.) before operating the equip-ment. The owner shall obtain operatingcertificates, permits, etc. required by the jurisdiction prior to commencing opera-tion.

I-4240 INSPECTION

All pressure vessels shall be inspected af-ter installation and prior to commencingoperation.


I-4310 SUPPORTS

Each pressure vessel shall be safely sup-ported. The potential for future hydrostaticpressure tests of the vessel after installationshall be considered when designing vesselsupports.

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I-4320 CLEARANCES

a. All pressure vessel installations mustallow sufficient clearance for normaloperation, maintenance, and inspection(internal and external).

b. Orientation of nozzles, manways, andattachments shall be such that suf-ficient clearance between the nozzles,manways and attachments, and thesurrounding structure(s) is maintainedduring installation, the attachment ofassociated piping, and operation.

I-4330 PIPING

Piping loads on the vessel nozzles shall beconsidered. Piping loads include weight ofthe pipe, weight of the contents of the pipe,expansion of the pipe from temperatureand pressure changes. The effects of pipingvibration on the vessel nozzles shall also beconsidered.

I-4700 INSTRUMENTS AND CONTROLS

I-4710 LEVEL INDICATING DEVICES

Steam drums of unfired steam boilers shall be provided with two level indicating de-vices. Direct level indicating devices should be connected to a single water column orconnected directly to the drum and theconnections and pipe shall be not less thanNPS 1/2 (DN 15). Indirect level indicating

devices acceptable to the jurisdiction may be used.

I-4720 PRESSURE INDICATINGDEVICES

The need for pressure indicating devicesshould be considered in the design of thepressure vessel, and when required, shall be

at least 25% above the highest set pressureof the pressure relief device.

I-4800 PRESSURE RELIEF DEVICES

All pressure vessels shall be protected bypressure relief devices in accordance withthe following requirements.

I-4810 DEVICE REQUIREMENTS

a. Pressure relief devices are to be manu-factured in accordance with a national orinternational standard and be certifiedfor capacity (or resistance to flow forrupture disk devices) by the NationalBoard.

b. Dead weight or weighted lever pressurerelief valves shall not be used.

c. An unfired steam boiler shall beequipped with pressure relief valves asrequired in I-2800.

d. Pressure relief devices shall be selected

(i.e., material, pressure, etc.) and in-stalled such that their proper function-ing will not be hindered by the natureof the vessel’s components.

I-4820 NUMBER OF DEVICES

At least one device shall be provided forprotection of a pressure vessel. Pressurevessels with multiple chambers with differ-ent maximum allowable working pressuresshall have a pressure relief device to protecteach chamber under the most severe coin-cident conditions.

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I-4830 LOCATION

a. The pressure relief device shall be in-stalled directly on the pressure vessel,unless the source of pressure is externalto the vessel and is under such positive

control that the pressure cannot exceedthe maximum allowable working pres-sure, then the device may be installedelsewhere in the system provided it isin communication with the vessel at alltimes.

b. Pressure relief devices intended for usein compressible fluid service shall beconnected to the vessel in the vaporspace above any contained liquid, orin the piping system connected to thevapor space.

c. Pressure relief devices intended for usein liquid service shall be connected be-low the normal liquid line.

I-4840 CAPACITY

a. The pressure relief device(s) shall havesufficient capacity to assure that the

pressure vessel is not exposed to pres-sure greater than that specified in theoriginal code of construction.

b. If an additional hazard can be created by exposure of a pressure vessel to fireor other unexpected source of exter-nal heat, supplemental pressure reliefdevices shall be installed to provideany additional capacity that should berequired.

c. Vessels connected together by a systemof piping not containing valves whichcan isolate any pressure vessel should beconsidered as one unit when determin-ing capacity requirements.

d. Heat exchangers and similar vesselsshall be protected with a pressure reliefdevice of sufficient capacity to avoidoverpressure in case of internal failure

e. When a non-reclosing device is installed

between a pressure relief valve andthe pressure vessel, the reduction incapacity due to installation of the non-reclosing device shall be determined inaccordance with the code of construc-tion by use of a National Board certifiedCombination Capacity Factor (CCF). Forrupture disks, if a certified combinationcapacity factor is not available the capac-ity of the pressure relief valve shall bemultiplied by 0.9 and this value used asthe capacity of the combination installa-tion.

f. The owner shall document the basis forselection of the pressure relief devicesused, including capacity, and have suchcalculations available for review by the jurisdiction.

I-4850 SET PRESSURE

a. When a single pressure relief device isused, the set pressure marked on thedevice shall not exceed the maximumallowable working pressure.

b. When more than one pressure relief de-vice is provided to obtain the requiredcapacity, only one pressure relief deviceset pressure needs to be at the maximumallowable working pressure. The setpressures of the additional pressurerelief devices shall be such that the pres-

sure cannot exceed the overpressurepermitted by the code of construction.

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I-4860 INSTALLATION ANDDISCHARGE PIPINGREQUIREMENTS

a. The opening through all pipe and fit-tings between a pressure vessel and its

pressure relief device shall have at leastthe area of the pressure relief device in-let. The characteristics of this upstreamsystem shall be such that the pressuredrop will not reduce the relieving capac-ity below that required or adversely af-fect the proper operation of the pressurerelief device.

b. A non-reclosing device installed be-tween a pressure vessel and a pressurerelief valve shall meet the requirementsof I-4860(a).

c. The opening in the pressure vessel wallshall be designed to provide unob-structed flow between the vessel and itspressure relief device.

d. When two or more required pressurerelief devices are placed on one con-nection, the inlet cross-sectional area ofthis connection shall be sized either to

avoid restricting flow to the pressurerelief devices or made at least equal tothe combined inlet areas of the pres-sure relief devices connected to it. Theflow characteristics of the upstreamsystem shall satisfy the requirements ofI-4860(a).

e. There shall be no intervening stop valves

between the vessel and its pressure reliefdevice(s), or between the pressure reliefdevice(s) and the point of discharge

except under the following conditions:

1. When these stop valves are so con-structed or positively controlled thatthe closing of the maximum numberof block valves at one time will notreduce the pressure relieving ca-

pacity below the required relievingcapacity; or,

2. Upon specific acceptance of the ju-risdiction, when necessary for thecontinuous operation of processing

equipment of such a complex naturethat shutdown of any part is not fea-sible, a full area stop valve betweena pressure vessel and its pressurerelief device should be provided forinspection and repair purposes only.This stop valve shall be arranged sothat it can be locked or sealed open,and it shall not be closed except byan authorized person who shallremain stationed there during thatperiod of operation while the valveremains closed. The valve shall belocked or sealed in the open position before the authorized person leavesthe station.

3. A full area stop valve should also be placed on the discharge side ofa pressure relief device when itsdischarge is connected to a commonheader for pressure relief devices toprevent discharges from these other

devices from flowing back to the firstdevice during inspection and repair.This stop valve shall be arranged sothat it can be locked or sealed open,and it shall not be closed except byan authorized person who shallremain stationed there during thatperiod of operation while the valveremains closed. The valve shall belocked and sealed in the open posi-tion before the authorized personleaves the station. This valve shall

only be used when a stop valve onthe inlet side of the pressure reliefdevice is first closed.

4. A pressure vessel in a system wherethe pressure originates from an out-side source should have a stop valve

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between the vessel and the pressurerelief device, and this valve neednot be sealed open, provided it alsocloses off that vessel from the sourceof the pressure.

f. Pressure relief device discharges shall bearranged such that they are not a hazardto personnel or other equipment and,when necessary, lead to a safe locationfor disposal of fluids being relieved.

g. Discharge lines from pressure reliefdevices shall be designed to facilitatedrainage or be fitted with drains toprevent liquid from collecting in thedischarge side of a pressure relief de-vice. The size of discharge lines shall be such that any pressure that may existor develop will not reduce the relievingcapacity of the pressure relief device,or adversely affect the operation of thepressure relief device.

h. Pressure relief devices shall be installedso they are readily accessible for inspec-tion, repair, or replacement.


a. The installer shall exercise care duringinstallation to prevent loose weld ma-terial, welding rods, small tools, andmiscellaneous scrap metal from get-ting into the vessel. The installer shallinspect the interior of the vessel and itsappurtenances where possible prior tomaking the final closures for the pres-ence of foreign debris.

b. The completed pressure vessel shall be pressure tested in the shop or in thefield in accordance with the originalcode of construction. When required by the jurisdiction, owner or user, theInspector shall witness the pressure test

of the completed installation, includingpiping to the pressure gage, pressure re-lief device, and, if present, level controldevices.

I-5000 PIPING

I-5100 INTRODUCTION

I-5110 SCOPE

This section provides requirements for theinstallation of pressure piping. For instal-lation of items that do not fall within thescope of this section, refer to the followingsections as applicable:

I-2000 Power BoilersI-3000 Heating Boilers and Potable Water

HeatersI-4000 Pressure Vessels

I-5120 ADDITIONS TO EXISTINGPIPING

Additions to existing piping systems shallconform to this section. That portion of theexisting piping system that is not part ofthe addition need not comply to this sec-tion provided the addition does not resultin a change in piping system operationor function that would exceed the designconditions of the existing piping system orresult in unsafe conditions.

I-5200 CERTIFICATION,

INSPECTION, AND JURISDICTIONAL

REQUIREMENTS


The owner is responsible for satisfying ju-risdictional requirements for certification

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and documentation. When required by jurisdictional rules applicable to the loca-tion of installation, the piping shall not beoperated until the required documentationhas been provided to the owner and the jurisdiction.


Piping shall have documented certificationfrom the fabricator and/or installer whenrequired by the code of construction. Thecertification, when required, shall identifythe revision level of the code of constructionto which the piping was designed, fabri-cated, and installed.


a. The owner shall determine jurisdictionalrequirements, (i.e., certificates, permits,licenses, etc.) before installing the equip-ment. The organization responsiblefor installation shall obtain all permitsrequired by the jurisdiction prior tocommencing installation.

b. The owner shall determine jurisdic-tional requirements, (i.e., certificates,permits, licenses, etc.) before operat-ing the equipment. The owner shallobtain operating certificates, permits,etc., required by the jurisdiction priorto commencing operation.

I-5240 INSPECTION

All piping shall be inspected after installa-tion and prior to commencing operation.

I-5250 OPERATING PERMIT

The owner shall obtain any operatingpermit(s) required by the jurisdiction, priorto placing the piping into service.

I-5300 LAYOUT AND CONFIGURATION

I-5310 PROXIMITY TO OTHEREQUIPMENT AND

STRUCTURES

The arrangement of the piping and its ap-purtenances shall take into considerationthe location of other structures and equip-ment adjacent to the piping, which mayresult in interference and/or damage as aresult of expansion, contraction, vibration,or other movements.

I-5320 FLANGES AND OTHERNON-WELDED JOINTS

The layout of the piping shall take intoconsideration the need to maintain piping joints and required access for maintenanceand inspection.

I-5330 VALVES

Consideration should be given to the ap-

propriate location and orientation of valvesnecessary for safe operation and isolationof the piping.

I-5400 MATERIALS

All materials for piping and its appurte-nances shall comply with the requirementsof the code of construction.

I-5500 HANGERS AND SUPPORTS

Support of piping shall consider loadsimposed on equipment or existing pipingto which it is attached. Non-piping at-tachments such as ladders and walkways,equipment supports, temporary supports,structural supports, etc. shall not be con-nected to the piping unless such loads have

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been considered in the design of the pipingand its supports. Design of hangers andsupports for piping shall consider loadsimposed by pressure testing. The installershall remove pins from non-rigid hangers,seal plugs from hydraulic snubbers, and

temporary supports used for installationprior to placing the piping in service.

I-5600 PROTECTION AND CLEANING

The installer shall exercise care during in-stallation to prevent loose weld material,welding rods, small tools, and miscella-neous scrap metal from getting into the pip-ing. The installer shall inspect, and wherenecessary clean the interior of the pipingand its appurtenances where possible, priorto making the final closures for the presenceof foreign debris.

I-5700 WELDING AND BRAZING

The installer should consider the impact ofperforming any preheating, welding, braz-ing, or postweld heat treatment on valves,

instrumentation, or other heat sensitiveequipment and, where appropriate, reviewthe equipment manufacturer’s recom-mended installation procedures prior toperforming the work.

I-5800 PRESSURE RELIEF DEVICES

When required by the original code ofconstruction, piping shall be protected bypressure relief devices in accordance with

the following requirements.

I-5810 DEVICE REQUIREMENTS

a. Pressure relief devices are to be manu-factured in accordance with a national orinternational standard and be certified

for capacity (or resistance to flow forrupture disc devices) by the NationalBoard.

1. In certain cases piping standards

permit the use of regulators, which

may include integral pressure reliefvalves to limit the pressure in a pip-ing system. In this case, capacitycertification of the pressure reliefvalve is not required.

b. Dead weight or weighted lever pressurerelief devices shall not be used.

c. Pressure relief devices shall be selected(i.e., material, pressure, etc.) and in-stalled such that their proper function-ing will not be hindered by the natureof the piping system’s contents.

I-5820 NUMBER OF DEVICES

At least one pressure relief device shall beprovided for protection of a piping system.A pressure relief device installed on a pres-sure vessel or other component connectedto the piping system should be used to meet

this requirement. Portions of piping systemswith different maximum allowable workingpressures shall have a pressure relief deviceto protect each portion separately.

I-5830 LOCATION

The pressure relief device should be installedat any location in the system provided thepressure in any portion of the system can-not exceed the maximum allowable work-

ing pressure. Pressure drop to the pressurerelief device under flowing conditions shall be considered when determining pressurerelief device location. The device shall be incommunication with the piping system it isprotecting at all times.

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I-5840 CAPACITY

a. The pressure relief device(s) shall havesufficient capacity to assure that the pip-ing is not exposed to pressures greaterthan that specified in the original code

of construction.

b. When a non-reclosing device is installed between a pressure relief valve and thepipe, the reduction in capacity due toinstallation of the non-reclosing deviceshall be determined in accordance withthe code of construction by use of aNational Board certified CombinationCapacity Factor (CCF). For rupturedisks, if a certified combination capacityfactor is not available, the capacity of thepressure relief valve shall be multiplied by 0.9 and this valve used as the capacityof the combination installation.

c. The owner shall document the basis forselection of the pressure relief devicesused, including capacity, and have suchcalculations available for review by the jurisdiction.

I-5850 SET PRESSURE

a. When a single pressure relief device isused, the set pressure marked on thedevice shall not exceed the maximumallowable working pressure, exceptwhen allowed by the original code ofconstruction.

b. When more than one pressure relief de-vice is provided to obtain the requiredcapacity, only one pressure relief device

set pressure needs to be at the maximumallowable working pressure. The setpressures of the additional pressurerelief devices shall be such that the pres-sure cannot exceed the overpressurepermitted by the code of construction.

I-5860 INSTALLATION ANDDISCHARGE PIPINGREQUIREMENTS

a. The opening through all pipe and fitting between a piping system and its pres-

sure relief device shall have at least thearea of the pressure relief device inlet.The characteristics of this upstreamsystem shall be such that the pressuredrop will not reduce the relieving ca-pacity below that required or adverselyaffect the operation of the pressure reliefdevice.

b A non-reclosing device installed be-tween a piping system and a pressurerelief valve shall meet the requirementsof I-5860(a).

c. The opening in the pipe shall be de-signed to provide unobstructed flow between the pipe and its pressure reliefdevice.

d. When two or more required pressurerelief devices are placed on the con-nection, the inlet cross-sectional area ofthis connection shall be sized either to

avoid restricting flow to the pressurerelief devices or made at least equal tothe combined inlet areas of the pres-sure relief devices connected to it. Theflow characteristics of the upstreamsystem shall satisfy the requirements ofI-5860(a).

e. There shall be no intervening stop valves between the piping system and its pres-sure relief device(s), or between thepressure relief device(s) and the point

of discharge except under the followingconditions:

1. When these stop valves are so con-structed or positively controlled thatthe closing of the maximum number

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of block valves at one time will notreduce the pressure relieving ca-pacity below the required relievingcapacity; or,

2. Upon specific acceptance of the ju-

risdiction, when necessary for thecontinuous operation of processingequipment of such a complex naturethat shutdown of any part is not fea-sible, a full area stop valve betweena piping system and its pressurerelief device should be provided forinspection and repair purposes only.This stop valve shall be arranged sothat it can be locked or sealed open,and it shall not be closed except byan authorized person who shallremain stationed there during thatperiod of operation while the valveremains closed. The valve shall belocked or sealed in the open position before the authorized person leavesthe station.

3. A full area stop valve may be placedon the discharge side of a pressurerelief device when its discharge isconnected to a common header for

pressure relief devices to preventdischarges from these other devicesfrom flowing back to the first deviceduring inspection and repair. Thisstop valve shall be arranged so thatit can be locked or sealed open, andit shall not be closed except by anauthorized person who shall remainstationed there during that period ofoperation while the valve remainsclosed. The valve shall be locked orsealed in the open position before

the authorized person leaves thestation. This valve shall only be usedwhen a stop valve on the inlet sideof the pressure relief device is firstclosed.

4. A piping system where the pressureoriginates from an outside sourceshould have a stop valve betweenthe system and the pressure reliefdevice, and this valve need not besealed open, provided it also closes

off that vessel from the source ofpressure.

f. Pressure relief device discharges shall bearranged such that they are not a hazardto personnel or other equipment andwhen necessary, lead to a safe locationfor disposal of fluids being relieved.

g. Discharge lines from pressure reliefdevices shall be designed to facilitatedrainage or be fitted with drains toprevent liquid from collecting in thedischarge side of a pressure relief de-vice. The size of discharge lines shall be such that any pressure that may existor develop will not reduce the relievingcapacity of the pressure relief device,or adversely affect the operation of thepressure relief device.

h. Pressure relief devices shall be installedso they are accessible for inspection,

repair, or replacement.

I-5900 EXAMINATION, INSPECTION, AND TESTING

THE OWNER SHALL ENSURE THATALL EXAMINATIONS, INSPECTIONS,AND TESTS REQUIRED BY THE CODEOF CONSTRUCTION HAVE BEEN PER-FORMED PRIOR TO OPERATION.

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Guide to Jurisdictions for Authorization ofOwners-Users to Make Adjustments toPressure Relief Valves

Appendix J

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APPENDIX J — GUIDE TO JURISDICTIONS FOR AUTHORIZATION OF

OWNERS-USERS TO MAKE ADJUSTMENTS TO PRESSURE RELIEF VALVES

J-1000 GENERAL

It is recommended that before an owner-useror their designees be authorized to make adjustments as defined in paragraph RE-1023,the following requirements should be met:

J-1010 TRAINING

The user shall establish a documented in-house training program. This program shallestablish training objectives and provide amethod of evaluating the training effective-ness. As a minimum, training objectives forknowledge level shall include:

a. Applicable ASME Code and NBICrequirements;

b. Responsibilities within the organization’squality system;

c. Knowledge of the technical aspects and

mechanical skills for making set pressureand/or blowdown adjustments to pres-sure relief valves;

d. Knowledge of the technical aspects andmechanical skills for marking of pressurerelief valve adjustments.

If the user established a designee, the designeeshall establish a training program and maketheir documentation available to the user andthe jurisdictional authority.

J-1020 DOCUMENTATION

Each user shall document the evaluation andacceptance of an employee’s or designee’squalifications.

J-1030 QUALITY SYSTEM

A written quality system shall be established by either the user or the designee with a writ-ten description available to the jurisdictionalauthority.

The written description shall include at aminimum:

a. Calibration of Test Equipment: This shalldescribe a system for the calibration ofmeasuring and test equipment. Documen-tation of these calibrations shall includethe standard used and the results. Allcalibration standards shall be calibratedagainst the equipment having valid rela-

tionships to nationally recognized stan-dards.

b. Valve Testing, Setting, and Sealing: Thissystem shall include provisions that eachvalve shall be tested, set, and all externaladjustments sealed according to the re-quirements of the applicable ASME CodeSection and NBIC RE-1023.

c. Valve Marking: An effective markingsystem shall be established to ensure

proper marking of the metal tag required by RE-1023. The written quality systemshall include a description of drawing ofthe metal tag.

A05

A05

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APPENDIX J — GUIDE TO JURISDICTIONS FOR AUTHORIZATION OF OWNERS-USERS TOMAKE ADJUSTMENTS TO PRESSURE RELIEF VALVES

J-1040 EXTERNAL ADJUSTMENTS

Only external adjustments to restore the re-quired set pressure and/or performance of apressure relief valve shall be made under theprovisions of RE-1023.

J-1050 REPAIRS

If disassembly, change of set pressure, or ad-ditional repairs are necessary, the valve shall be repaired by an organization which meetsthe requirements of the NBIC.

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Inspection, Repairs, and Alterationsfor Yankee Dryers

Appendix K

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APPENDIX K — INSPECTION, REPAIR, AND ALTERATION OF YANKEE DRYERS

K-1000 INSPECTION OF YANKEE

DRYERS (ROTATING CAST-

IRON PRESSURE VESSELS)

WITH FINISHED SHELLOUTER SURFACES

K-1010 SCOPE

This part describes guidelines for the inserviceinspection of a Yankee dryer. A Yankee dryeris a rotating steam-pressurized cylindricalvessel commonly used in the paper industry,and is made of cast iron, finished to a highsurface quality, and characterized by a center

shaft connecting the heads.

“Yankee dryers” are primarily used in the pro-duction of tissue-type paper products. Whenused to produce machine-glazed (MG) paper,the dryer is termed an MG cylinder. A wetpaper web is pressed onto the finished dryersurface using one or two pressure (pressing)rolls. Paper is dried through a combinationof mechanical dewatering by the pressureroll(s); thermal drying by the pressurizedYankee dryer and a steam-heated or fuel-firedhood. After drying, the paper web is removedfrom the dryer.

The dryer is typically manufactured in a rangeof outside diameters from eight to 23 ft (2.4 mto 7 m), widths from eight to 28 ft (2.4 m to 8.5m), pressurized and heated with steam up to160 psi (1100 kPa), and rotated at speeds up to7000 ft/min (2135 m/min). Typical pressureroll loads against the Yankee dryer are up to600 pounds per lineal inch (105 kN/m). A

thermal load results from the drying processdue to difference in temperature between in-ternal and external shell surfaces. The dryer

has an internal system to remove steam andcondensate. These vessels can weigh up to 220tons (200 tonnes).

The typical Yankee dryer is an assembly ofseveral large castings. The shell is normally agray iron casting, in accordance with ASMEdesignation SA-278. Shells internally may besmooth bore or ribbed. Heads, center shafts,and journals may be gray cast iron, ductilecast iron, or steel.

K-1020 ASSESSMENT OF

INSTALLATION

The Inspector verifies that the owner or useris properly controlling the operating condi-tions of the dryer. The Inspector does this byreviewing the owner’s comprehensive assess-ments of the complete installation, operatingenvironment, maintenance, and operatinghistory.

The dryer is subjected to a variety of loadsover its life. Some of the loads exist individu-ally, while others are combined. Considerationof all the loads that can exist on a Yankee dryerare required to determine the maximum al-lowable operating parameters. There are fourloads that combine during normal operationto create the maximum operating stresses,usually on the outside surface of the shell atthe axial center line. These are:

a. Pressure load due to internal steampressure;

b. Inertial load due to dryer rotation;

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c. Thermal gradient load due to the dryingof the web;

d. Pressure roll load (line or nip load)23 dueto pressing the wet web onto the dryer.

Steam pressure, inertial, and thermal gradi-ent loads impose steady-state stresses. Thesestresses typically change when the dryershell thickness (effective thickness for ribbeddryers) is reduced to restore a paper-mak-ing surface, the grade of tissue is changed orspeed of the dryer is changed.

The pressure roll(s) load imposes an alternat-ing stress on the shell face. The resulting maxi-mum stress is dependent on the magnitude ofthe alternating and steady-state stresses.

Section VIII, Div. 1, of the ASME Code onlyprovides specific requirements for the analysisof pressure loads. Although the Code requiresanalysis of other loads, no specific guidancefor thermal, inertial, or pressure roll loads isprovided. Hence, additional criteria must beapplied by the manufacturer to account for allthe steady-state and alternating stresses.

To maintain product quality, the dryer surface

is periodically refurbished by grinding. Thisresults in shell thickness reduction. Therefore,the manufacturer does not provide a single setof maximum allowable operating parametersrelating steam pressure, rotational speed, andpressure roll load for a single design shellthickness. The manufacturer, or another quali-fied source acceptable to the Inspector, insteadprovides a series of curves that graphicallydefines these maximum allowable operatingparameters across a range of shell thicknesses.This document is known as the “De-rate

Curve.” See Figure K-1020.

In addition to the loads on the dryer due tonormal operation, other nonstandard loadevents can occur. These nonstandard loadevents should be recorded in an operation ormaintenance log. Examples of nonstandardload events include:

a. Excessive thermal load due to local orglobal heating rate during warm-up;

b. Excessive thermal load due to local orglobal cooling rate during shut-down;

c. Excessive thermal load due to inappropri-ate use or malfunctioning auxiliary heat-ing devices causing localized heating;

d. Excessive thermal load due to the mis-application or uncontrolled applicationof water or other fluids for production,cleaning or fire fighting;

e. Impact load.

If nonstandard load events have occurred,then the Inspector should ensure that an ap-propriate assessment of the structural integ-rity on the dryer has been performed.

K-1030 CAUSES OF

DETERIORATION AND

DAMAGE

Three types of deterioration or damage typi-cally encountered in Yankee dryers are localthinning, cracking, and corrosion. Many timesthese mechanisms are interrelated, one beingthe precursor of another.

23 Pressure roll load, line load, and nip load are terms that are used interchangeably to refer to the interaction betweenthe pressure roll(s) and the Yankee dryer. It is called “nip” load because the pressure roll is rubber-coveredand is pressed up against the Yankee with enough force to create a nip (or pinch) that forces the paper into linecontact between the rolls and provides some mechanical dewatering. The paper then sticks onto the Yankeesurface and follows the Yankee dryer for thermal dewatering by the steam-heated Yankee surface. This “nipload” is called a “line load” because the units are load (force) per length of line contact. The units are poundsper linear inch (PLI) and kiloNewtons per meter (kN/m).

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K-1031 LOCAL THINNING

Internally, a Local Thin Area (LTA) can oc-cur on the pressure-retaining surfaces due tosteam and condensate erosion, mechanicalwear, and impact, and removal of material

flaws. These assume features ranging from broad shallow areas washed-out by erosion, tomore groove-like flaws, including gouges andindentations from contacting metal parts.

Externally, the process is typically one of wear-corrosion in circumferential bands. Except onthe shell edges, local thinning never achievessignificant depth because the papermakingprocess will tolerate only the smallest depar-ture from surface contour. On the shell edges,

beyond the papermaking surface, wear-cor-rosion may advance to comparatively greaterdepths. However, the stresses are far less inthis area than under the papermaking surface,so the wear is inconsequential in consider-ations of load-carrying ability. Only in the

instance of steam leakage between flanges,has the resultant local thinning ever beenimplicated in Yankee failure.

Steam leakage is detrimental to the long-termstructural integrity of the vessel, in that theescaping steam, under high velocity, erodesever-widening paths in the cast-iron sur-faces over which it passes, thinning the crosssection. Steam cutting of connecting boltsis another possible outcome. Either result

FIGURE K-1020 Approve reorganization and update of Part RB to be incorporated into Draft200

�

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reduces load-carrying capacity of the part. Asafety hazard can also be created for operatingpersonnel, who may be burned by the highvelocity steam jets.

a. Interface leakage, including joints and

bolted connections

1. Joint Interface Corrosion Jacking forces, which develop from

the expansion of corrosion products between head-to-shell flanges, causeflange separation and create leakagepaths between the flanges and/orthrough the bolt holes.

2. Insufficient Joint Clamping Force Through inadequate design, improper

assembly, loss of washer/gasket, orstress corrosion cracking of connect-ing bolts, the clamping force betweenmating flanges is insufficient to retaininternal pressure.

3. Washer/Gasket Functional Loss Deterioration, caused by corrosion or

expulsion, provides a path for escap-ing steam and condensate.

4. Flange Machining Variation Variations in surface contour of flangefaces may create leakage paths.

5. Through-Wall Leakage Cast iron inherently exhibits shrink-

age porosity. Where porosity linkagesoccur between internal and externalsurfaces, a path for steam leakageis made available. Such leakage islargely an operational issue, as holesare formed in the paper product, de-

manding expedient attention.

K-1032 CRACKING

Cracks in cast-iron parts are problematic be-cause of the relatively low fracture toughnesscompared with standard, more ductile pres-sure vessel materials and because strength-

ening repair through welding is prohibited.Furthermore, Yankee dryers are subject to both low- and high-cycle fatigue loading.Consequently, considerable emphasis isplaced upon quality inspection for and timelyremediation of cracks, the central causes ofwhich (in Yankee dryers) are:

a. Through joints and bolted connections

1. Joint Interface Corrosion Jacking forces, which develop from

the expansion of corrosion products between head-to-shell flanges, causeflange separation and create leakagepaths between the flanges and/orthrough the bolt holes.

2. Insufficient Joint Clamping Force Through inadequate design, improper

assembly, loss of washer/gasket, orstress corrosion cracking of connect-ing bolts, the clamping force between

mating flanges is insufficient to retaininternal pressure.

3. Washer/Gasket Functional Loss Deterioration, caused by corrosion or

expulsion, provides a path for escap-ing steam and condensate.

4. Flange Machining Variation Variations in surface contour of flange

faces may create leakage paths.

b. Through-Wall Leakage Cast iron inherently exhibits shrinkage

porosity. Where porosity linkages occur between internal and external surfaces, apath for steam leakage is made available.Such leakage in the shell is largely anoperational issue, as holes are formed inthe paper product, demanding expedientattention.

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c. Impact from Objects Passing Through theYankee/Pressure Roll Nip

Because of cast iron’s low fracture tough-ness, it is especially intolerant of local,high impact loads.

d. Stress Magnification Around Drilled Holes Surface defects, caused by porosity and

indentations, are frequently repaired withdriven plugs, having some level of inter-ference fit. Pumping ports, threaded fora tapered pipe fitting, are often installedas a standard Yankee design feature forsealant injection into flange interfaces.When installed, both produce an area ofincreased stress, local to the hole’s edge. Inthe case of driven plugs this stress can beexaggerated by excessive interference fitsand by closely-grouped or over-lappingplugs. Over-torque of threaded, taperedplugs can cause cracks to develop at theperiphery of the hole.

e. Thermal Stress and/or MicrostructuralChange from Excessive Local Heating andCooling

Transient thermal stresses are usually thehighest encountered by a Yankee dryer.Temperature differential through and

between parts can be of such magnitudeas to exceed the strength of the material.When abnormal thermal loads occur,nondestructive examination is crucialto ensure the vessel’s fitness-for-service.Microstructural change and transientthermal stresses, sufficiently high to causecracking in Yankee dryers, have resulted,or could result, from:

• bearing failure• rapid warm-up

• excessive steam temperature• heat from fires• application of water sprays to fight

fires and remove paper jams• continuous and excessive local cooling

from water sprays

• operating heating or cooling systemswhile the Yankee is stationary; e.g.,high temperature air impingementhoods, infra-red heating devices, coat-ing showers

• welding and electrical arcs on cast-

iron parts• excessive local temperature due to

improper thermal spray application

f. Joint Interface Corrosion The products of corrosion occupy a larger

volume than the base metal. The forcescreated by this expansion are sufficientto cause cracking in cast-iron flanges.Without remediation, expansion willcontinue until failure occurs. Corrosionproducts form in the presence of moisturein the crevice created between flanges,wherever the clamping force is insufficientto maintain contact between the matingsurfaces.

g. Stress-Corrosion Cracking of StructuralBolts

Stress-corrosion cracking (SCC) is theresult of the combination of a corrodingagent, material sensitivity, tensile stress,and temperature. At stress levels suffi-

ciently high to induce SCC in the presenceof a corrosive medium, attack proceedsalong or through grain boundaries per-pendicular to the direction of maximumtensile stress. Cracking can initiate withlittle or no evidence of general corro-sion.

K-1033 CORROSION

Corrosion culminates with a failure in com-

ponent functionality by diminishing load-carrying capacity or by generating forces beyond the material’s strength. In additionto SCC, corrosion-jacking (head to shell joint),wear-corrosion, and deterioration of washersdescribed above, oxygen pitting and general

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K-2000 GENERAL REQUIREMENTS

FOR REPAIRS AND

ALTERATIONS TO YANKEE

DRYERS

K-2010 SCOPE

This section provides additional requirementsfor repairs and alterations to Yankee dryerpressure-retaining components and shall beused in conjunction with K-1000.

K-2020 REPLACEMENT PARTS

Yankee dryer replacement pressure-retainingparts shall be fabricated in accordance withthe manufacturer’s design and the originalcode of construction. Yankee dryer pressure-retaining parts may include:

• shell• heads• center shaft, stay, or trunnion• stay bars• structural bolting• journals

Replacement of non-pressure-retaining parts,

when different from the manufacturer’s de-sign, shall be evaluated for any possible effecton the pressure-retaining parts.

K-2030 EXAMINATIONS AND TEST

METHODS

In addition to the requirements of RC-2051 andRC-3031 , the following are recommended:

a. Acoustic emission testing

b. Metallographic examination when ther-mal damage is suspected due to opera-tional or repair activities, microstructureanalysis.

K-2040 DETERMINATION OF

ALLOWABLE OPERATING

PARAMETERS

A Yankee dryer is designed and intendedto have its shell thickness reduced over the

life of the vessel through routine wear andgrinding. The Yankee dryer shell is groundon the outside surface to restore the qualityor shape of the papermaking surface, essentialto the manufacturing of tissue or other paperproducts.

Design documentation is required thatdictates the maximum allowable operatingparameters as shell thickness is reduced.Calculations, used to determine those pa-rameters, are in accordance with ASMECode requirements for primary membranestress and design criteria based upon otherrelevant stress categories; e.g., fatigue andmaximum principal stress. Calculation ofthese parameters requires that the respectivestresses, resulting from the imposed loads, becompared to the appropriate material strengthproperties. Hence, knowledge of the appliedstresses in the shell and the tensile and fatigueproperties of the material are essential.

Yankee dryers are subjected to a variety ofloads that create several categories of stress.Yankee dryers are designed such that thestress of greatest concern typically occurs onthe outside surface at the axial centerline ofthe shell.

a. Steam Pressure Load – The internal steampressure is one of the principal designloads applied to the Yankee dryer. Thesteam pressure expands the shell radially,causing a predominately circumferential

membrane tensile stress. Because the shellis constrained radially by the heads ateither end of the shell, the steam pressurealso causes a primary bending stress in thevicinity of the head-to-shell joint. The ends

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of the shell are in tension on the insideand compression on the outside due to thesteam pressure. The steam pressure alsocauses a bending stress in the heads.

b. Inertia Load – The rotation of the Yankee

dryer causes a circumferential membranestress in the shell similar to that caused by the steam pressure load. This stress isincluded in the design of the shell and in-creases with dryer diameter and speed.

c. Thermal Gradient Load – The wet sheet,applied to the shell, causes the outsidesurface to cool and creates a thermal gra-dient through the shell wall. This thermalgradient results in the outside surface being in tension and the inside surfacein compression. With this cooling, theaverage shell temperature is less than thehead temperature, which creates bendingstresses on the ends of the shell and in theheads. The ends of the shell are in tensionon the outside and compression on theinside.

Other thermal loading also occurs on aYankee. The use of full width showersfor a variety of papermaking purposes

affects the shell similar to a wet sheet. Theuse of edge sprays produce high bendingstress in the ends of the shell due to themechanical restraint of the heads.

Warm-up, cool-down, hot air impinge-ment from the hood, moisture profilingdevices, fire fighting, and wash-up canall produce non-uniform thermal stressesin the pressure containing parts of theYankee dryer. Heating or cooling differentportions of the Yankee dryer at different

rates causes these non-uniform stresses.

d. Line Load – The line load from the contact-ing pressure roll(s), results in an alternat-ing, high cycle, bending stress in the shell.

This stress is greatest at the centerline ofthe shell. The load of the pressure rolldeflects the shell radially inward causinga circumferential compressive stress onthe outside surface and a tensile stresson the inside. Because the shell has been

deflected inward at the pressure roll nip,it bulges outward about 30 degrees oneach side of the nip. The outward bulgecauses a tensile stress on the outside shellsurface at that location and a correspond-ing compressive stress on the inside. Sincethe shell is passing under the pressure roll,its surface is subjected to an alternatingload every revolution.

K-2041 ASME CODE PRIMARY

MEMBRANE STRESS

CRITERION

Yankee dryers are typically designed and fab-ricated in accordance with Section VIII, Div. 1,of the ASME Code. The maximum allowablestress for cast iron is specified in UCI-23 ofthe ASME Code.

Section VIII, Div. 1, requires design stressesto be calculated such that any combination

of loading expected to occur simultaneouslyduring normal operation of the Yankee dryerwill not result in a general primary stressexceeding the maximum allowable stressvalue of the material. In the ASME Code,the combination of loading resulting in theprimary membrane stress is interpreted to becomposed only of the circumferential stressfrom steam pressure. Sometimes, the stressfrom the inertial loading is included in thisconsideration.

In Section VIII, Div. 1, it is very important tonote that no formulas are given for determin-ing the stresses from thermal gradient loads,inertial loads, and pressure roll nip loads.Hence, additional criteria need to be incor-

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porated to establish the maximum allowableoperating parameters of the Yankee dryer. Asthe thickness of the shell is reduced, one ormore of these criteria will control the variousoperating parameters. Two such additionalcriteria are based upon the maximum princi-

pal and fatigue stress.

a. Maximum Principal Stress Criterion The maximum principal stress in a Yankee

shell is the sum of the stresses that aresimultaneously applied to the shell, andis always aligned in the circumferentialdirection. The purpose of this criterion isto recognize the paper making applicationof the Yankee dryer and to prevent cata-strophic failure, by including all stresses.The ASME Code does not provide specificformulas for the full array of dryer stressesencountered in a paper making applica-tion.

b. Fatigue Stress Criterion Under normal operation, the stresses

due to the steam pressure, inertial andthermal gradient loads are consideredto be steady-state stresses. When actingsimultaneously, the sum of these stressesmust be calculated and combined with

the alternating stress due to the pressureroll line load. A fatigue stress criterionlimits the alternating stress at a givenmean stress using fatigue failure criteriadescribed by the Goodman or Smith Dia-gram. The purpose of this limitation is toprevent crack initiation in the outside walldue to the combination of stresses.

K-2042 ADJUSTING THE MAXIMUM

ALLOWABLE OPERATING

PARAMETERS OF THE YANKEE DRYER DUE TO A

REDUCTION IN SHELL

THICKNESS FROM

GRINDING OR MACHINING

The outside surface of the Yankee dryer shellis routinely ground to restore the quality of the

papermaking surface. The papermaking sur-face degrades due to wear, corrosion, and localthinning. As the shell thickness is reduced, themaximum allowable operating parameters areadjusted. Adjustment of the maximum allow-able operating parameters requires accurate

shell thickness measurements.

Over the life of the Yankee dryer, the adjust-ment of the maximum allowable operating pa-rameters will require that the original designpressure and/or the pressure roll line load bereduced. After the maximum allowable oper-ating parameters are adjusted per the De-rateCurve, the appropriate load limiting devicesare reset (e.g., steam safety relief valve, lineload limiting device).

K-2043 DOCUMENTATION OF

SHELL THICKNESS AND

ADJUSTED MAXIMUM

ALLOWABLE OPERATING

PARAMETERS

Yankee dryers are designed and intended tohave the shell thickness reduced over the lifeof the vessel as a result of routine wear andgrinding. Yankee shell grinding is routinely

performed to restore the quality or shape ofthe papermaking surface.

Design documentation, a De-rate Curve, isrequired, which dictates the maximum allow-able operating parameters, based on imposedloads over a range of shell thickness. Thedocumentation shall be obtained from theoriginal dryer manufacturer or from anotherqualified source acceptable to the Inspector.

Yankee dryer shell grinding requires accurate

shell thickness measurements in conjunctionwith the De-rate Curve in order to set load-limiting devices. The resulting shell thicknessand maximum allowable operating param-eters after grinding shall be documented,and the Inspector notified that load-limitingdevice settings have changed.

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K-2050 STAMPING

Stamping is not required for repairs that donot affect the pressure-retaining capabilityof the Yankee shell, as indicated on the De-rate Curve, or other pressure-retaining parts

as indicated on the original Manufacturer’sData Report.

Stamping is required for repairs that do affectthe pressure-retaining capability of the Yankeeshell, as indicated on the De-rate Curve, orother pressure-retaining parts as indicated onthe original Manufacturer’s Data Report.

Stamping is required for alterations as listedin K-4020.

Stamping, when required, shall meet therequirements for stamping in RC-3040. Thelocation of stamping shall be described in theremarks section of Form R-2.

K-3000 YANKEE DRYER REPAIR

METHODS

K-3010 SCOPE

This section provides additional requirementsfor repair methods to Yankee dryer pressure-retaining components and shall be used inconjunction with K-1000 and K-2000.

K-3020 REPAIR GUIDE FOR YANKEE

DRYERS

Welding or brazing shall not be used on anyYankee dryer pressure-retaining component

manufactured from cast iron. The Manufactur-er’s Data Report shall be carefully reviewedto determine the material of construction ofeach Yankee Dryer component such as shell,heads, and journals.

Structural deterioration or damage caused bycorrosion, thinning, or cracking shall not be re-paired until their extent has been determined by suitable nondestructive examination.

The user shall have a plan covering the scope

of the repair. The plan shall ensure that thework involved is compatible with the originaldesign specification and good engineeringpractices.

All repair work shall be documented.

K-3030 PROCEDURES THAT DO

NOT REQUIRE STAMPING

OR NAMEPLATE

ATTACHMENT

All repair procedures, shall be acceptableto the Inspector, and when verified by theowner-user to not affect pressure-retainingcapability of the Yankee dryer, do not requirestamping or nameplate attachment. Exam-ples of repairs are:

Grinding and machining:

• removal of shell overhung flange

• removing bolt-stop ring for test specimens• head/shell joint corrosion removal• journal grinding• shell surface grinding (crowning)• crack removal• head flange OD reduction• back spot facing of flange surfaces (head,

shell, journal)

Metallizing (full face, spot, edge):

• applying a metallized coating

• grinding of a metallized coating

Epoxy filling of surface imperfection

Installation of spoiler bars

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Maintain/repair/ replace internal condensateremoval system

Driven plug repair when completed as de-scribed in K-3053.

K-3050 DAMAGE REPAIR

K-3051 REPAIR OF LOCAL

THINNING

A Local Thin Area (LTA) may develop in apressure-retaining part or may result from theoriginal casting process. Inservice thin areasmay result from mechanical wear, erosion-corrosion caused by steam and condensateflow, corrosion, impact damage, or grindingfor the removal of material flaws.

Evaluation of thinning for repair shall con-sider the unique design and loading character-istics of the Yankee dryer. Local thin areas areoften analyzed as specific cases by the finiteelement method.

a. When a LTA is evaluated by finite ele-ment method, analysis should considerthe location of the thin area and account

for strength provided by the vessel cen-tershaft and heads in addition to thestrength provided by the shell alone. Suchstructural analysis should consider allrelevant loads to ensure safe operation ofthe shell according to the De-rate Curve,or other pressure-retaining parts as indi-cated on the original Manufacturer’s DataReport.

b. Following evaluation and determina-tion of maximum allowable operating

parameters, a LTA can be coated or filledto prevent further wear or deterioration.Grooves and gouges should always belightly ground to remove sharp notchesand edges. Welding or brazing repairsare NOT permitted on cast-iron pressure-retaining components.

c. Where the LTA is of sufficient size to causea reduction in maximum allowable oper-ating parameters according to the De-rateCurve, an R-2 Form shall be submitted.

d. Depending upon the cause of the LTA,

further monitoring may be necessary toensure deterioration has been arrested.

e. Inspection data, including all thicknessreadings and corresponding locationsused to determine the minimum and av-erage thicknesses, and the accompanyingstress analysis, should be included in thedocumentation and retained for the life ofthe vessel.

K-3052 TREATMENT OF

CRACK-LIKE FLAWS

Crack-like flaws are planar flaws which arepredominantly characterized by a length anddepth with a sharp root radius. They mayeither be embedded or surface breaking. Insome cases it may be advisable to treat volu-metric flaws, such as aligned porosity, inclu-sions, and laps, as planar flaws, particularlywhen such volumetric flaws may contain

microcracks at the root.

a. Knowledge of local stress level and clas-sification, and of flaw origin, type, size,location, and angle relative to the princi-pal stress direction is essential in makingdeterminations regarding remediation.It is also important to know whetherthe crack is active. Acoustic EmissionsTesting can be used to determine if thecrack is active. Various other methods ofnondestructive examination should be

employed to determine crack length anddepth. Ultrasonics is the recommendedsizing technique for depth and inclina-tion of crack-like flaws. Magnetic particle,specifically the wet fluorescent technique,and dye penetrant methods are applicablein determining the length of a surface

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flaw. Radiographic methods may also beuseful. Metallographic analysis is crucialin differentiating between original castingflaws and cracks.

b. Remediation of crack-like flaws, that have

been determined to be cracks, is mostoften accomplished through removal viagrinding or machining. Because cast ironis categorized as a brittle material, thisis the conservative approach regardingcrack-like flaws. Welding/brazing repairsare NOT permitted for cast-iron parts.

c. Crack-like flaws that have been identi-fied as cracks, but which developed fromnormal service exposure or excessiveoperating conditions, shall be remediated by appropriate means regardless of loca-tion.

d. Crack-like flaws that have been identifiedas cracks that developed through non-standard load events, such as by waterhoses from operation or firefighting or me-chanical damage, shall be remediated if inthe shell. Cracks in other pressure-retain-ing parts, shall be analyzed, documented,and monitored to ensure their presence

will not be, or have not been, affected bycurrent operating conditions.

e. Crack-like flaws that are not identified ascracks, but existed in the original mate-rial; i.e., material flaws, shall be analyzed,documented, and monitored to ensuretheir presence will not be, or have not been, affected by current operating condi-tions.

All documents pertaining to the crack-like

flaw assessment shall be retained for thelife of the vessel. Documentation shouldaddress the engineering principles em-ployed, including stress analysis methodsand flaw sizing, the source of all materialdata used, identification of any potentialmaterial property degradation mecha-

nisms and the associated influence onthe propagation of flaw, and the criteriaapplied to the assessment procedures.

K-3053 DRIVEN PLUG REPAIR

Shell surface imperfections should be repairedwith smooth, driven plugs as described inASME Section VIII, Div. 1, UCI-78, with thefollowing additional requirements:

a. Maximum plug length (depth) shall belimited to 20% of shell effective thickness,and plug diameter shall not exceed theplug length (depth).

b. Total surface area of plugs shall not exceed4 sq. in. in an 8 in. diameter circle (2580 sq.mm in a 200 mm diameter circle).

c. Average number of shell plugs shall notexceed one plug per 1 sq. ft. (1 plug per0.1 sq. m) of the surface.

d. The land distance between edges of plugsshall be at least equal to the diameter ofthe larger plug.

e. The plug material shall conform in allrespects to the material specification ofthe base material.

f. The installed plug shall have an interfer-ence fit. The average hold diameter isdetermined after the plug hole is drilledor reamed. The maximum plug diametershall not exceed 1.012 times the averagehole diameter. This provides an interfer-ence fit while minimizing the residualstresses.

g. All plug repair work shall be documentedin the form of a plug repair map or othersuitable method of recording and retainedin the dryer’s permanent file.

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K-4000 ALTERATIONS TO YANKEE

DRYERS

K-4010 SCOPE

This section provides additional requirementsfor alterations to Yankee dryer pressure-retaining components and shall be used inconjunction with K-1000 and K-2000.

K-4020 ALTERATION TYPES

Any change in the Yankee dryer (shell, heads,center shaft, fasteners), as described on theoriginal Manufacturer’s Data Report, whichaffects the pressure-retaining capability shall be considered an alteration. Examples ofalterations are:

a. Drilling/enlarging of bolt holes in castingsfor larger diameter bolts;

b. Replacement of structural bolts differingin size, material, or design, from thosedescribed on the Manufacturer’s DataReport;

c. Removal of shell overhung flange;

d. Journal machining;

e. Head flange outside diameter reduction;

f. Machining of head flange or shell flangesurface to remove corrosion;

g. Operating above the nameplate tempera-ture.

Alteration procedures shall be written, re-viewed, approved, and accepted by the In-spector prior to the start of work.

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Continued Service, Inspection, and Repairfor DOT Vessels

Appendix L

452.1

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452.2

APPENDIX L — CONTINUED SERVICE, INSPECTION, AND REPAIRFOR DOT VESSELS

L-1000 GENERAL REQUIREMENTS

L-1010 SCOPE

This appendix provides rules for continuedservice inspections, repairs, and modificationsof transport tanks, i.e., cargo tanks, rail tanks,portable tanks, and ton tanks that transportdangerous goods as required in the Codeof Federal Regulations, Title 49, Parts 100through 185, and the United Nations Rec-ommendations for Transport of DangerousGoods-Modal Regulations. This appendix,where applicable shall be used in conjunc-tion with Parts RA , RB , RC , and RD of theNBIC and Section XII “Transport Tanks” ofthe ASME Boiler and Pressure Vessel Code.

This appendix will establish the appropriatemethods to be used for continued service,i.e., inspections, repairs, and modifications oftransport tanks. This appendix will establishthe criteria for inspections, reports, documentcontrol, and Inspector duties and responsibili-

ties. The Inspector shall be a National Boardrecognized Inspector, i.e., Authorized Inspec-tor (AI), Qualified Inspector (QI), CertifiedIndividual (CI), or a Registered Inspector(RI). The Registered Inspector is a positionestablished by CFR 49 Parts 100 through 185for Continued Service Inspections. This indi-viduals duties and responsibilities are subjectto DOT and not QAI-1

L-1015 TERMINOLOGY

The terminology used in this appendix, insome cases may be in conflict with termsand definitions normally used in the repairand alteration of pressure-retaining items.Considering these differences, this appendixin the Definition Section has incorporated

definitions and terms specified in CFR 49,Parts 100 through 185.

When conflicts are identified between this ap-pendix and the regulations of the CompetentAuthority regarding the examination, inspec-tion, testing, repair, and maintenance for thecontinued qualification of transport tanks, theregulations of the Competent Authority takeprecedence.

Rules for repairs and modifications of trans-port tanks are provided in the repair andmodification section of this appendix.

L-1020 ADMINISTRATION

The Competent Authority’s requirementsdescribe the frequency, scope, type of inspec-tion, (internal, external, or both), type of ex-amination (nondestructive, spark test, etc.),and the documentation requirements for theinspection.

For transport tanks under the jurisdiction ofthe Department of Transportation, the Regis-tered Inspector shall have a thorough knowl-edge of the Code of Federal Regulations, Title49, Parts 100 through 185.

L-1030 STAMPING

Transport tanks represented as manufacturedto a DOT specification or a United Nation’s(UN) standard shall be marked on a non-

removable component of the transport tankwith specification markings conforming tothe applicable specification. The specifica-tion marking is required to located in anunobstructed area with letters and numeralsidentifying the standard or specification. Un-less otherwise specified by Part 178.3 of the

A05

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452.3

Code of Federal Regulations, the markingsmust identify the name and address or symbolof the transport tank manufacturer or, wherespecifically authorized, the symbol of the ap-proval agency certifying compliance with aUN standard.

Symbols required by the Department of Trans-portation (DOT) must be with the approval ofthe DOT Associate Administrator. Duplica-tive symbols are not authorized. Stampingand symbol requirements for transport tanksthat are under different rules than CFR 49,Parts 100 through 185 shall comply with theapplicable Competent Authorities rules andregulations.

The detailed markings, i.e., stamped, embossed, burned, printed, etc., size of the mark-ings, capacities, etc. are specified in Part 178.3of the Code of Federal Regulations, Title 49,as follows:

a. ASME Stamped Transport Tanks Transport tanks stamped with the ASME

Section XII Code Symbol shall satisfy theapplicable requirements of that Code.Transport tanks manufactured prior tothe adoption of ASME Section XII by the

Competent Authority were manufacturedin accordance with ASME Section VIII,Div. 1. Stamping with the ASME SectionVIII, Div. 1 “U” Code Symbol Stamp isdependant on pressure and/or medialimitations.

b. When the stamping on a transport tank becomes indistinct or the nameplate is lostor illegible, but traceability to the originaltransport tank is still possible. To satisfythis requirement, as a minimum, original

source data from the manufacturer of thevessel or records in possession of the tankowner should be used to establish trace-ablity to the stamping with the concur-rence of the Inspector, and approval of theCompetent Authority, and if required the Jurisdiction. The Inspector shall instruct

the owner or user to have the stampeddata replaced. All re-stamping shall bedone in accordance with the original codeof construction (ASME Section XII, orASME Section VIII, Div. 1, as applicable).Request for permission to re-stamp or re-

place the nameplate shall be made to theCompetent Authority and if required the Jurisdiction. Application must be made onthe Replacement of Stamped Data Form,NB-136. Proof of the stamping and othersuch data, as is available, shall be fur-nished with the request. When traceabilitycannot be established, the CompetentAuthority shall be contacted.

c. Re-stamping or replacement of nameplates Re-stamping or replacement of the name-

plate as authorized by the Competent Au-thority shall only be done in the presenceof the Inspector, i.e., AI, QI, CI, or NationalBoard Commissioned Inspector, as re-quired by ASME Section XII and the ap-plicable Modal Appendix, or as required by the Competent Authority. For transporttanks manufactured to ASME SectionVIII, Div. 1, re-stamping or replacementshall only by done in the presence of anAuthorized Inspector or a National Board

Commissioned Inspector.

L-1040 POTENTIALDETERIORATION ANDFAILURE MECHANISMS

An effective inspection and test programrequires an understanding of the applicablepotential failure mechanisms and the appli-cable inspection and test methods to assurethe continued structural integrity of a trans-

port tank.

This appendix includes a general discussionof mechanisms and effective inspection andtest methods. Additionally, some specificguidance is given on how to evaluate thetransport tanks for repairs, modifications, andcontinued service requirements.

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L-1050 CLASSIFICATIONBOUNDARIES

Transport tanks are classified as Class 1, Class2, and Class 3. The classification is established by the applicable Modal Appendix of Section

XII of the ASME Boiler and Pressure Vessel Code.Also contained in the Modal Appendix is thetype of Inspector, i.e. Authorized Inspector,Qualified Inspector, and Certified Individualthat is permitted to perform the applicablefabrication inspection of the transport tank,i.e., cargo tank, tank car, portable tank, andton tank. The classification of the transporttank, except for continued service inspectionsdetermines the Code of Construction require-ments for repairs or modifications.

For continued service inspections, the owner-user’s Registered Inspector can be used toperform inspections and testing in accordancewith the Code of Federal Regulations, Title 49,Parts 100 through 185, Transportation.

L-1060 PRESSURE, TEMPERATURE,AND CAPACITYREQUIREMENTS FORTRANSPORT TANKS

Section XII has established pressure, tempera-ture, and maximum thickness requirementsfor Transport Tanks as follows:

a. Pressure: 0 to 208 bar (full vacuum to3,000 psig);

b. Temperature: -269°C to 343°C (-452°F to650°F);

c. Maximum material thickness: 38 mm

(1-1/2 in.).

Transport tanks manufactured prior to theadoption of Section XII by the Code of Fed-eral Regulations, Title 49, Parts 100 through185, Transportation, the code of constructionrequired was Section VIII, Div. 1. Transport

tanks manufactured to this Code were re-quired to be stamped with the “U” Code Sym- bol Stamp in accordance with Section VIII,Div. 1, if the design pressure of the transporttank was 35 psi (depending on material beingtransported) and greater. If the design pres-

sure was less than 35 psi (depending on themedia being transported), the transport tankwas constructed in accordance with SectionVIII, Div. 1, but not stamped with the “U”Code Symbol Stamp.

For these transport tanks, the requirementsestablished in this appendix for continuedservice inspection, repairs, or modificationsshall apply, unless specifically exempted bythe DOT.

L-1070 REFERENCE TO OTHERCODES AND STANDARDS

Other existing inspection codes, standardsand practices pertaining to the continued ser-vice inspection, i.e, CFR 49, Parts 100 through185, ASME Section XII, etc. of transport tankscan provide useful information and referencesrelative to the inspection techniques listed inthis appendix. Additionally, supplementary

guidelines for assisting in the evaluation ofinspection results and findings are also avail-able. Some acceptable requirements andguidelines are as follows:

a. American Society of Mechanical Engineers– ASME Boiler and Pressure Vessel Code , Sec-tion VIII, Div. 1 (Rules for Construction ofPressure Vessels).

b. American Society of Mechanical Engi-neers:

• ASME Section V (Nondestructive Ex-amination)

• ASME Section IX (Welding and BrazingQualifications).

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452.5

c. Code of Federal Regulations, Title 49,Parts 100 through 185, Transportation.

d. American Petroleum Institute – API 579Fitness for Service.

e. ADR 2003, European Agreement Concern-ing the International Carriage of Danger-ous Goods by Road. (Published by theUN Economic Commission for Europe,Information Service, Palais des Nations,CH-1211 Geneve, Suisse).

f. CGA G-4.1, Cleaning Equipment for Oxy-gen Service.

g. CGA S-1.2, Pressure Relief Device Stan-dard, Part 2: Cargo and Portable Tanksfor Compressed Gases. (Published bythe Compressed Gas Association, Inc.[CGA], 4221 Walney Road, Chantilly, VA20151).

h. IMDG Code 2002, International Mari-time Dangerous Goods Code (includingAmendment 31-02. (Published by theInternational Maritime Organization[IMO], 4 Albert Embankment, London,SE1 7SR).

i. RID 2003, Carriage of Dangerous Goods.(Published by the Intergovernmental Or-ganization for International Carriage byRail [OTIF], Gyphenhubeliweg 30, CH-3006 Berne, Suisse).

j. United Nations Recommendations on theTransport of Dangerous Goods — ModalRegulations. (Published by the UnitedNations Publications, 2 UN Plaza, NewYork, New York 10017).

k. SSPC Publication #91-12, Coating andLining Inspection Manual. (Published by Steel Structures Paint ing Council,4400 Fifth Avenue, Pittsburgh, PA 15213-2683).

L-1080 CONCLUSION

a. During any continued service inspectionsor tests of transport tanks, performed bythe Registered Inspector, the actual op-erating and maintenance requirements

as specified in this appendix shall besatisfied. The Registered Inspector shalldetermine, based on the applicable re-quirements of the Code of Federal Regula-tions, Title 49, Parts 100 through 185, andthis appendix, whether the transport tankcan continue to be safely operated.

b. Defects or deficiencies in the condition,operation, and maintenance requirementsof the transport tank, including piping,valves, fittings, etc., shall be discussedwith the owner or user of the transporttank at the time of inspection. Defects ordeficiencies shall be corrected using theappropriate methods prior to returningthe transport tank to service.

L-2000 PERSONNEL SAFETY ANDINSPECTION ACTIVITIES

L-2010 SCOPE

Proper inspection of transport tanks may re-quire pre-inspection planning. This planningshould include development of an inspectionplan that will satisfy the applicable techni-cal requirements of this appendix, the Codeof Federal Regulations, Title 49, Parts 100through 185, Transportation, and appropriatesafety considerations. The inspection planshould also include the applicable failureand deterioration mechanisms and inspection

methods and the requirements of the appli-cable Competent Authority.

This appendix describes pre-inspection andpost-inspection activities applicable to alltransport tanks. Specific inspection require-

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452.6

ments for transport tanks are identified inSections L-3100 for Cargo Tanks, L-3200 forPortable Tanks, L-3300 for Ton Tanks and L-3400 for Tank Cars.

L-2100 PERSONNEL SAFETY

Personnel safety is the joint responsibility ofthe owner or user and the Registered Inspec-tor. All applicable safety regulations shall be followed. This includes, if applicable, allgovernmental rules and regulations. Owner’sor user’s personnel safety programs and/orsafety programs by the Inspector ’s employer,or similar regulations such as confined spacerequirements also apply.

L-2120 TRANSPORT TANK ENTRYREQUIREMENTS

a. No transport tank shall be entered until ithas been properly prepared for inspection.The owner or user and the Inspector shalldetermine that the transport tank may beentered safely. This shall include:

1. Potential hazards associated with the

entry into the transport tank have been identified by the owner or userand are brought to the attention ofthe Inspector, along with acceptablemeans or methods for mitigating eachof these hazards;

2. Coordination of entry into the trans-port tank by the Inspector and theowner or user representative(s) work-ing in or near the transport tanks;

3. If personnel protective equipment isrequired to enter the transport tank,the necessary equipment is available,and the Inspector is properly trainedin its use;

4. An effective energy isolation pro-gram is in place and in effect that willprevent the unexpected release ofenergy or media to enter the transporttanks.

b. The Inspector shall be satisfied that a safeatmosphere exists before entering thetransport tank. The oxygen content of breathable atmosphere shall be between19.5% and 23.5%.

c. The Inspector shall not be permitted toenter an area if toxic, flammable, or inertgases or vapors are present and aboveacceptable limits without proper personalprotective equipment. Protective equip-ment may include, among other items,protective outer clothing, gloves, eye pro-tection, foot protection, or respirators.

The Inspector shall have proper traininggoverning the selection and use of anypersonal protective clothing and equip-ment necessary, particularly related torespiratory protection if the testing of theatmosphere of the transport tank revealsany hazards. This requirement is to ensurethat the inspection may be performed

safely.

L-2200 INSPECTION ACTIVITIES

L-2210 PREPARATION FORINTERNAL INSPECTION

The owner or user has the responsibilityto prepare a transport tank for internal in-spection. Requirements for safety including

occupational safety and health regulations(federal, state, local, or other), the owner’sor user’s own safety program and the safetyprograms of the Inspector’s employer areapplicable for inspections. The transport tank

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452.7

shall be prepared in the following manner oras deemed necessary by the Inspector.

a. When a transport tank is connected toa common header with other transporttanks or in a system where liquids or gases

are present, the transport tank shall beisolated by closing, locking, and/or tag-ging stop valves in accordance with theowner’s or user’s procedures.

b. When toxic or flammable materials areinvolved, additional safety precautionsshould require removing pipe sectionsor blanking pipelines before entering thetransport tank. The means of isolatingthe transport tank shall be acceptable tothe Inspector and in compliance with ap-plicable occupational safety and healthregulations.

c. The transport tank shall be allowed to coolor warm to ambient temperature at a rateto avoid damage to the transport tank.

d. The transport tank shall be drained of allliquid and shall be purged of any toxic orflammable gases or other contaminantsthat were contained in the transport tank.

Mechanical ventilation using a fresh air blower or fan shall be started after thepurging operation and maintained un-til all pockets of “dead air” which maycontain toxic or flammable or inert gasesare reduced to acceptable limits. Duringthe air purging and ventilation of thetransport tank involved with flammablegases, the concentration of the vapor in airshould pass through the flammable range before a safe atmosphere is obtained. Allnecessary precautions shall be taken to

eliminate the possibility of explosion orfire.

e. Manhole, if applicable, and hand holeplates, washout plugs, inspection plugsand any other item requested by the In-spector shall be removed.

f. The Inspector shall not enter a transporttank until all safety precautions have beentaken. The temperature of the transporttank shall be such that the inspectionpersonnel will not be exposed to excessiveheat or cold. The transport tank should be

cleaned as necessary.

g. A qualified person (attendant) shall re-main outside the transport tank at thepoint of entry while the Inspector is insideand shall monitor activities inside andoutside and communicate with the Inspec-tor as necessary. The attendant shall havemeans of summoning rescue assistance ifneeded and to facilitate rescue proceduresfor those inside the transport tank withoutpersonally entering the transport tank.

NOTE: If a transport tank has not been prop-erly prepared for an internal inspection, theInspector shall decline to make the inspec-tion.

L-2220 PRE-INSPECTIONACTIVITIES

Prior to conducting the inspection, a review

of the history of the transport tank and ageneral assessment of current conditions shall be performed. This shall include a review ofinformation, such as:

• Date of the last inspection;• Current Inspection Certificate;• ASME Code Name Plate and /or Speci-

fication;• If applicable National Board registration

number;• Serial number of identification marking

of the transport tank;• Operating conditions and normal contents

of the transport tank;• Previous inspection report or inspection

certificates;• Records of wall thickness checks, espe-

cially where corrosion is a consideration;

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Table L-3100 — Periodic Inspections and Tests

Test or InspectionTank Specification,Configuration, and Service

Test and Inspection InternalAfter Original Certification Date

External VisualInspection

All cargo tanks designed to be loaded by vacuumwith full opening in the rear head

6 Months

All other cargo tanks 1 Year

Internal VisualInspection

All insulated cargo tanks, except MC 330, MC 331,& MC 338

1 Year

All cargo tanks transporting ladingcorrosive to the cargo tank

1 Year

All other cargo tanks, except MC 338 5 Years

Lining Inspection All lined cargo tanks transporting lading corrosiveto the cargo tank

1 Year

Leakage Test MC 330 and MC 331 cargo tanks inchlorine service

2 Years

All other cargo tanks, except MC 338 1 Year

Pressure Test

Note1 – Sodium MetalNote2 – MAWP <15 psig

All cargo tanks which are insulated with no manholeor insulated and lined, except MC 338

1 Year

All cargo tanks designed to be loaded by fullvacuum with full opening in the rear head of thecargo tank

2 Years

MC 330 and MC 331 cargo tanks in chlorineservice

2 Years

All other cargo tanks 5 Years

Thickness Test All unlined cargo tanks in corrosive service, exceptMC 338

2 Years

1 Pressure testing is not required for MC 330 and MC 331 cargo tanks in dedicated sodium metal service.

2 Pressure testing is not required for uninsulated lined cargo tanks with a design pressure or MAWP of 15 psig or less, which successfully passedan external visual inspection and lining inspection at least once a year.

a. Insulated cargo tanks: If the insulationon the cargo tank precludes a completeand thorough external visual inspection,the cargo tank shall be subjected to aninternal visual inspection, if equippedwith a manhole or inspection openings.

This inspection shall include all internalsurfaces, including welds, nozzle attach-ments and, if equipped, baffles, internalstiffeners, surge protection devices fordefects, corrosion, missing or loose attach-ment, or;

b. Lined, coated or if the cargo tank is sodesigned to preclude an internal visualinspection: If the cargo tank is externallylined, coated, or of a design that wouldprevent a complete and thorough externalvisual examination, the internal areas of

the cargo tank that are not obstructed bythe lining or coating shall be internallyinspected and/or;

c. Lined, coated, or if the cargo tank is sodesigned to preclude access to the inter-

nal surfaces of the cargo tank, the cargotank shall be subjected to a hydrostatic orpneumatic test in accordance with L-3160 of this section;

d. All corroded or abraded areas of a cargotank wall must be thickness tested in ac-cordance with the following procedures:

1. Measurements must be made usinga device capable of accurately mea-suring thickness within ± 0.002 of aninch;

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452.10

2. Any individual performing thicknesstesting must be trained in the properuse of the thickness testing device inaccordance with the testing devicemanufacturer’s instructions;

3. Minimum thickness requirementsfor the heads, shell and baffle, and bulkhead, when used as tank rein-forcement, shall meet the minimumthickness for inservice requirementsfor MC 300, MC 303, MC 304, MC 306,MC 307, MC 310, MC 311, and MC312 cargo tanks constructed of steel,steel alloys, aluminum, and aluminumalloys are based on 90% of the mini-mum manufactured thickness. Table3183-1 provides minimum inserviceminimum thicknesses for steel andsteel alloys: Table L-3183-2 providesminimum thicknesses for aluminumand aluminum alloys.

L-3120 INSPECTION OF PIPING, VALVES AND MANHOLES

The cargo tank piping, valves, and gasketsmust be carefully inspected for corroded

areas, and the piping system and valve at-tachment welds or threads must be inspectedfor corrosion, leakage, or any other defectsthat might render the cargo tank unsafe fortransportation service. This examination shallinclude:

a. All devices for securing manhole coversmust be in satisfactory working conditionand the area must not show any evidenceof leakage at either the manhole cover orthe manhole gasket.

1. When inspecting gaskets on any fullopening of the cargo tank, the inspec-tor should visually examine the gasketfor defects to include cracks and/orsplits that may prevent the gasketmaterial from sealing properly.

2. If the gasket shows any evidence ofcuts or cracks that are likely to causefailure, the gasket shall be replaced.

b. All emergency devices and valves includ-ing self-closing stop-valves, excess flow

valves, and remote closure devices must be free of corrosion, distortion, erosion,and any external damage that will preventsafe operation of the cargo tank. Remoteclosure devices and self-closing stopvalves must be operated during inspec-tion to demonstrate that the devices areoperating as designed.

c. Any missing bolts, nuts, and fusible linksor elements shall be replaced. Loose boltsand nuts must be tightened.

d. All reclosing pressure relief valves shall be externally inspected for any corrosionor damage that might prevent the devicefrom operating as designed.

1. All reclosing pressure relief valves oncargo tanks carrying lading corrosiveto the pressure relief valve shall beremoved from the cargo tank for in-spection and testing.

2. Each reclosing pressure relief valverequired to be removed and tested asspecified in (d) (1) above must open atthe required test pressure and reseatto a leak-tight condition at 90% ofthe set-to-discharge pressure or thepressure prescribed for the applicablecargo tank specifications.

L-3130 INSPECTION OF

APPURTENANCES AND STRUCTURAL

ATTACHMENTS

Major appurtenances, as defined in CFR49, 180.407 (d)(2)(viii), include but are notlimited to suspension system attachments,

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452.11

connecting structures, and those elementsof the upper coupler (fifth wheel) assemblythat can be inspected without dismantling theupper coupler (fifth wheel) assembly shall beinspected for any corrosion or damage thatmight prevent safe operations.

a. If the cargo tank transports lading thatis corrosive to the cargo tank, the uppercoupler (fifth wheel) assembly must be in-spected at least once in a two year period.The upper coupler (fifth wheel) shall beremoved for inspection of the following:

1. Corroded and abraded areas;

2. Dents;

3. Distortions;

4. Weld failures;

5. Any other condition that might renderthe cargo tank unsafe for transporta-tion service.

b. If the cargo tank is constructed of mild orhigh strength low alloy steel and employsring stiffeners or other appurtenances

that create air cavities adjacent to the ringstiffeners or other appurtenances to thecargo tanks shell and these areas cannot be visually externally inspected, then thefollowing shall be performed:

1. A thickness test on the stiffener ringsshall be performed at least once everytwo years of at least four symmetri-cally distributed readings to establishan average thickness for the ring stiff-ener or appurtenance. The thickness

requirements are specified in TablesL-3183-1 or L-3183-2 , as applicable

2. If any of the thickness testing readingsfor the ring stiffeners are less than theaverage thickness by more than 10%,thickness testing must be performed

from inside the transport tank onthe area of the tank wall covered bythe appurtenance or ring stiffener. Ifthe results of the thickness test of thetransport tank fail to conform to theminimum thickness requirements

prescribed for the design as manu-factured, the tank must be repairedor removed from hazardous materialservice. The owner of the transporttank can derate the tank to transportauthorized material and reducedmaximum weight of lading, or reducepressure or a combination thereof un-der the following conditions:

i. The reduced loadings based onthe cargo tanks design conditionsand material thicknesses are ap-propriate for the reduced loadingconditions. This reduced load-ing shall be certified by a DesignCertifying Engineer and a revisedmanufacturer’s certificate shall beissued reflecting these reducedloading conditions;

ii. The cargo tank motor vehicle’smanufacturer’s nameplate shall

be revised to reflect the reducedlimits;

iii. If (a) and (b) above can not be satis-fied, the owner of the cargo tankshould not return the cargo tankto hazardous material service. Theowner shall remove, or obliterate,or in a secure manner cover thetank’s specification plate;

iv. The inspector shall record the

results of the thickness test on thecargo tank’s inspection report.

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L-3140 VISUAL INTERNALINSPECTION

When performing an internal visual inspec-tion of a cargo tank and the cargo tank isequipped with a manhole or an inspection

opening, the inspector shall examine the inter-nal surfaces for corroded and abraded areas,dents, distortions, defects in welds, and anyother conditions that might render the cargotank unsafe for transportation service. As aminimum the inspection shall include:

a. The cargo tank shell and heads;

b. If equipped, the cargo tank corrosionresistant liner must be inspected at leastonce a year. The inspection shall includeprocedures for rubber liners and linersother than rubber (elastomeric materials).The requirements for lining inspectionsare provided in Table L-3100 of this sec-tion;

c. If the cargo tank is not equipped with amanhole or inspection opening, the cargotank shall be subjected to a hydrostatic orpneumatic test as provided in Table L-3100 of this section.

L-3150 LINING INSPECTIONS

Cargo tank linings include rubber linings andlinings other than rubber (elastomeric materi-als) that are used to protect the tank from cor-rosion or other harmful effects of the ladingmaterial being transported. The Inspectionrequirements are:

a. Rubber linings must be inspected for holes

by using a high frequency spark tester,as described in this section. If holes arefound, they must be repaired using equip-ment and procedures prescribed by thelining manufacturer or lining installer;

b. Linings other than rubber (elastomericmaterials) must be inspected and tested in

accordance with procedures using equip-ment and procedures prescribed by thelining manufacturer or lining installers;

c. If degraded or defective areas of thecargo tank lining are discovered, the lin-

ing in these areas shall be removed andthe thickness of the cargo tank wall areaunder the lining defect shall be tested inaccordance with the following:

1. Measurements shall be made using adevice capable of accurately measur-ing thickness to within ± 0.002 of aninch;

2. The individuals performing the thick-ness test must be trained in the properuse of the thickness testing device inaccordance with the manufacturer’sinstructions;

3. The minimum inservice thicknessrequirements for series MC 300 cargotanks for steel and steel alloy and alu-minum and aluminum alloy materialis specified in Tables L-3183-1 andL-3183-2.

L-3160 PRESSURE TESTS

Cargo tanks may be tested by either the hy-drostatic or pneumatic test method. Whenperforming a pressure test, the test procedureshall include the test method (hydrostatic orpneumatic) used for the cargo tank, and thetest shall include all appurtenance, all baffles, bulkheads, and upper coupler (fifth wheel)that comprise the cargo tank and shall bepressure tested at pressures established in

Table L-3161. The pressure test procedureshall include the following:

a. The pressure test shall be performed in ac-cordance with a test pressure that includesprovision for the inspector to perform aninternal and external visual inspection ofall surfaces of the cargo tank. For MC 338

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452.13

cargo tanks, and cargo tanks not equippedwith a manhole, an internal visual inspec-tion is not required.

1. The visual external inspection shall be conducted while the cargo tank is

under test pressure.

2. The visual internal shall be conductedafter the pressure test is completed.

b. When performing the pressure test all self-closing pressure relief valves, includingemergency relief vents, and normal ventsshall be removed for inspection and test.

1. Each self-closing pressure relief valvethat is an emergency relief vent shall be capable of opening at the requiredset pressure and seat to a leak-tightcondition at 90% of the set-to-dis-charge pressure, or the pressure pre-scribed for the applicable cargo tank.It should be noted that self-closingpressure relief valves not tested or fail-ing the pressure test must be repairedor replaced;

2. Normal vents (1 psig vents) shall be

tested according to the testing criteriaestablished by the valve manufac-turer.

c. If the cargo tank is not carrying a corro-sive lading, all areas that are covered bythe upper coupler (fifth wheel) assemblymust be inspected for corroded, abradedareas, dents, distortions, defects in welds,and any other condition that might renderthe tank unsafe for transport service. Theupper coupler (fifth wheel) assembly must

be removed from the cargo tank for thisinspection.

d. If the cargo tank motor vehicle has mul-tiple cargo tanks, each cargo tank shall be tested separately. The adjacent cargotanks shall be empty and at atmosphericpressure.

e. When performing the hydrostatic or pneu-matic test, the following requirementsshall be specified in the test procedure:

1. All closures, except the pressure reliefdevice shall be in place during the

test; 2. All required loading and unloading

venting devices that are rated less thanthe test pressure may be removed dur-ing the test, or:

i. If the venting devices are notremoved, the device shall berendered inoperative by clamps,plugs, or other equally effectiverestraining devices;

ii. The restraining devices shallnot prevent detection of leaks ordamage of the venting device andshall be removed immediatelyafter the test.

L-3161 HYDROSTATIC ORPNEUMATIC TEST METHOD

a. The owner or user of the cargo tank mayeither apply the hydrostatic or pneumatictest method to satisfy the requirements ofthe pressure test specified in Table L-3100 of this section.

If the hydrostatic test method is used, thecargo tank shall be completely filled in-cluding, if equipped, its dome with wateror other liquids having similar viscosity.During the hydrostatic test, the inspectorshall:

1. Ensure that the cargo tank is com-pletely filled and free of any air pock-ets. During this operation, the liquidshould flow freely out of the cargotanks test vent;

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2. Ensure that the temperature of the testmedia does not exceed 100°F;

3. Ensure that the test pressure can notexceed the test pressures specified inTable L-3161;

4. Ascertain that the test pressure shall be maintained for a minimum of 10minutes; and

5. Visually examine the cargo tank forleakage, bulging or other defects. Ifany of the proceeding occurs, termi-nate the test, drain the cargo tank, andevaluate the cargo tanks capabilitiesfor repair or replacement of the af-fected areas.

b. If the owner and/or user elect to use thepneumatic test method, precaution should be employed due the possibility of failureof the cargo tank under pneumatic testpressure conditions. The test area should be limited to authorized personnel onlyand the test personnel shall be experi-enced in the pneumatic testing method.The pneumatic test pressure for the cargotank shall be:

Table L-3161 — Pressure Test Requirements

Cargo Tank Specification Test Pressure

MC 300, MC 301, MC 302, MC 303,MC 305, and MC 306

20.7 kPa (3 psig) or design pressure, whicheveris greater

MC 304 and MC 307 275.8 kPa (40 psig) or 1.5 times design pressure,whichever is greater

MC 310, MC 311, and MC 312 20.7 kPa (3 psig) or 1.5 times design pressure,whichever is greater

MC 330 and MC 331 1.5 times either MAWP or the re-rated pressure,whichever is applicable

MC 338 1.25 times either MAWP or the re-rated pressure,whichever is applicable

DOT 406 34.5 kPa (5 psig) or 1.5 times the MAWP,whichever is greater

DOT 407 275.8 kPa (40 psig) or 1.5 times the MAWP,whichever is greater

DOT 412 1.5 times the MAWP

1. gradually increased to one-half the testpressure;

2. after reaching one-half the test pres-sure, the test pressure shall be in-creased at rate of approximately one-

tenth of the test pressure until the testpressure is reached. The test pressureshall not exceed the test pressuresspecified in Table L-3161;

3. when the test pressure is reached, thetest pressure shall be held for a least 5minutes, then reduced to the MAWPof the cargo tank;

4. at MAWP the inspector shall examinethe cargo tank for any leakage, bulg-ing, or any other defects; and

5. visually examine the cargo tank forleakage, bulging, or other defects. Ifany of the preceeding occurs, termi-nate the test, drain the cargo tank ofall air or inert gas, and evaluate thecargo tanks suitability for repairs orreplacement of the affected areas.

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L-3162 PRESSURE TESTINGINSULATED CARGO TANKS

When pressure testing an insulated cargo tank,the insulations and jacketing are not requiredto be removed, unless it is not possible to reach

the test pressure and maintain a condition ofpressure equilibrium after the test pressureis reached, or the vacuum integrity cannot bemaintained in the insulation space.

For MC 338 cargo tanks that transport flam-mable gas or oxygen, refrigerated liquid ifthe cargo tank is opened for any reason, thecleanliness of the cargo tank shall be verifiedprior to closure as required by CFR Title 49,Part 178.338-15 of.

L-3163 PRESSURE TESTING CARGO TANKS

CONSTRUCTED OF QUENCHED AND TEMPERED

STEELS

When testing MC 330 and MC 331 cargo tanksconstructed of quenched and tempered steels,in accordance with ASME Section XII, ModalAppendix 1, and for cargo tanks constructed

prior to the adoption of ASME Section XII,Part UHT of ASME Section VIII, Div. 1, ofthe ASME Boiler and Pressure Vessel Code , orconstructed of other quenched and temperedsteel, without postweld heat treatment, usedfor the transportation of anhydrous ammo-nia or any other hazardous material that aresubject to stress corrosion cracking, and thetransportation of liquefied petroleum gas thefollowing is required:

a. The cargo tanks must be subjected to an

internal visual inspection of all internalsurfaces of the cargo tank using the wetfluorescent magnetic particle examinationmethod immediately prior to performingthe required pressure test;

b. The fluorescent magnetic particle exami-nation has to be performed in accordancewith ASME Section V of the Boiler andPressure Vessel Code;

c. The required pressure test as specified in

Table L-3100 shall be required.

L-3164 PRESSURE TESTING CARGO TANKS EQUIPPED WITH A HEATING SYSTEM

If the cargo tank is equipped with a heatingsystem, employing a medium such as, but notlimited to steam or hot water hydrostatically,pressure is as follows:

a. The cargo tank must be tested at least onceevery five years;

b. The test pressure for the heating systemshall be at least to the maximum systemdesign operating pressure;

c. The test pressure shall be maintained fora least 5 minutes;

d. If the heating system employs flues for

heating the lading, the flues must be testedto ensure that the lading cannot leak intothe flues or into the atmosphere.

L-3165 EXCEPTIONS TO PRESSURE TESTING

MC 330 and MC 331 cargo tanks are not re-quired to be pressure tested that are in dedi-cated sodium metal service.

Uninsulated cargo tanks, with a design pres-sure or MAWP of 15 psig or less, which can be externally visually inspected and a lininginspection at least once every five years, arenot required to be pressure tested.

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L-3166 ACCEPTANCE CRITERIA

The acceptance criteria for the hydrostatic orpneumatic pressure test of the heating systemis based on the cargo tanks capabilities tosuccessfully pass the pressure test, without

showing evidence of permanent distortion,or other evidence of weakness that mightrender the cargo tank unsafe for transporta-tion service.

If the cargo tank does not satisfy the require-ments for the pressure test of the heatingsystem identified in (a) above, the cargo tankcan not be returned to transportation service,unless:

a. Cargo tanks with a heating system, whichdoes not hold pressure, should remainin-service as an unheated cargo tank ifthe heating system remains in place andis structurally sound and no lading mayleak into the heating system; and

b. The specification information for the heat-ing system on the nameplate is changed toindicate that the cargo tank has no work-ing heating system.

L-3167 INSPECTION REPORT

The Inspector shall prepare a written inspec-tion report which identifies the results of thepressure test and specifies the following:

a. Manufacturer’s serial number of the cargotank;

b. Name of the cargo tank manufacturer;

c. DOT or MC specification number;

d. MAWP of the cargo tank;

e. Minimum thickness of the head and shellof the cargo tank;

f. Identify whether the cargo tank is lined,insulated, or both; and

g. Identify if the cargo tank is for specialservice. i.e., transport material corrosiveto the cargo tank, dedicated service, etc.

The written inspection report shall provide forthe following additional information:

a. The type of test or inspection per-formed;

b. Date of the test or inspection (month andyear);

c. Listing of all items tested or inspected, in-cluding information about pressure reliefvalve:

1. If the relief valve is removed, inspect-ed and tested or replaced;

2. If applicable, type of the device;

3. Set to discharge pressure at which thedevice will reseat;

4. If the device was reinstalled, repaired,

or replaced;

d. Information regarding the inspection ofthe upper coupler (fifth wheel) assembly,and when applicable:

1. If the coupler assembly (fifth wheel)visually inspected in place; or

2. If the coupler assembly (fifth wheel)removed for examination.

e. Information regarding leakage, and typeof pressure test (hydrostatic or pneu-matic);

f. The test pressure and holding time duringthe test;

g. Location of defects found and the methodof repair;

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h. Minimum thickness of the cargo tanksheads and shells, as specified in Table L-3183-1 or Table L-3183-2 , as applicable;

1. Name and address of the person per-forming the test;

2. Registration number of the facility orperson performing the test;

3. Continued qualification statement,such as:

i. “cargo tank meets the require-ments of DOT specification identi-fied in this report”; or

ii. “cargo tank fails to meet the re-quirements of the DOT specifica-tion identified in this report.”

i. DOT registration number of the registeredinspector, and dated signature of theregistered inspector and the cargo tankowner.

The owner and the motor carrier shall retaina copy of the test and inspection reports untilthe next test or inspection of the same type

is successfully completed. This requirementdoes not apply to a motor carrier leasing acargo tank for fewer than 30 days.

L-3168 ADDITIONALREQUIREMENTS FOR MC 330

AND MC 331 CARGO TANKS

After completion of the pressure test, eachmotor carrier operating a Specification MC330 and MC 331 cargo tank in anhydrous am-

monia, liquefied petroleum gas, or any otherservice that is prone to stress corrosion crack-ing, shall make a written report containing thefollowing information:

a. Carrier’s name, address of principal placeof business, and telephone number;

b. Complete identification plate data re-quired by Specification MC 330 and MC331 cargo tanks, including data required by the ASME Boiler and Pressure VesselCode;

c. Carrier’s equipment number;

d. Statement indicating whether or not thecargo tank was stress relieved after fabri-cation;

e. Name and address of the person perform-ing the test and date of the test;

f. Statement of the nature and severity ofany defects found. As a minimum, theinformation shall include:

1. identification of the location of thedefects detected, such as in weld,heat-affected zone, the liquid phase,the vapor phase, or the head to shellseam; or

2. If no defects or damage was discov-ered, this also shall be reported.

g. Statement indicating the methods em-

ployed to make repairs; that made therepairs; and the date the repairs werecompleted. If the cargo tank was stressrelieved after the repairs were completed,whether full or local stress relieving wasperformed;

h. Statement of the disposition of the cargotank, such as:

1. “cargo tank scrapped”; or

2. “cargo tank returned to service.”

i. Statement whether or not the cargo tankis used in anhydrous ammonia servicethat is subject to stress corrosion crack-ing. If the cargo tank had been used inanhydrous ammonia service since the last

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report, the owner has to provide a state-ment in the report indicating whether eachshipment of ammonia was certified by itsshipper as containing at least 0.2 % water by weight;

j. A copy of the written inspection reportmust be retained by the carrier at its prin-cipal place of business during the periodthe cargo tank is in the carrier’s serviceand for one year there after.

Upon written request to and with the ap-proval of the Field Administrator, RegionalService Center, Federal Motor Carrier SafetyAdministration for the region in which amotor carrier has its principal place of busi-ness, the carrier may maintain the reports ata regional or terminal office.

L-3169 CERTIFICATES ANDREPORTS

Each person offering a DOT specificationcargo tank for sale or lease must provide thepurchaser or lessee with the following:

a. A copy of the cargo tank certificate of

compliance;

b. If applicable, a copy of the record of repair,modification, stretching, or rebarrelling;

c. The most recent inspection and testreports.

Copies of the documents and reports identi-fied in (a) above must be provided to the les-see if the cargo tank is leased for more than30 days.

L-3170 LEAKAGE TEST

When leakage testing is required by TableL-3100 of this section, the test shall include

testing the product piping with all valvesand accessories in place and operative, exceptthat any venting devices set to discharge atless than the leakage test pressure must beremoved or rendered inoperative during thetest. The leakage test shall include:

a. All internal or external self-closing stopvalves must be tested for leakage;

b. Each cargo tank of a multi-cargo tankmotor vehicle must be tested with theadjacent cargo tanks empty and at atmo-spheric pressure;

c. The leakage test shall be maintained for aminimum of five minutes;

d. Cargo tanks in liquefied compressed gasservice shall be:

1. Inspected externally for leaks duringthe leakage test;

2. Suitable safeguards must be providedto protect personnel should a failureoccur, as follows:

i. Cargo tanks may be leakage tested

with the hazardous material in thecargo tank during the test;

ii. The leakage test pressure shall not be less than 80% of the MAWPmarked on the specification plate,unless the cargo tank has a MAWPof 690 kPa (60 psig) or more,should be leak tested at its maxi-mum normal operating pressureprovided it is in dedicated serviceor services;

iii. MC 330 or MC 331 cargo tanks indedicated liquefied petroleum gasservice may be leakage tested atnot less than 414 kPa (60 psig);

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iv. An operator of a MC 330 or MC331cargo tank and a non-specificationcargo tank equipped with a metershould check leak tightness of theinternal self-closing stop valve byconducting a meter creep test;

v. A non-specification cargo tank isa cargo tank that conforms andis marked in conformance withthe edition of the ASME Code ineffect when the cargo tank wasfabricated and should be usedfor the transportation of liquifiedpetroleum gas, provided the cargotanks satisfies the following:

a. The cargo tank has a minimumdesign pressure no lower than250 psig;

b. The cargo tank has a watercapacity of 13,247.5 L (3500gallons) or less.

e. The cargo tank has been manufactured inaccordance with the ASME Code prior to January 1, 1981. This requirement requiresthe cargo tank to be stamped with the

ASME Code Symbol Stamp and docu-mented on an ASME Manufacturer’s DataReport;

f. The cargo tank shall conform to the ap-plicable provisions of NFPA 58, exceptif NFPA is inconsistent with the require-ments of Parts 178 and 180 of Title 49;

g. The cargo tank shall be leakage tested inaccordance with Table L-3100 of this sec-tion;

h. MC 330 and MC 331 cargo tanks in dedi-cated service for anhydrous ammonia may be leakage tested at not less than 414 kPa(60 psig);

i. Non-specification cargo tanks must beleakage tested at pressure of not less than16.6 kPa (2.4 psig), if the cargo tanks com-plies with one of the following:

1. For the transport of petroleum prod-

ucts that have a liquid capacity of13,250 L (3500 gallons);

2. Permanently secured non-bulk tanksto a motor vehicle and protectedagainst leakage or damage in the eventof turnover, having a liquid capacity ofless than 450 L (119 gallons), used fortransportation of a flammable liquidpetroleum product.

The cargo tank is used to transport petroleumdistillate fuels that are equipped with a vaporcollection equipment and should be leakagetested in accordance with the EnvironmentalProtection Agency’s “Model 27-Determinationof Vapor Tightness of Gasoline Delivery TankUsing Pressure-Vacuum Test”, as follows:

a. The test method and procedures and max-imum allowable pressure and vacuumchanges are in 40 CFR 63.425(e)(1);

b. The hydrostatic test alternative, using liq-uid in Environmental Protection Agency’s“Method 27-Determination of VaporTightness of Gasoline Delivery Tank Us-ing Pressure-Vacuum Test” should not beused to satisfy the leak testing require-ments of this section. The test shall beconducted using air;

c. Cargo tanks equipped with vapor collec-tion equipment should be leakage testedin accordance with (2) above.

Cargo tanks that fails to retain leakage testpressure shall not be returned to service asa specification cargo tank, unless all sourcesof leakage are properly repaired prior to re-turning the cargo tank to hazardous materialservice.

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It is required that after July 1, 2000, that theRegistered Inspector that performs inspectionon MC 330 and MC 331 cargo tanks inspect thedelivery hose assembly and the piping systemof the cargo tank under leakage test pressureutilizing the rejection criteria for cargo tanks

unloading liquefied compressed gas. It should be noted that an operator should remove andreplace damaged sections or correct defectsdiscovered as provided in L-3180 of this sec-tion. If any of the following is discovered, itis cause for rejection:

a. No operator shall use a delivery hose as-sembly for liquefied compressed gas if itis determined that any of the followingconditions exist:

1. Damage to the hose cover that exposesthe reinforcement;

2. If the wire braid reinforcement iskinked or flattened so as to perma-nently deform the wire braid;

3. Soft spots when the hose is not underpressure, or any loose outer coveringon the hose;

4. Damaged, slipping, or excessivelyworn hose couplings;

5. Loose or missing bolts or fastenings onthe bolted hose coupling assembly.

b. No operator can use a cargo tank with apiping system for unloading liquefiedcompressed gasses if any of the followingconditions exist:

1. Any external leaks identifiable with-

out the use of instruments;

2. Bolting that is loose, missing, or se-verely corroded;

3. Manual stop valves that will notactuate;

4. Rubber hose flexible connectors withany of the following conditions:

i. damaged to the hose cover thatexposes the reinforcement;

ii. if the wire braid reinforcement iskinked or flattened so as to perma-nently deform the wire braid;

iii. soft spots when the hose is underpressure, or any loose out coveringon the hose;

iv. damaged, slipping, or excessivelyworn hose couplings;

v. loose or missing bolts or fasten-ings on the bolted hose couplingassembly.

5. Stainless steel flexible connectors withdamaged reinforcement braid;

6. Internal self-closing stop valves thatfail to close or that permit leakagethrough the valve detectable withoutthe use of instruments;

7. Pipes or joints that are severely cor-roded.

L-3180 NEW OR REPLACEDDELIVERY HOSEASSEMBLIES

The operator shall repair hose assembliesand place the cargo tank back inservice ifretested successfully in accordance with thefollowing:

a. The new and/or replaced hose assembly istested at a minimum of 120% of the hose’sMAWP;

b. The operator shall visually examine thedelivery hose assembly while its underpressure;

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c. If the test is successful, the operator shallassure that the delivery hose assembly ispermanently marked with the month andyear of the test;

d. It should be noted that after July 1, 2000,

the operator shall complete a record docu-menting the test and inspection, whichshall include the following:

1. The date and signature of the Inspec-tor that performed the inspection;

2. The owner of the hose assembly;

3. The hose identification number;

i. The date of the original deliveryof the hose assembly and tests;

ii. Notes of any defects observed;

iii. Any repairs that may have beenmade; and

iv. Identification in the written reportthat the delivery hose assemblypassed or failed the tests and in-spections.

L-3181 THICKNESS TESTING

Thickness testing of the head and shell of un-lined cargo tanks used for the transportationof materials corrosive to the cargo tank shall be measured at least once every two years.

Cargo tanks measuring less than the sum ofthe minimum prescribed thickness in TablesL-3183-1 , or L-3183-2 as applicable plus one-

fifth of the original corrosion allowance shall be tested annually.

L-3182 TESTING CRITERIA

The testing criterion that shall be used forthese requirements is as follows:

a. The measuring device shall be capable of

accurately measuring thickness to within± 0.002 of an inch;

b. The individuals performing thicknesstesting shall be trained in the properuse of the thickness testing device usedin accordance with the testing devicemanufacturer’s instructions;

c. Thickness testing shall be performed inthe following areas, as a minimum:

1. Areas of the tank shell and heads, in-cluding around any piping that retainslading;

2. Areas of high shell stress, such as the bottom center of the cargo tank;

3. Areas near openings;

4. Areas around weld joints;

5. Areas around shell reinforcements;

6. Areas around appurtenance attach-ments;

7. Areas near the upper coupler (fifthwheel) assembly attachments;

8. Areas near suspension system attach-ments and connecting structures.

d. Known thin areas in the tank shell and

nominal liquid level lines; and

e. Connecting structures joining multiplecargo tanks of carbon steel in a self-sup-porting cargo tank motor vehicle.

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L-3183 THICKNESS REQUIREMENTS

a. The minimum thickness for MC 300, MC301, MC 302, MC 303, MC 304, MC 305,MC 306, MC 307, MC 310, and MC 312cargo tanks are determined based on the

definition of minimum thickness definedin CFR, Title 49, Part 178.320(a).

b. Tables L-3183-1 and L-3183-2 identify the“Inservice Minimum Thickness” values to be determined the minimum thickness forthe referenced cargo tank.

c. The tables are divided into three columns.The column headed “Minimum Manufac-tured Thickness” indicates the minimumvalues required for new construction ifDOT 400 series cargo tanks.

d. The Inservice minimum thicknesses forcargo tanks specified in (a) above are based on 90% of the manufactured thick-ness specified in the DOT Specification,rounded off to three places.

L-3190 CARGO TANKS THAT NO LONGER CONFORM TO THE

MINIMUM THICKNESS REQUIREMENTS IN TABLES L-3183-1 AND L-3183-2

If a cargo tank does not conform to theminimum thickness requirements in TablesL-3183-1 and L-3183-2 for the design asmanufactured, the cargo tank should be usedat a reduced maximum weight of lading orreduced MAWP, or combinations thereof,provided the following is met:

a. The cargo tank’s design and thicknessare appropriate for the reduced loadingsconditions as follows:

1. The cargo tank’s design and thicknessfor the appropriate reduced loadingshall be certified by a Design Certify-ing Engineer;

2. A revised manufacturer ’s certificateshall be issued; and

3. The cargo tanks motor vehicle’s name-plate shall reflect the revised servicelimits.

It is required if a cargo tank no longer con-forms with the minimum thickness require-ments prescribed in the specification, that thecargo tank cannot be returned to hazardousmaterial service. The cargo tank’s specificationplate shall be removed, obliterated, or coveredin a secure manner. The inspector shall requirethat the cargo tank is calculated to identify thethickness of the material as required in L-3166and L-3167 of this section.

MC cargo tanks constructed prior to October1, 2003, requires that the minimum thickness,minus the corrosion allowance as provided onthe Manufacturer’s Data Report.

MC cargo tanks constructed after October 1,2003, requires that the minimum thicknesswill be the value indicated on the specifica-tion plate of the cargo tank. If no corrosionallowance is indicated on the Manufacturer’sData Report, then the thickness of the cargo

tank shall be the thickness of the material ofconstruction indicated on the Manufacturer’sData Report, with no corrosion allowance.

L-3191 MINIMUM THICKNESS FOR 400 SERIES CARGO TANKS

400 series cargo tanks are required to satisfythe minimum thickness requirements as es-tablished in Part 178.320(a) of Title 49 for DOT406 cargo tanks, Part 178.347.2 of Title 49 for

DOT 407 cargo tanks and Part 178.348.2 ofTitle 49 for DOT 412 cargo tanks.

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Table L-3183-1 — Inservice Minimum ThicknessesFor Steel and Steel Alloys

Minimum manufacturedthickness (US gage or inches)

Nominal decimalequivalent for inches

Inservice minimumreference (inches)

19 0.0418 0.038

18 0.0478 0.04317 0.0538 0.048

16 0.0598 0.054

15 0.0673 0.061

14 0.0747 0.067

13 0.0897 0.081

12 0.1046 0.094

11 0.1196 0.108

10 0.1345 0.121

9 0.1495 0.135

8 0.1644 0.1487 0.1793 0.161

3/16 0.1875 0.169

1/4 0.2500 0.225

5/16 0.3125 0.281

3/8 0.3750 0.338

Table L-3183-2 — Inservice Minimum Thicknesses For Aluminumand Aluminum Alloys

Minimum manufactured thickness Inservice minimum thickness (inches)0.078 0.070

0.087 0.078

0.096 0.086

0.109 0.098

0.130 0.117

0.141 0.127

0.151 0.136

0.172 0.155

0.173 0.156

0.194 0.1750.216 0.194

0.237 0.213

0.270 0.243

0.360 0.324

0.450 0.405

0.540 0.486

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L-3192 DOT 406 CARGO TANKS

a. It is required that all heads, shells, bulk-heads, and baffles materials used in theconstruction of DOT 406 cargo tanks satis-fy Parts A and B of Section II of the ASME

Boiler and Pressure Vessel Code , except thatthe following materials are authorizedfor cargo tanks constructed in accordancewith ASME Boiler and Pressure Vessel Code that are not stamped with the “U” CodeSymbol Stamp should be constructedout of ASTM materials specified in Part178.345-2 of Title 49. These materials areas follows:

• ASTM A 569• ASTM A 570• ASTM A 572• ASTM A 607• ASTM A 622• ASTM A 656• ASTM A 715

Aluminum alloys suitable for fusion weld-ing and conforming with the O, H 32, or H34 temper of one of the following ASTMSpecifications may be used for cargo tanksconstructed in accordance with the ASME

Boiler and Pressure Vessel Code:

• ASTM B 209, Alloy 5052• ASTM B 209, Alloy 5086• ASTM B 209, Alloy 5154• ASTM B 209, Alloy 5254• ASTM B 209, Alloy 5454• ASTM B 209, Alloy 5652

All heads, bulkheads, and baffles must be ofO temper (annealed) or stronger temper. Allshell material shall be of H 32, or H 34 temper,

except that the lower ultimate strength tempershould be used if the minimum shell thicknessin the tables are increased in proportion to thelesser ultimate strength.

b. Table L-3192-1 specifies the minimumthickness requirements for heads or

bulkheads and baffles when used as tankreinforcement be based on the volumecapacity in gallons per inch of length forMC 406 cargo tanks constructed out ofMild Steel (MS), High Strength Low AlloySteel (HSLA), Austenitic Stainless Steel

(SS), or Aluminum (AL).

c. Table L-3192-2 specifies the minimumthickness requirements for shell basedon the cargo tank motor vehicle ratedcapacity in gallons when the cargo tank isconstructed out of Mild Steel (MS), HighStrength Low Alloy Steel (HSLA), Aus-tenitic Stainless Steel (SS), or Aluminum(AL). The thickness requirements in thesetables are specified in decimal of an inchafter forming.


a. It is required that the type of materialsused for DOT 407 cargo tanks, dependingon the type of media being transferred beeither Mild Steel (MS), High Strength LowAlloy Steel (HSLA), Austenitic StainlessSteel (SS), or Aluminum.

b. The minimum required thickness ofmaterials specified in Table L-3193-1 forDOT 407 cargo tanks, when the minimumthickness requirements are based on thevolume capacity in gallons per square inchfor the cargo tank’s heads, or bulkheadsand baffles, when these item are used forreinforcement purposes. All thicknessesare expressed in decimals of an inch afterforming

c. The minimum required thickness of

materials specified in Table L-3193-2 forDOT 407 cargo tanks, when the minimumthickness requirements are based on thevolume capacity in gallons per square in.for the cargo tanks shell. All thicknessesare expressed in decimals of an inch afterforming

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Table L-3192-1 — Minimum Thickness for Heads

Materials

Volume capacity in gallons per inch of length

14 or less Over 14 to 23 Over 23

MS HSLASS

AL MS HSLASS

AL MS HSLASS

AL

Thickness .100 .100 .160 .115 .155 .173 .129 .129 .187

Table L-3191-2 — Minimum Thickness for Shells

Cargo tank motor vehicle rated capacityin gallons MS SS/HSLA AL

More than 0 to at least 4,500 0.100 0.100 0.151

More than 4,500 to at least 8,000 0.115 0.100 0.160

More than 8,000 to at least 14,000 0.129 0.129 0.173

More than 14,000 0.143 0.143 0.187

Note: The maximum distance between bulkhead, baffles, or ring stiffeners shall not exceed 60 inches

Table L-3193-1 — Minimum Thickness for Heads (DOT 407)

Volume capacityin gallonsper square inch 10 or less

Over10 to 14

Over14 to 18

Over18 to 22

Over22 to 26

Over26 to 30 Over 30

Thickness (MS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156

Thickness (HSLA) 0.100 0.100 0.115 0.129 0.129 0.143 0.156

Thickness (SS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156

Thickness (A) 0.160 0.160 0.173 0.187 0.194 0.216 0.237

Table L-3193-2 — Minimum Thickness for Shells (DOT 407)

Volume capacityin gallonsper square inch 10 or less

Over10 to 14

Over14 to 18

Over18 to 22

Over22 to 26

Over26 to 30 Over 30

Thickness (MS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156

Thickness (HSLA) 0.100 0.100 0.115 0.129 0.129 0.143 0.156

Thickness (SS) 0.100 0.100 0.115 0.129 0.129 0.143 0.156

Thickness (A) 0.151 0.151 0.160 0.173 0.194 0.216 0.237

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a. It is required that the type of materialsused for DOT cargo tanks, depending onthe type of media being transferred beeither Mild Steel (MS), High Strength Low

Alloy Steel (HSLA), Austenitic StainlessSteel (SS), or Aluminum.

b. The minimum required thickness ofmaterials specified in Table L-3194-1 forDOT 412 cargo tanks, when the minimumthickness requirements are based on thevolume capacity in gallons per squareinch for cargo tanks head, or bulkheadsand baffles, when these items are used forreinforcement purposes. All thicknessesare expressed in decimals of an inch afterforming

c. The minimum required thickness ofmaterials specified in Table L-3194-2 forDOT 412 cargo tanks, when the minimumthickness requirements are based on thevolume capacity in gallons per square infor the cargo tank’s shell. All thicknessesare expressed in decimals of an inch afterforming.

L-3200 INSPECTION AND TESTS OF PORTABLE TANKS

For hazardous material ladings, all portabletanks shall be inspected and tested at frequen-cies specified in Table L-3210. The inspectionand tests shall include visual inspection ofexternal and internal surfaces, leak test, pres-sure test, thickness measurements, and liningtest. It should be noted that the informationin L-3210 is a summary of CFR Title 49, Part

180.601 through Part 180.605. The user is re-sponsible for full compliance with the require-ments in CFR Title 49, Part 180.601 throughPart 180.605.

All portable tanks shall be visually inspected(internal, unless otherwise noted, and exter-nally) for any evidence of dents, corroded orabraded areas, leakage, or any other conditionthat might render the portable tank unsafe fortransportation service. The inspection shall

include:

a. Inspection of the shell for pitting, corro-sion or abrasions, dents, distortions orabrasions, defects in welds, or any otherconditions, including leakage;

b. Inspection of the piping, valves, and gas-kets for corroded areas, defects, and otherconditions, including leakage that may be unsafe during filling and discharge ortransportation.

In addition to the required frequencies es-tablished in Table L-3210 , it is required thatportable tanks be inspected and tested whenany of the following occurs.

a. The portable tank has been in an accidentand has been damaged to an extent thatmay adversely affect the portable tank’sability to retain hazardous materials;

b. The portable tank has been out of hazard-ous material transportation service for aperiod of one year or more;

c. The portable tank has been modified fromits original design specification; and

d. The portable tank is in an unsafe operat-ing condition based on the existence ofobserved damage, leaks, or missing safetydevices, etc.

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5 2 .2 7

Table L-3194-1 — Minimum Thickness for Heads (DOT 412)

Volume capacity (gallons per inch) 10 or less Over 10 to 14 Over 14 to

Lading density at 60°F in poundsper gallon

10 lbsandless

Over10 to13 lbs

Over13 to16 lbs

Over16 lbs

10 lbsandless

Over10 to13 lbs

Over13 to16 lbs

Over16 lbs

10 lbsandless

Over10 to13 lbs

Thickness (inch), steel 0.100 0.129 0.157 0.187 0.129 0.157 0.187 0.250 0.157 0.250

Thickness (inch), aluminum 0.144 0.187 0.227 0.270 0.187 0.227 0.270 0.360 0.227 0.360

Table L-3194-2 — Minimum Thickness for Shells (DOT 412)

Volume capacity (gallons per inch) 10 or less Over 10 to 14 Over 14 to

Lading density at 60°F in poundsper gallon

10 lbs

andless

Over

10 to13 lbs

Over

13 to16 lbs Over16 lbs

10 lbs

andless

Over

10 to13 lbs

Over

13 to16 lbs Over16 lbs

10 lbs

andless

Over

10 to13 lbs

Thickness (inch), steelDistances between heads (and bulk-heads, baffles, and ring stiffeners whenused as tank reinforcement

0.129 0.157 0.187 0.250 0.157 0.250

36 in. or less 0.100 0.129 0.157 0.187 0.100 0.129 0.157 0.187 0.100 0.129

Over 36 in. to 54 in. 0.100 0.129 0.157 0.187 0.100 0.129 0.157 0.187 0.129 0.157

Over 54 in. to 60 in. 0.100 0.129 0.157 0.187 0.129 0.157 0.187 0.250 0.157 0.250

Thickness (inch), aluminumDistances between heads (and bulk-heads, baffles, and ring stiffeners when

used as tank reinforcement

0.144 0.187 0.227 0.270 0.187 0.227 0.270 0.360 0.227 0.360

36 in. or less 0.144 0.187 0.227 0.270 0.144 0.187 0.227 0.270 0.144 0.187

Over 36 in. to 54 in. 0.144 0.187 0.227 0.270 0.144 0.187 0.227 0.270 0.187 0.227

Over 54 in. to 60 in. 0.144 0.187 0.227 0.270 0.187 0.227 0.270 0.360 0.227 0.360

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452.28

L-3210 PERIODIC INSPECTIONAND TEST

Portable tanks shall be tested and inspectedin accordance with the frequency set forth inTable L-3210 and the procedures set forth in

Section L-3230 through L-3264.

L-3220 INTERMEDIATE PERIODIC INSPECTION AND TEST

Intermediate periodic inspections and testingshall be performed in accordance with TableL-3210. The intermediate periodic inspectionand testing shall include:

a. An external and an internal inspection ofthe portable tank and its fittings takinginto the account the hazardous materials being transported;

b. A leakage test of the transport tank; and

c. A test for satisfactory operation of allservice equipment.

When inspecting portable tanks equippedwith sheathing and thermal insulation, etc.,

the insulation need only be removed to the

extent required for a reliable appraisal of thecondition of the portable tank

For portable tanks intended for the trans-portation of a single hazardous material, theinternal inspection may be waived if the por-

table tank is subjected to a leakage test that isperformed in accordance with L-3230 of thissection prior to each filling.

Portable tanks used for dedicated transporta-tion of refrigerated liquefied gases that are notfitted with inspection openings are exemptfrom the internal inspection requirements, but shall be externally inspected.

L-3230 INTERNAL AND EXTERNAL INSPECTIONS

All portable tanks that are subject to five yearperiodic inspection and testing (pressure test)are required to be inspected, both internally,unless exempt, and externally. The internaland external inspection shall include:

a. Sheathing, thermal insulation, etc. Thesheathing and thermal insulation needonly be removed to the extent required

for reliable appraisal of the condition ofthe portable tank.

Table L-3210 — Inspection Intervals

Specification Periodic Inspection and Test1

Intermediate PeriodicInspection and Test2

IM or UN Portable Tanksonce placed in service

5 years 2-1/2 years

DOT 51 Portable Tanks 5 years —

DOT 56 or DOT 57 Portable Tanks(The first periodic inspection and test is

required 4 years after being placed intoservice and each 2-1/2 years thereafter.)

2-1/2 years —

DOT 60 Portable Tanks(The first periodic inspection and test isrequired 4 years after being placed intoservice and then per the schedule to theright.)

For the first 12 yearsof service.................................2 years

After 12 yearsof service..................................Yearly

1 Retesting is not required on a rubber lined tank, except before relining.2 For IM and UN Portable Tanks, periodic inspection and test shall include at least an internal and external of the portable tank and fittings, taking into account the hazardous material intended to be transported.

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452.29

b. Except for DOT Specification 56 and 57portable tanks, all reclosing pressurerelief devices must be removed from thetank and tested separately unless they can be tested while installed on the portabletank.

c. For portable tanks where the shell andequipment have been pressure testedseparately after assembly, the portabletank shall be subjected to a leakage testand effectively tested and inspected forcorrosion.

d. Portable tanks used for the transporta-tion of refrigerated, liquefied gases areexempt from the internal inspection andthe hydrostatic test or other pressure testduring the 5 year periodic inspection ifthe portable tank was originally testedto a minimum test pressure of 1.3 timesthe design pressure using inert gas andprovided that:

1. The portable tank and its appurte-nances were constructed to ASMESection XII, or ASME Section VIII,Division 1; the portable tank shall beinspected in accordance with the ap-

plicable requirements of this Code.

2. Portable tanks shall be either hydro-statically or pneumatically tested withthe formula 1.5 x design pressure +static head + 14.7 psi, if the tank isdesigned for external pressure.

3. The portable tank shall be subjected toeither a hydrostatic or pneumatic testat a test pressure of 1.5 x the sum ofthe design pressure + the static head

of lading + 14.7 psi, if subjected to ex-ternal vacuum. If the portable tank isconstructed in accordance with ASMESection XII or Part UHT of ASME Sec-tion VIII, Div. 1, the test pressure shall be twice the design pressure.

4. A pneumatic test may be used in lieuof a hydrostatic test if the followingconditions are met:

i. The owner/user has taken neces-sary precautions to ensure the

safety of the inspection and testpersonnel;

ii. The pneumatic test pressure shall be reached gradually by increas-ing the test pressure to one-half ofthe test pressure. Once this pres-sure is reached, the test pressurewill be increased in incrementsof approximately one-tenth of thetest pressure until the required testpressure is reached; and

iii. When the test pressure is reached,the test pressure shall be reducedto at least four-fifths of the testpressure and held for a sufficienttime to permit inspection of theportable tank.

L-3240 EXCEPTIONAL INSPECTION AND TEST

Exceptional inspection and test is necessarywhen a portable tank shows evidence of dam-age, corroded areas or leakage, or other con-ditions that indicate a deficiency that couldaffect the integrity of the portable tank.

The extent of the exceptional inspection andtest shall depend on the amount of deterio-ration of the portable tank. The exceptionalinspection and test shall include the require-ments of L-3230 of this section.

Pressure relief devices do not need to beincluded in this test unless there is reason to believe the relief device has been affected bydamage or deterioration.

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452.30

L-3250 INTERNAL AND EXTERNAL INSPECTION PROCEDURE

An internal and external inspection, whenrequired, shall be performed by the owner-user. The inspection shall be conducted by

the Inspector. This individual shall ensurethat the portable tank is safe for continuedtransportation service. The Inspector shallevaluate the results of the inspection and re-port the applicable findings. The inspectionshall include:

a. Inspection of the shell for pitting, cor-rosion or abrasions, dents, distortions,defects in welds, or any other conditions,including leakage;

b. Inspection of the piping, valves, and gas-kets for corroded areas, defects, and otherconditions, including leakage that mightmake the portable tank unsafe for filling,discharge or transportation;

c. The tightening devices for manhole coversare operative and there is no leakage at themanhole cover or gasket;

d. Missing or loose bolts or nuts on any

flanged connections including pipingflanges, pressure relief device connectionsor blank flanges. If any bolts are looseor missing, these shall be tightened orreplaced;

e. All emergency devices and valves toensure that they are free from corrosion,distortion and any damage or defects thatcould prevent the devices from operatingas designed;

f. All remote closures and self-closing stopvalves shall be operated to demonstratetheir proper operation;

g. The required markings on the portabletanks shall be legible and in accordance

with the applicable requirements of CFRTitle 49, Part 178.3, and Part 180.605;

h. The framework, supports and the ar-rangements for lifting the portable tankto ensure that they are in a satisfactory

condition.

L-3260 PRESSURE TESTSPROCEDURES FORSPECIFICATION 51, 57, 60, IM

OR UN PORTABLE TANKS

This section provides the requirements forpressure test procedures for Specification 51,57, 60, IM or UN Portable Tanks as providedin CFR Title 49, Part 180.605(h). Pressure testrequirements for Specification 51, 57, 60, IMand UN Portable Tanks are identified in TableL-3260 of this subsection.

L-3261 SPECIFICATION 57PORTABLE TANKS

Specification 57 portable tanks shall be leaktested by a minimum sustained air pressure ofat least 3 psig applied to the entire tank.

During each air pressure test, the entire sur-face of all joints, whether welded or threadedshall be coated with or immersed in a solutionof soap and water, heavy oil, or other materialsuitable for the purpose of detecting leaks.

The test pressure shall be held for a minimumof five minutes plus any additional time re-quired to examine all portions of the portabletank.

During the air test, the pressure relief devicemay be removed or left in place. If the reliefdevice is left in place during the test, the de-vice’s discharge opening shall be plugged.

All closure fittings must be in place duringthe pressure test.

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452.31

Table L-3260 — Pressure Testing Requirements

Specification Leak Test Hydrostatic Pneumatic Test Media Minimum Test Pressure

51 and 56 — X X Liquid or Air 2 psi or at least 1-1/2times the design pressure,whichever is greater

51 and 56 used fortransport refrigeratedliquified gas

X X X Liquid or Air 90% of the MaximumAllowable WorkingPressure

51 and 56 for thetransport of all othermaterials

— X X Liquid or Air 25% of the MaximumAllowable WorkingPressure

57 X — — — 3 psi to the entire tank

60 — — — Water or othersimilar liquid

60 psig

UN nonrefrigeratedgases

— — — Water 130% of Maximum Allow-able Working Pressure

UN refrigerated gases — X X Water or Air 1.3 times design pressure

IM refrigerated or non-refrigerated liquifiedgases

— X X Water or Air 150% of the MaximumAllowable WorkingPressure

If the portable tank is lagged or insulated,the lagging or insulation does not have to beremoved if it is possible to maintain the re-quired test pressure at a constant temperaturewith the portable tank disconnected from thesource of pressure.

L-3262 SPECIFICATION 51 OR 56 PORTABLE TANKS

Specification 51 or 56 portable tanks shall betested using either air or liquid. The minimumtest pressure shall be at least 2 psig or at leastone and one half times the maximum allow-able working pressure (or re-rated pressure)of the portable tank. The greater test pressureshall be used.

The leak testing of all refrigerated liquefiedgas tanks shall be performed at 90% of themaximum allowable working pressure of theportable tank.

Leak testing for all other portable tanks shall be at a test pressure of at least 25% of themaximum allowable working pressure of theportable tank.

If the portable tank is hydrostatically tested,

the entire surface of the portable tank shall beinspected for leaks. This includes all welded joints and threaded connections. The require-ments below shall be followed for hydrostatictesting:

a. The hydrostatic test pressure shall be heldfor a minimum of 5 minutes plus anyadditional time required to complete theinspection;

b. The pressure relief device should be

removed or left in place during the hy-drostatic test. If the relief device is left inplace during the test, the device shall beisolated to avoid the relief device fromdischarging in accordance with the devicemanufacturer’s recommendations;

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452.32

c. It is required for DOT 51 specificationtanks that the relief valve be removedduring the pressure test;

d. All closure fittings shall remain in placeduring the hydrostatic test.

If the portable tank is pressure tested by air,during the test all surfaces of welded jointsand thread connections of the portable tankshall be inspected for leaks and the followingprocedure shall be followed:

a. All welded joints and threaded connec-tions shall be coated with or immersed ina solution of soap and water, or heavy oilor other material suitable for the purposeof detecting leaks;

b. The air test pressure shall be held for aminimum of five minutes. This time pe-riod should be increased if so required bythe Inspector;

c. The pressure relief device should be re-moved or left in place during the air test.If the relief device is left in place duringthe test, the device shall be isolated toavoid the pressure relief device from dis-

charging in accordance with the devicemanufacturer’s recommendations;

d. For Specification 51 portable tanks, therelief device shall be removed during thepressure test;

e. All closure fittings shall remain in placeduring the air test.

If the portable tank is lagged or insulatedand the pressure test performed is either hy-

drostatic or pneumatic, it is not necessary toremove the lagging or insulation for pressuretesting provided the decay in test pressurecan be measured at a constant temperaturewhile the portable tank is disconnected fromthe source of pressure.

L-3263 SPECIFICATION 60PORTABLE TANKS

Specification 60 portable tanks shall be tested by completely filling the portable tank withwater or other liquid having a similar viscos-

ity. The test procedure shall include:

a. The temperature of the liquid shall notexceed 37.7°C (100°F) during the test;

b. The test pressure applied shall be at least60 psig;

c. The test pressure shall be maintained fora minimum of 10 minutes. This time pe-riod may be increased if required by theInspector;

d. During the 10-minute time period, theportable tank shall be capable of maintain-ing the test pressure with no evidence ofleakage;

e. All closures shall be left in place while thepressure test is being performed;

f. The pressure gage shall be located at thetip of the vessel during the test; and

g. Reclosing pressure relief devices must be removed from the tank and testedseparately unless they can be tested whileinstalled on the portable tank.

L-3264 SPECIFICATION IM ORUNPORTABLE TANKS

All Specification IM or UN Portable Tanks,except for UN Portable Tanks used for non-

refrigerated and refrigerated liquefied gases,and all piping, valves, and accessories, exceptpressure relief devices shall be hydrostaticallytested with water, or other liquid similar indensity and viscosity as follows:

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452.34

g. If the portable tank is damaged or a defi-ciency is discovered that might render theportable unsafe, the tank shall be repairedto a satisfactory condition. This test shall be witnessed by the applicable approvalagency. As a minimum, the repair proce-

dures shall include:

1. Retesting to the original pressure testrequirements;

2. If the hydrostatic or pneumatic test issuccessful, the witnessing approvalagency shall apply its name, identi-fying mark, or identifying numberon the portable tank’s nameplate asrequired in L-3270 of this section.

All thermal cutting or welding on the shellof IM or UN portable tanks shall be done inaccordance with this section. After completionof the thermal cutting or welding operation,a pressure test shall be performed to the re-quirements of the portable tank’s original testrequirements.

L-3270 INSPECTION AND TEST MARKINGS FOR IM OR

UN PORTABLE TANKS

Each IM or UN portable tank shall be durablyand legibly marked, in English, with the date(month and year) of the last pressure test.

The identifying agency shall witness the test,when required, and the date of the last visualinspection.

The markings required on the portable tank’sidentification plate shall be identified as fol-

lows:

a. Placed on or near the metal identificationplate;

b. The size of the letters and numerals onthe plate shall be no less than 3mm (0.1inches) high; and

c. If the letters and numerals are stampedinto the portable tank’s shell, they shall be at least 12mm (0.5 inches) high.

L-3280 INSPECTION AND TEST

MARKINGS FORSPECIFICATION DOT 51, 56,

57, OR 60

Each Specification DOT 51, 56, 57, or 60 portable tank shall be durably and legibly marked,in English, with the date (month and year) ofthe most recent periodic test.

The markings shall be placed near the metalcertification plate and shall be in accordancewith the following:

a. Shall be marked on a non-removable com-ponent of the portable tank that identifiesthe specification markings;

b. Located in an unobstructed area withletters and numerals identifying the stan-dard or specification, e.g. UN 1A1, DOT4B240ET, etc;

c. Shall identify the name and address or

symbol of the portable tank manufac-turer or, where specifically authorized, thesymbol of the approval agency certifyingcompliance with the UN standard;

d. The markings shall be stamped, embossed, burned, printed or otherwise marked onthe portable tank to provide adequateaccessibility, permanency, contrast, andlegible, so as to be readily apparent andunderstood;

e. The letters and numerals shall be at least 3mm (0.1 inches) high if stamped on a plate,and shall be at least 12.0 mm (0.5 inches)high when stamped on the portable tank’sshell.

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452.35

L-3290 RECORD RETENTION

The owner of each portable tank or his autho-rized agent shall retain a written report of thedate and results of all required inspectionsand tests, including the following:

a. If applicable, the ASME Manufacturer’sData Report (U-1 or U1A Forms);

b. The name and address of the personperforming the inspection and/or test inaccordance with the applicable specifica-tion;

c. The manufacturer’s data report includinga certificate(s) signed by the manufac-turer;

d. The authorized agency, as applicable, in-dicating compliance with the applicablespecification of the portable tank; and

e. The records shall be retained in theowner’s files or should be retained bythe owner’s authorized agent during thetime that the portable tank is used. Theserecords do not have to be maintained forDOT 56 and DOT 57 Specification tanks.

L-3300 GENERAL REQUIREMENTS FOR DOT SPECIFICATION’S 106A AND 110A TANK CARS (TON TANKS)

All Specification DOT 106A and DOT 110AMuti-Unit Ton Tanks shall be shall be cylin-drical, circular in cross section and shall haveheads of an approved design, with all fittings,i.e., couplings, nozzles, etc., located in the

heads of the tank.

L-3310 SPECIAL PROVISIONS FOR TON TANKS

49 CFR, Section 179.300 has specific criteriafor ton tanks that shall be met to satisfy DOTSpecification’s 106A and 110A. The limitations

are as follows:

a. Ton tanks shall have a water containingcapacity of at least 1500 pounds, but in nocase can the water containing capacity ofthe Ton Tank exceed 2600 pounds;

b. Ton tanks shall not be insulated;

c. Thickness of plates for DOT Specification’s106A and 110A Ton Tanks shall be in ac-cordance with Table L-3310-1;

d. The maximum carbon content for carbonsteel used in the fabrication of ton tanksshall not exceed 0.31 percent;

e. Permitted materials can be either anASME, SA material or an ASTM Materialpermitted by Table L-3310-2;

f. DOT Specification 106A Ton Tanks shallonly use forged-welded heads, convex to

pressure. The forged-welded heads shall be torispherical with an inside radiusnot greater than the inside diameter ofthe shell. The heads shall be one piece,hot formed in one heat so as to provide astraight flange at least 4 inches long. Theheads must have a snug fit into the shell;

g. DOT Specification 110A Ton Tanks shallonly use fusion welded heads formedconcave to pressure. The fusion weldedheads shall be an ellipsoid of 2:1 ratio and

shall be of one piece, hot formed in oneheat so as to provide a straight flange atleast 1-1/2 inches long;

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452.36

Table L-3310-1 — Thickness of Plates and Safety Valve Requirements

DOT Specification 106A500-X 106A800-X 110A500-W 110600-W 110A800-W 110A1000-W

Minimum required bursting pressure, psig

NoneSpecified

NoneSpecified

1,250 1,500 2,000 2,500

Minimum thicknessshell, inches,Test Pressure (See CFR179.300-15

13/32500

11/16800

11/32500

3/8600

15/32800

19/321000

Start-to-discharge, or burstpressure (maximum psi)

375 600 375 450 600 700

Table L-3310-2 — Acceptable Materials with Acceptable Tensile Strengthand Elongation Requirements

Material Specification

Minimum Tensile Strength (psi)in the welded condition.These values are to be used in the design

calculations.

Minimum Elongation in 2 inches(percent) in the welded condition.These values are to be used in the design

calculations.

ASTM A 240 type 304 75,000 25

ASTM A 240 type 304L 70,000 25

ASTM A 240 type 316 75,000 25

ASTM A 240 type 316 L 70,000 25

ASTM A 240 type 321 75,000 25

ASTM A 285 Gr. A 45,000 29

ASTM A 285 Gr. B 50,000 20

ASTM A 285 Gr. C 55,000 20

ASTM A 515 Gr. 65 65,000 20

ASTM A 515 Gr. 70 70,000 20ASTM A 516 Gr. 70 70,000 20

h. All longitudinal welded joints on DOTSpecification 106A and DOT Specification110A Ton Tanks shall be a fusion weld.DOT Specification 106A Ton Tank head toshell attachments shall be a forged-welded joint.24 DOT Specification 110 A Ton Tankhead to shell attachments shall be a fusion

weld.

i. Postweld heat treatment is required afterwelding for all DOT Specification 106Aand Specification 110A Ton Tanks;

j. DOT Specification 106A and DOT Speci-fication 110A Ton Tanks shall be of such adesign as to afford maximum protectionto any fitting or attachment to the head,including loading and unloading valves.The protection housing25 shall not project beyond the end of the ton tanks and shall

be securely fastened to the tank head;

k. If applicable, siphon pipes and their cou-plings on the inside of the ton tank’s headand lugs on the outside of the tank head

25 Safety relief valves shall not be covered by the protec-tive housing.

24 The forged-welded joint shall be thoroughly ham-mered or rolled to insure a sound weld.

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452.37

L-3320 VISUAL INSPECTION OF TON TANKS

Without any regard to any other periodicinspection and test requirements, a ton tankshall be visually inspected for evidence of

any:

a. Defects in welds;

b. Abrasions;

c. Corrosion;

d. Cracks;

e. Dents;

f. Distortions; or

g. Any other conditions that might make theton tank unsafe for transportation.

L-3330 INSPECTION AND TESTS OF DOT SPECIFICATION 106A AND DOT SPECIFICATION 110A TON TANKS

Each ton tank shall be retested by subjectingthe ton tank to a hydrostatic test in accordancewith Table L-3330. The hydrostatic test shallinclude an evaluation of the tank’s permanent

for attaching valve protection housingshall be fusion welded prior to performingpostweld heat treatment;

l. DOT Specification 106 and DOT Specifi-cation 110 Ton Tanks are required to be

equipped with one or more approvedtypes of pressure relief devices. The de-vice shall be made out of metal and thepressure relief devices shall not be subjectto rapid deterioration by the lading. Thedevice’s inlet fitting to the tank shall bea screw-type fitting and installed or at-tached directly into the ton tank’s heador attached to the head by other approvedmethods. For thread connections, the fol-lowing shall apply:

1. The threaded connections for all open-ings shall be in compliance with theNational Gas Taper Threads (NGT);

2. Pressure relief devices shall be set forstart-to-discharge and rupture discsshall burst at a pressure not exceed-ing the pressure identified in TableL-3310-1.

m. Fusible plugs if used shall be required

to relieve the pressure from the tank ata temperature not exceeding 175°F andshall be vapor tight at a temperature notexceeding 130°F.

Table L-3330 — Ton Tank Periodic Inspection and Test Frequencies

Retest Interval, yearsMinimum Retest

Pressure, psigPressure Relief Valve

Pressure, psig

DOTSpecification Tank

PressureReliefDevice

TankHydrostaticExpansion Tank Air Test

Start-to-Discharge Vapor Tight

106A500 5 2 500 100 375 300106A500X 5 2 500 100 375 300

106A800 5 2 800 100 600 480

106A800X 5 2 800 100 600 480

106A800NCI 5 2 800 100 600 480

110A500-W 5 2 500 100 375 300

110A600-W 5 2 600 100 500 360

110A800-W 5 2 800 100 600 480

110A1000-W 5 2 1,000 100 750 600

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452.38

expansion. As a minimum the hydrostatic testand the expansion procedure shall include:

a. The hydrostatic test pressure shall bemaintained for a minimum of 30 seconds.This time period may be extended as long

as necessary to secure complete expansionof the ton tank.

b. The pressure gage used for the hydrostatictest shall be accurate within one percent ofthe range of the pressure gage. The accu-racy of the pressure gage shall be verifiedprior to performing the hydrostatic test.

c. The expansion test procedure shall includethe following requirements:

1. The expansion shall be recorded incubic cm;

2. Permanent volumetric expansion shallnot exceed 10% of the total volumetricexpansion at the test pressure;

3. The expansion gage shall be accuratewithin one percent of the hydrostatictest pressure.

d. The ton tank shall not show any signs ofleakage or stress during the hydrostaticand expansion test.

e. The retest may be made at any time duringthe calendar year the retest falls due.

L-3331 AIR TESTS

All specification DOT 106 A and DOT 110 ATon Tanks, in addition to the hydrostatic test

shall be subjected to an air test at frequenciesand pressures specified in Table L-3330.

The air test shall be under positive controlto ensure safety to all inspection and testpersonnel.

Any leakage observed will require the tontank to be repaired and retested prior to plac-

ing the ton tank back into service.

L-3332 PRESSURE RELIEF DEVICE TESTING

All pressure relief devices shall be retested byair or gas for the start-to-discharge and vaportightness requirements at frequencies andpressures specified in Table L-3330.

L-3333 RUPTURE DISCS ANDFUSIBLE PLUGS

All rupture discs required by L-3310(l)(2) andfusible plugs required by L-3310(m) shall beremoved from the ton tank and inspected.The inspection shall include but not limitedto the following:

a. All rupture discs shall be inspected forcorrosion, leakage, and manufacturer

tolerances;

b. All fusible plugs shall be inspected for cor-rosion, loose, or deteriorated temperaturesensitive materials;

c. Any indication specified in (a) and (b)above will require the rupture disc orfusible plug to be replaced with devicesspecified in L-3310(l)(2) and L-3310(m) ofthis section.

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452.39

L-3334 SUCCESSFUL COMPLETION OF THE PERIODIC

RETESTING

If the results of the periodic retest are success-ful, the ton tank shall be plainly and perma-

nently stamped on one head or chime of eachton tank. The stamping shall include:

a. The month and year of the test followed by a “V”;

b. Dates of previous tests and all prescribedmarking shall not be removed. Previousdates and markings on the Ton Tank’shead or chime shall be legible.

L-3335 EXEMPTIONS TO PERIODIC HYDROSTATIC RETESTING

Ton tanks that satisfy DOT 106A and DOT110A that are used exclusively for transport-ing fluorinated hydrocarbons and mixturesthereof, and are free from corroding compo-nents related to the ton tank may be exemptedfrom the periodic hydrostatic retest if:

a. The ton tank is given a complete internal

and external visual inspection of all heads,shells, nozzles, couplings, pressure reliefdevices, i.e. pressure relief valves andrupture discs and fusible plugs for dete-rioration and leakage.

b. The visual internal and external inspec-tion is performed by qualified personnel,i.e. registered inspector, employee of theowner-user, etc.

L-3336 RECORD OF RETESTINSPECTION

The owner or the person performing therequired pressure test and visual inspectionis required to retain a written record of the

results as long as the ton tank is in service. Thewritten report shall identify the following:

a. Date of the test and inspection;

b. DOT Specification Number of the ton

tank;

c. Ton Tank identification (registered symboland serial number, date of manufacture,and ownership symbol);

d. Type of protective coating, i.e. painting,etc;

e. Statement as to the need for refinishing orrecoating the ton tank;

f. Conditions checked for:

1. leakage;

2. corrosion;

3. gouges;

4. dents or digs:

5. broken or damaged chimes, or protec-

tive rings;

6. fire damage;

7. internal conditions;

8. test pressure;

9. the written report shall also identifythe results of the test:

i. disposition of the tank, i.e. re-

turned to service, returned tothe manufacturer for repair, orscrapped;

ii. Identification of the person per-forming the retest or inspection.

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452.40

L-3340 STAMPING REQUIREMENTS OF DOT 106A AND DOT 110A TON TANKS

To identify compliance with CFR 179.300-1each DOT 106A and DOT 110A ton tank shall

be plainly and permanently stamped withletters and figures 3/8 of an inch high onvalve end chime of the ton tank’s head. Theminimum requirements for the stamping areas follows:

a. DOT Specification Number;

b. Material and cladding material if any.This information shall be stamped directly below the DOT Specification Number;

c. Owner’s or builder’s identifying symboland serial number. This information shall be stamped directly below the materialidentification stamping. The owner’s or builder’s symbol shall be registered withthe Bureau of Explosions (duplications arenot authorized);

d. Inspector’s official mark. This informa-tion shall be stamped directly below theowner’s or builder’s symbol;

e. Date of the original ton tank test (monthand year). Provisions should be madethat subsequent tests may easily be addedthereto;

f. Water capacity of the ton tank inpounds;

g. A duplicate of the stamping that satisfies(a) through (f) should be used if the plateis made of brass and is permanently at-

tached to the ton tank’s head.

DEFINITIONS

These Definitions shall be used in conjunctionwith those of Appendix 4 of the NBIC. Whereconflicts between the two arise, those listed below shall prevail.

Approval means a written authorization,including a competent authority approvalfrom the Associate Administrator or otherdesignated department official, to perform afunction for which prior authorization by theAssociate Administrator is required.

Approval Agency means an organization ora person designated by the DOT to certifypackaging as having been designed, manu-factured, tested, modified, marked, or main-tained in compliance with applicable DOTregulations.

Approved means approval issued or recog-nized by the department unless otherwisespecifically indicated.

Appurtenance means any attachment to a cargotank that has no lading retention or contain-ment function and provides no structuralsupport to the cargo tank.

Associate Administrator means the Associ-ate Administrator for Hazardous MaterialsSafety, Research, and Special Programs Ad-ministration.

Atmospheric gas means air, nitrogen, oxygen,argon, krypton, neon, and xenon.

Attachments Light Weight means welded to acargo tank wall such as a conduit clip, brakeline clip, skirting structure, lamp mounting

bracing, or placard holder.

Attachments – Structural Members means thesuspension sub-frame, accident protectionstructures, external circumferential reinforce-ments, support framing, and kingpin sub-frame (upper coupling).

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Authorized Inspector (AI) means an inspectorregularly employed by an ASME-accreditedAuthorized Inspection Agency (AIA) who has been qualified to ASME developed criteria, toperform inspections under the rules of any ju-risdiction that has adopted the ASME Code.

Baffle (To Be Determined).

Bulkhead means a liquid-tight transverse clo-sure at the ends of or between (compartment)cargo tanks.

Bar means 1 BAR = 100 kPa (14.5 psi) Bottle means an inner packaging having aneck of relatively smaller cross section thanthe body and an opening capable of holdinga closure for retention of the contents.

Bottom Shell means that portion of a tank carsurface, excluding the head ends of the tankcar that lies within two feet, measured circum-ferentially, of the bottom longitudinal centerline of the tank car tank.

Bulk Packaging means a packaging other thanthe vessel or a barge, including a transportvehicle or freight container, in which hazard-

ous materials are loaded with no intermediateform of containment and which has:

a. A maximum capacity greater than 450L(119 gallons) as a receptacle for a liquid;

b. A maximum net mass greater than 400kg (882 pounds) and a maximum capac-ity greater than 450L (119 gallons) as areceptacle for a solid; or

c. A water capacity greater than 454 kg (1000

pounds) as a receptacle for a gas.

Cargo Tank (To Be Determined).

Cargo Tank Motor Vehicle (To Be Determined).

Carrier means a person engaged in the trans-portation of passengers or property by:

a. land or water, as a common, contract orprivate carrier; or

b. Civil aircraft.

Certified Individual means an individual thatis qualified and certified by a manufactureraccredited by ASME to construct Class 3 Sec-tion XII Transport Tanks.

Combination Packaging means a combination ofpackaging for transport purposes, consistingof one or more inner packaging secured in anon-bulk outer packaging. It does not includea composite packaging.

Combustible Liquid means any liquid that doesnot meet the definition of any other hazardclass specified in 173.129 of Title 49 and has aflash point above 60.5°C (141.5°F) and below93°C (100°F).

Competent Authority means a national agencyresponsible under its national law for thecontrol or regulation of a particular aspect ofthe transportation of hazardous materials. In

the United States, the Associate Administratorof the US Department of Transportion is theCompetent Authority.

Composite Packaging means a packagingconsisting of an outer package and an innerreceptacle so constructed that the inner re-ceptacle and the outer package are integral.Once assembled, it remains an integratedsingle unit. It is filled, stored, shipped, andemptied as such.

Compressed Gas in Solution means a non-liqui-fied compressed gas which is dissolved in asolvent.

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452.42

Constructed and Certified in Accordance with theASME Code means a cargo tank that is con-structed and stamped in accordance with theASME Code and is inspected and certified byan Authorized Inspector, Qualified Inspector,or a Certified Individual.

Corrosive Material means a liquid or solid thatcauses full thickness destruction of humanskin at the site of contact within a specifiedperiod of time. A liquid that has a severe cor-rosion rate on steel or aluminum based onthe criteria in 173.173(c) (3) of Title 49 is alsoa corrosive material.

Cryogenic Liquid means a refrigerated liquefiedgas having a boiling point colder than -90°C(-130°F) at 101.3 kPa (14.7 psia) absolute.

Design Certification means that each cargotank or cargo tank motor vehicle design type,including its required accident damage pro-tection device, must be certified to conformto the specification requirements by a DesignCertifying Engineer who is registered withthe Department. An accident damage protec-tion device is a rear-end protection, overturnprotection, or piping protection.

Design Certifying Engineer (To Be Deter-mined).

Design Type means one or more cargo tanksthat are made:

a. to the same specification;

b. by the same manufacturer;

c. to the same engineering drawings andcalculations, except for minor variations

in piping that do not affect the ladingretention capabilities of the cargo tank;

d. of the same materials of constructions;

e. to the same cross-sectional dimensions;

f. to a length varying by no more than 5percent;

g. with the volume varying by no more than5 percent (due to the change in lengthonly); and

h. for the purposes of 178.338 of Title 49 only,with the same insulation system.

DOT or Department means U.S. Departmentof Transportation.

Elevated Temperatures Material means a mate-rial which, when offered for transportation ortransported in a bulk packaging:

a. Is in a liquid phase and at a temperatureat or above 100°C (212°F);

b. Is in a liquid phase with a flash point at orabove 37.8°C (100°F) that is intentionallyheated and offered for transportation ortransported at or above the flash point;or

c. Is in a solid phase and at a temperature ator above 240°C (464°F).

Extreme Dynamic Loadings means the maxi-mum loading of a cargo tank motor vehiclemay experience during its expected life, ex-cluding accident loadings resulting from anaccident, such as overturn or collision.

Flammable Gas (To Be Determined).

Gas means a material which has a vaporpressure greater than 300 kPa (43.5 psia) at50°C (122°F) or is completely gaseous at 20°C(68°F) at a standard pressure of 101.3 kPa

(14.7 psia).

Gross Weight or Gross means the weight of apackaging plus the weight of its contents.

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Hazardous Class means the category of hazardassigned to a hazardous material under thedefinitional criteria of part 173 of Title 49 andthe provisions of the 172.101 table. A materialshould meet the defining criteria for morethan one hazard class but is assigned to only

one hazard class.

Hazardous Zones means one of four levelsof hazard (Hazard Zones A through D) asassigned to gases, as specified in 173.116(a)of Title 49 and one of two levels of hazard(Hazard Zones A and B) assigned to liquidsthat are poisonous by inhalation as specifiedin 173.133(a) of Title 49. A hazard zone is basedon the LC 50 value for acute inhalation toxicityof gases and vapors.

Hazardous Material means a substance ormaterial that the Secretary of Transportationhas determined is capable of posing an un-reasonable risk to health, safety, and propertywhen transported in commerce and has beendesignated as hazardous under section 5103of Federal hazardous law (49 U.S.C. 5103).The term includes hazardous substances,hazardous wastes, marine pollutants, elevatedtemperature materials, materials designatedas hazardous in the Hazardous Material Table

(49 CFR 172.101), and materials that meetthe defining criteria for hazard classes anddivisions of 173 of subchapter C of 171.8 ofTitle 49.

High Pressure Liquefied Gas means a gas witha critical temperature between -50°C (-58°F)and + 65°C (149°F).

Inner Packaging means a packaging for whichan outer packaging is required for transport.It does not include the inner receptacle of a

composite packaging.

Inner Receptacle means a receptacle tbat re-quires an outer packaging in order to performits containment function. The inner receptacleshould be an inner packaging of a combina-tion packaging or the inner receptacle of acomposite packaging.

Inspection Pressure means the pressure usedto determine leak tightness of the cargo tankwhen testing with pneumatic or hydrostaticpressure.

Lading means the hazardous material con-

tained in the cargo tank

Liquified Compressed Gas means a gas whenpackaged under pressure for transportation ispartially liquid at temperatures above -50°C(-58°F).

Liquid means a material, other than an el-evated temperature material, with a meltingpoint or initial melting point of 20°C (68°F)or lower at a standard pressure of 101.3 kPa(14.7 psig).

Liquid Phase means a material that meets thedefinition of liquid when evaluated at thehigher of the temperature at which it is offeredfor transportation or at which it is transported,not at the 37.8 °C (100°F) temperature speci-fied in ASTM D 4359-84.

Low Pressure Liquified Gas means a gas with acritical temperature above + 65°C (149°F).

Manufacturer (To Be Determined).

Marking means a descriptive name, identifica-tion number, instructions, cautions, weight,specification, or UN marks, or combinationsthereof, required by Title 49 on outer packag-ing or hazardous materials.

Maximum Allowable Working Pressure (MAWP) (To Be Determined).

Mode means any of the following transporta-

tion methods: rail, highway, air, or water.

Modification (To Be Determined).

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452.44

Motor Vehicle means a vehicle, machine, trac-tor, trailer, or semi-trailer, or any combinationthereof, propelled or drawn by mechanicalpower and used upon the highways in thetransportation of passengers or property. Itdoes not include a vehicle operated exclusive-

ly on a rail or rails or a trolley bus operated byelectric power derived from a fixed overheadwire, furnishing local passenger transporta-tion similar to street-railway service.

Multi-Specification Cargo Tank Motor Vehicle means a cargo tank with two or more cargotanks fabricated to more than one cargo tankspecification.

Normal Operating Loading means a cargo tankmotor vehicle equipped with two or morecargo tanks fabricated to more than one cargotank specification.

Non-Liquified Compressed Gas means whenpackaged under pressure for transportationis entirely gaseous at -50°C (-58°F) with acritical temperature less than or equal to -50°C(-58°F).

Operator means a person who controls the useof aircraft, vessel, or vehicle.

Outer Packaging means the outermost enclo-sure of a composite or combination packagingtogether with any absorbent material, cush-ioning, and any other components necessaryto contain and protect inner receptacles orinner packaging.

Owner means the person who owns a cargotank motor vehicle used for the transporta-tion of hazardous materials, or that person’sauthorized agent.

Packaging means a receptacle and any othercomponents or materials necessary for thereceptacle to perform its containment functionin conformance with the minimum packingrequirements of Title 49.

Packing Group means a grouping accordingto the degree of danger present by hazardousmaterials. Packing Group I indicates greatdanger; Packing Group II indicates mediumdanger; Packing Group II indicates minordanger; Packing Group III indicates minor

danger.

Person means an individual, firm, co-partner-ship, corporation, company, association, or joint-stock (including any trustee, receiver,assignee, or similar representative); or anygovernment or Indian tribe (or an agency orinstrumentality of any government or Indiantribe) that transports hazardous materialto further a commercial enterprise or offersa hazardous material for transportation incommerce.

Poisonous gas means a material which is a gasat 20°C (68°F) or less and a pressure of 101.3kPa (14.7 psia) [a material which has a boilingpoint of 20°C (68°F) or less at 101.3 kPa (14.7psia] and which:

a. Is known to be so toxic to humans as topose a hazard to health during transporta-tion; or

b. In the absence of adequate data on humantoxicity, is presumed to be toxic to humans because when tested on laboratory ani-mals it has an LC50.

Poisonous material means a material, otherthan a gas, which is known to be so toxic tohumans as to afford a hazard to health dur-ing transportation, or which in the absence ofadequate data on human toxicity.

Portable Tanks means a bulk packaging (ex-

cept cylinder having a water capacity of 1000pounds or less) designated primarily to beloaded onto, or on, or temporarily attached toa transport vehicle or ship and equipped withskids, mountings, or accessories to facilitatehandling of the tank by mechanical means. Itdoes not include a cargo tank, tank car, multi-unit tank car tanks, or trailers carrying 3AX,3AAX, or 3T cylinders.

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452.45

psi means pounds per square inch.

psia means pounds per square inch absolute.

psig means pounds per square inch gage.

Qualified Inspector (To Be Determined).

Rail Car means a car designed to carry freightor nonpassenger personnel by rail, and in-cludes a box car, flat car, gondola car, hoppercar, tank car, and occupied caboose.

Rebarrelling means replacing more than 50%of the combined shell and head material of acargo tank.

Repair (To Be Determined).

Receptacle means a containment vessel forreceiving and holding materials, includingany means of closing.

Registered Inspector (To Be Determined).

Replacement of a Barrel (To Be Determined).

SCF (standard cubic foot) means one cubic footof gas measured at 60°F, and 14.7 psia.

Single Packaging means a nonbulk packagingother than a combination packaging.

Solid means a material that is not a gas orliquid.

Solution means any homogenous liquid mix-ture of two or more chemical compounds orelements that will not undergo any segrega-tion under conditions normal to transporta-tion.

Specification Packaging means a packagingconforming to one of the specifications orstandards for packaging in Part 178 or Part179 of Title 49.

Strong Outside Container means the outermostenclosure which provides protection againstthe unintentional release of its contents underconditions normally incident to transporta-tion.

Structural Attachments (To Be Determined).

Tanks means a container, consisting of a shelland heads that form the pressure vessel hav-ing opening designed to accept pressure tightfittings or closure, but excludes any appurte-nances, reinforcements, fittings, or closures.

Test Pressure means the pressure to whicha tank is subjected to determine structuralintegrity.

Top Shell means the tank car surface, exclud-ing the head ends and bottom shell of thetank car.

Transport Vehicle means a cargo-car-carryingvehicle such as an automobile, van, tractor,truck, semi trailer, tank car, or rail car usedfor the transportation of cargo by any mode.Each cargo-carrying body (trailer, rail car, etc.)is a separate transport vehicle.

UFC means Uniform Freight Classification.

UN means United Nations. UN Portable Tank means an intermodal tankhaving a capacity of more than 450L (118.9gallons). It includes a shell fitted with ser-vice equipment and structural equipment,including stabilizing members external tothe shell and skids, mountings or accesso-ries to facilitate mechanical handling. A UNportable tank must be capable of being filled

and discharged without the removal of itsstructural equipment and must be capable of being lifted when full. Cargo tanks, rail tankcar tanks, nonmetallic tanks, nonspecificationtanks, bulk bins, and IBC’s and packagingmade to cylinder specifications are not UNportable tanks.

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UN Recommendation means the UN Recom-mendations on the Transport of DangerousGoods.

UN Standard Packaging means a conforming tostandards in the UN Recommendations.

Vessel includes every description of watercraft,used or capable of being used, as a means oftransportation on the water.

Viscous Liquid means a liquid material whichhas a measured viscosity in excess of 2500centistokes at 25°C (77°F), when determinedin accordance with the procedures specifiedin ASTM Method D 445-72 “Kinematic Viscos-ity of Transparent and Opaque Liquids (andthe Calculation of Dynamic Viscosity”), orASTM Method D 1200-70 “Viscosity of Paints,Varnishes, and Lacquers by Ford ViscosityCup.”

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Interpretations

These interpretations are not part of the NBIC and are providedfor information only.

Beginning with the 2005 Addendum:Only interpretations involving the current edition will beprovided with this and future addenda. All previouslypublished interpretations are available on the National BoardWeb site, nationalboard.org.

The index for interpretations will be updated and retained foreach addendum.

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PARAGRAPH INDEX

Foreword ......................................................................................................................... 95-20

Code Cases 1923 .................................................................................................................. 98-24 .......................................................................................................................... 98-56

1945 .................................................................................................................. 98-24 .......................................................................................................................... 98-56 2203 .................................................................................................................. 98-12

RA-2130 Procedure for Obtaining or Renewing a National Board Certificate of Authorization ......................................................................... 98-21RA-2151 Outline of Requirements for a Quality System for Qualification for the National Board “R” Symbol Stamp .................. 98-13RA-2213 General Rules ................................................................................................. 04-02RA-2231 Condition of Use .............................................................................................. 98-2RA-2262 Nameplate Contents ...................................................................................... 98-25 .......................................................................................................................... 98-26 .......................................................................................................................... 95-26

RA-2274 Use of Owner/User Personnel During Repairs ........................................ 01-12RA-2281 Test Medium and Testing Equipment ......................................................... 98-17RA-2330 Procedure for Obtaining or Renewing a National Board “NR” Certificate of Authorization ................................................................ 98-7 .......................................................................................................................... 98-41RA-3020 Prerequisites for Accreditation .................................................................... 98-16RA-3050 General Conditions ....................................................................................... 98-11

RB-3234 Pressure Testing ............................................................................................. 95-38RB-3237 Inspection Interval ......................................................................................... 98-19RB-3238 Conditions that Affect Remaining Life Evaluation .................................. 01-26 ............................................................................................................................ 98-3 .......................................................................................................................... 95-57RB-3550 Operational Inspection ................................................................................. 95-55RB-3640 Inspection of Parts and Appurtenances ....................................................... 98-9RB-4000 Restamping or Replacement of Nameplates ............................................. 98-35 .......................................................................................................................... 95-47RB-4010 Replacement of Stamped Data..................................................................... 01-13

RC-1000 General Requirements .................................................................................. 95-19RC-1010 Scope ................................................................................................................ 98-22RC-1020 Construction Standard .................................................................................. 95-36 .......................................................................................................................... 95-48RC-1040 Materials ......................................................................................................... 01-28RC-1050 Replacement Parts ......................................................................................... 04-05

.......................................................................................................................... 04-06 .......................................................................................................................... 98-14 .......................................................................................................................... 98-27 .......................................................................................................................... 98-28 .......................................................................................................................... 98-37 .......................................................................................................................... 95-48RC-1090 Welding ........................................................................................................... 01-27 ............................................................................................................................ 98-6 .......................................................................................................................... 95-51

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INTERPRETATIONS

RC-1110 Nondestructive Examination ....................................................................... 04-06 .......................................................................................................................... 01-24 .......................................................................................................................... 98-10 .......................................................................................................................... 95-41RC-2031 Routine Repairs .............................................................................................. 04-09 .......................................................................................................................... 04-10

.......................................................................................................................... 01-19 .......................................................................................................................... 01-20 .......................................................................................................................... 01-22 .......................................................................................................................... 01-23 ............................................................................................................................ 98-1 ............................................................................................................................ 98-4 .......................................................................................................................... 98-18 .......................................................................................................................... 98-31 .......................................................................................................................... 98-42 .......................................................................................................................... 95-27 .......................................................................................................................... 95-28 .......................................................................................................................... 95-31 .......................................................................................................................... 95-33

.......................................................................................................................... 95-53RC-2050 Examination and Test .................................................................................... 04-05 .......................................................................................................................... 04-06 .......................................................................................................................... 98-27 .......................................................................................................................... 98-33 .......................................................................................................................... 98-36 .......................................................................................................................... 95-27 .......................................................................................................................... 95-32 .......................................................................................................................... 95-39 .......................................................................................................................... 95-54RC-2051 Methods .......................................................................................................... 04-06 .......................................................................................................................... 01-15RC-2070 Documentation ............................................................................................... 01-29 .......................................................................................................................... 95-50RC-2082 Repair Plan ..................................................................................................... 01-14RC-3000 Alterations to ASME Section VIII, Div. 2 .................................................... 01-16RC-3020 Design .............................................................................................................. 98-14 .......................................................................................................................... 95-22RC-3021 Calculations .................................................................................................... 01-17RC-3022 Re-Rating ........................................................................................................ 04-03 .......................................................................................................................... 04-04 .......................................................................................................................... 01-11 .......................................................................................................................... 98-14 .......................................................................................................................... 98-15 .......................................................................................................................... 98-20

.......................................................................................................................... 98-32RC-3030 Examination and Test .................................................................................... 98-15 .......................................................................................................................... 98-34 .......................................................................................................................... 98-38RC-3050 Documentation ............................................................................................... 01-25 .......................................................................................................................... 95-50

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Part RD Repair Methods .............................................................................................. 04-01

RD-1010 Scope .................................................................................................................. 98-6RD-2020 Scope .................................................................................................................. 98-8RD-2030 Wasted Areas .................................................................................................. 98-42RD-2050 Re-Ending or Piecing Pipes or Tubes .......................................................... 98-36

RD-2060 Patches ............................................................................................................. 95-52RD-2070 Stays ................................................................................................................. 98-40

RE-1050 Replacement Parts ......................................................................................... 04-07 .......................................................................................................................... 04-08

Appendix 2 Stamping and Nameplate Information ...................................................... 95-24

Appendix 4 Glossary of Terms .......................................................................................... 95-21 .......................................................................................................................... 95-29 .......................................................................................................................... 95-34 .......................................................................................................................... 95-43 .......................................................................................................................... 95-45

Appendix 5 National Board Forms ................................................................................... 98-39 .......................................................................................................................... 95-25 .......................................................................................................................... 95-30 .......................................................................................................................... 95-40 .......................................................................................................................... 95-42

Appendix 6 Examples of Repairs and Alterations.......................................................... 01-21 .......................................................................................................................... 98-23 .......................................................................................................................... 98-29 .......................................................................................................................... 98-30 .......................................................................................................................... 95-44 .......................................................................................................................... 95-46 .......................................................................................................................... 95-48 .......................................................................................................................... 95-49Appendix 8 Repairs ............................................................................................................. 01-18

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SUBJECT INDEX

alterations to ASME Section VIII, Div. 2 .................................................................................. 01-16alternatives to PWHT ................................................................................................................... 98-6attachments ............................................................................................................................ 98-1 blisters, repair of ........................................................................................................................... 98-9

calculations .......................................................................................................................... 01-17deaerators, inspection of ............................................................................................................. 98-9definition of repair ...................................................................................................................... 98-23 .......................................................................................................................... 98-29 .......................................................................................................................... 98-30 .......................................................................................................................... 95-43 .......................................................................................................................... 95-45 .......................................................................................................................... 95-46 .......................................................................................................................... 95-49definition of alteration ................................................................................................................ 95-21 .......................................................................................................................... 95-36 .......................................................................................................................... 95-44 .......................................................................................................................... 95-45

definition of inspector ................................................................................................................ 95-29definition of non-load bearing .................................................................................................. 95-33demonstration requirements ..................................................................................................... 98-41derating .......................................................................................................................... 98-20deterioration .......................................................................................................................... 01-26documentation .......................................................................................................................... 01-25 .......................................................................................................................... 95-50examination and test.................................................................................................................. . 04-05 .......................................................................................................................... 04-06examples of repairs and alterations .......................................................................................... 01-21general rules .......................................................................................................................... 04-02inspection interval....................................................................................................................... 98-19inspection interval....................................................................................................................... 95-57 joint review demonstration requirements ............................................................................... 98-21material thickness ....................................................................................................................... 98-36materials .......................................................................................................................... 01-28MTR .......................................................................................................................... 98-37nameplates .......................................................................................................................... 95-24non “U” stamped vessels ........................................................................................................... 95-23nondestructive examination ...................................................................................................... 04-06 .......................................................................................................................... 01-24 .......................................................................................................................... 98-10nuclear components ...................................................................................................................... 98-7original code of construction ..................................................................................................... 95-19out-of-service ............................................................................................................................ 98-3

owner-user inspection ................................................................................................................ 98-11 .......................................................................................................................... 98-16piping .......................................................................................................................... 98-22pressure relief valves .................................................................................................................... 98-2 .......................................................................................................................... 98-13 .......................................................................................................................... 98-17 .......................................................................................................................... 98-24 .......................................................................................................................... 98-25

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.......................................................................................................................... 98-26 .......................................................................................................................... 95-26 .......................................................................................................................... 95-55 .......................................................................................................................... 95-56pressure testing .......................................................................................................................... 98-15 .......................................................................................................................... 98-27

.......................................................................................................................... 98-33 .......................................................................................................................... 98-34 .......................................................................................................................... 98-38 .......................................................................................................................... 95-27 .......................................................................................................................... 95-32 .......................................................................................................................... 95-39 .......................................................................................................................... 95-38pressure testing repairs .............................................................................................................. 01-15qualification of welders/welding procedures ........................................................................ 95-51quality system manual ............................................................................................................... 98-13“R” forms .......................................................................................................................... 98-39 .......................................................................................................................... 95-27 .......................................................................................................................... 95-28

.......................................................................................................................... 95-30 .......................................................................................................................... 95-40 .......................................................................................................................... 95-42 .......................................................................................................................... 95-48 .......................................................................................................................... 95-50repair methods .......................................................................................................................... 04-01repairs .......................................................................................................................... 01-18repair plan .......................................................................................................................... 01-14reclassification .......................................................................................................................... 95-22replacement nameplates ............................................................................................................ 98-35 .......................................................................................................................... 95-47replacement parts ........................................................................................................................ 04-05 .......................................................................................................................... 04-06 .......................................................................................................................... 04-07 .......................................................................................................................... 04-08 .......................................................................................................................... 98-14 .......................................................................................................................... 98-27 .......................................................................................................................... 98-28 .......................................................................................................................... 01-29replacement of stamped data .................................................................................................... 01-13re-rating .......................................................................................................................... 04-03 .......................................................................................................................... 04-04 .......................................................................................................................... 01-11 .......................................................................................................................... 98-14 .......................................................................................................................... 98-15

.......................................................................................................................... 98-32routine repairs .......................................................................................................................... 04-09 .......................................................................................................................... 04-10 .......................................................................................................................... 01-19 .......................................................................................................................... 01-20 .......................................................................................................................... 01-22 .......................................................................................................................... 01-23 ............................................................................................................................ 98-1 ............................................................................................................................ 98-4 .......................................................................................................................... 98-18 .......................................................................................................................... 98-31

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INTERPRETATIONS

.......................................................................................................................... 98-42 .......................................................................................................................... 95-25 .......................................................................................................................... 95-27 .......................................................................................................................... 95-28 .......................................................................................................................... 95-31 .......................................................................................................................... 95-53

.......................................................................................................................... 95-54stays .......................................................................................................................... 95-40timing of repairs ............................................................................................................................ 98-5 .......................................................................................................................... 95-41use of editions/addenda ............................................................................................................ 95-20use of owner/user personnel during repairs .......................................................................... 01-12welding .......................................................................................................................... 01-27welding methods ......................................................................................................................... 04-06window patch .......................................................................................................................... 95-52

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INTERPRETATIONS

A05

A05

A05

INTERPRETATION 04-01Subject: Part RD 2004 EditionQuestion: Does the NBIC prohibit the use of welded encapsulation box as an alteration method

to encapsulate a local thin area on a pressure-retaining item in lieu of using weld metal build up or a flush patch?

Reply: No, however, repair of alteration methods other than those addressed in the NBIC shall be acceptable to the inspector and the jurisdiction.

INTERPRETATION 04-02Subject: Part RA-2213 2004 EditionQuestion: Does paragraph RA-2213 require a VR Certificate holder to verify that the manufacturer’s

nameplate capacity is correct in the process of repairing a Code stamped valve?

Reply: Yes, “condition” in RA-2213 includes nameplate information as well as physical condi-tion of the valve.

INTERPRETATION 04-03Subject: Part RC-3022(b) & (d), Re-rating 2004 Edition with 2004 AddendaQuestion: When re-rating a pressure retaining item, is it a requirement that insulation or refractory

be removed prior to the pressure test?

Reply: Yes. A sufficient amount of refractory or insulation, as determined by the inspector,shall be removed to allow the inspector to perform a visual inspection of the pressure-retaining item.

INTERPRETATION 04-04Subject: Part RC-3022(b) & (d), Re-rating 2004 Edition with 2004 AddendaQuestion: When re-rating a pressure-retaining item for lethal service, is it required to have the

paint, lining, or other coverings removed prior to the pressure test when required bythe original code of construction?

Reply: Yes.

INTERPRETATION 04-05Subject: Part RC-1050(c), RC-2050 2001 Edition with 2003 AddendaQuestion: When a replacement part is supplied by an “S” part manufacturer in accordance with

RC-1050(c), without a pressure test in accordance with the original code of construction,may the “R” stamp holder install the part following the requirements of RC-2050 forthe part’s welds and attachment welds?

Reply: Yes.

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INTERPRETATION 04-06Subject: Part RC-1050(c), RC-2050, RC-2051, RC-1110 2004 Edition with 2004 AddendaQuestion: When performing nondestructive examinations listed in RC-2051(e) and RC-3030(c),

are written procedures and appropriately qualified personnel required?

Reply: Yes, when required by the original code of construction.

INTERPRETATION 04-07Subject: Part RE-1050, Source of Parts 2004 Edition with 2004 AddendaQuestion: Do the requirements of NBIC, paragraph RE-1050, demand that critical parts be pur-

chased directly from the valve manufacturer or their authorized representative?

Reply: No.

INTERPRETATION 04-08

Subject: Part RE-1050, Replacement Parts 2004 Edition with 2004 AddendaQuestion: Do replacement of critical parts fabricated to a specification derived from the examina-

tion of parts fabricated by the valve manufacturer and a review of documents availablein the public domain meet the requirements of RE-1050?

Reply: No.

INTERPRETATION 04-09Subject: Part RC-2031, Flush Routine Repairs 2004 Edition with 2004 AddendaQuestion: May repairs that are not included in RC-2031(a) be performed and documented as

routine repairs?

Reply: No.

INTERPRETATION 04-10Subject: Part RC-2031, Flush Patches in Pipes and Tubes NPS 5 or less 2004 Edition with 2004 AddendaQuestion: May the installation of a flush patch to boiler tubes or pipes NPS 5 (DN 125) and smaller,

where neither postweld heat treatment nor NDE other than visual examination is re-quired by the original code of construction, be considered a routine repair?

Reply: Yes.

A05

A05

A05

A05

A05

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Index

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A

Addenda — IntroductionAdditional Requirements for Alterations

— RC-3000Additional Requirements for Repairs

— RC-2000Administrative Requirements — Part RAAdministrative Procedures “VR”/“NV” —

Appendix 7-2000Acceptance Inspection — RC-1130 , Appendix 9-1120Accreditation — RA-1020 , RA-2000 ,

RE- 1030; Programs — RA-1010Acoustic Emission — RB-3180Adjustments Pressure Relief Valves — RE-1022;

Authorization of Owner-Users — Appendix JAlteration — RC-1000 , RC-3000 ,

Appendix 4 , Appendix 8-4000 , Appendix 9-3000 , 9-4000 , Appendix K-4000

Alternatives, Postweld Heat Treatment —RC-1103 , RD-1000 , RD-1100;

Nondestructive Examination —RC-1110;

Verification Testing — RA-2226; Marking, Stamping — Appendix 8-6000Allowable Stress Values — RD-3000ASME Code Replacement Parts — RC-1050; Section VIII Division 2 and 3 —

RC-2080 , RC-3025 Application of NBIC — ix thru xiiiAssembler — Appendix 4 , RA-2200Audit — Appendix 4 , RE-1071American National Standards Institute

(ANSI) — Appendix 4American Petroleum Institute (API) —

Introduction Annual Review “VR” — RE-3040Arch Tubes — Appendix 3-3120Ash Removal — Appendix I-2520Authorized Nuclear Inspector —

Appendix 4 , RA-2360

B

Boilers Inspection — RB-5000 , RB-8510; Watertube — RB-5601; Black Liquor — RB-5602; Organic and Inorganic Fluid — RB-5603;

Waste Heat — RB-5604; Cast Iron — RB-5605; Electric — RB-5606; Fired-Coil Water Heaters — RB-5607; Fired-Storage Water Heaters — RB-5608; Firetube — RB-5609; Historical/Hobby — Appendix C; Locomotive — Appendix 3Boiler Installation — Appendix I-2000; Heating/Potable Water Heaters —

Appendix I-3000; Report — Appendix I-2960 , I-3930

Boiler Repair — RD-2000 , Appendix 3 , Appendix 6-2000 , Appendix C

Boiler Relief Devices — RB-8510Boiler Room Requirements —

Appendix I-2340 , I-3350Bonding — Appendix 9Blowoffs — Appendix I-2650 , I-3670Bulges — RB-4460 , RD-2020 ,

Appendix H-3530Burners and Stokers — Appendix I-2620

C

Calculations — RC-3021 , Appendix 9-3022Capacity Certification — Appendix 4 Caulking Riveted Seams —

Appendix 3-3410 , Appendix CCertification — Appendix I-2200 , I-3220 ,

I-4200 , I-5200Chimney or Stack — Appendix I-2510 , I-3510Clearances — Appendix I-2330 , I-3340 ,

I-4320Cleaning — RB-2210 , Appendix I-5600Combustion Air — Appendix I-2440 , I-3353Controls — RB-5528 , RB-6253 , RB-7353 ,

Appendix I-2700 , I-3700 , I-4700Compressed Air Vessels — RB-6430Construction Standards — RC-1020 ,

RE-1021 , Appendix 9-1040

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INDEX

Condition of Installation — RB-5300 , RB-6210

Connections — Appendix I-2412 , I-2722 , I-3660 , I-3832 , I-3833 , I-3853 , I-3854

Corrosion — RB-4100 , RB-5510 ,Appendix H-3550 , Appendix K-1033;

Control of — RB-4200Coatings — RB-4250Cracks — RB-4480 , RD-2020 ,

Appendix K-1032Creep — RB-4420Curing — Appendix 9-1080Cuts or Gouges — Appendix H-3540

D

Deaerators — RB-6420Defect Repairs — RD-2020Definitions — RE-1024 , Appendix H-3100; Definition of Repair to Pressure Relief

Valves — RE-1020Dents — RB-6220 , Appendix H-3520Deposits Waterside — RB-5522De-rating — RC-3022 , Appendix K-2042 ,

K-2043Design — RC-3020 , Appendix 9-3020Device Data — RB-8200

Device Condition — RB-8210Device Requirements — Appendix I-4810 ,

I-5810 , I-5820 , I-5830Distribution of “R” Forms — RC-2072 ,

RC-3052 , Appendix 8-3000 , Apendix 9-2082 , 9-3052

Documentation — RC-2070 , RC-3050 ,Appendix C-6090

Drains — Appendix I-2343 , I-3530Drawings — RC-2021 , RC-3023 ,

Appendix 9-2020 , 9-3024

E

Economizers — Appendix I-2871Eddy Current — RB-3160Electrical (installation) —

Appendix I-2430 , I-3430

Emergency Valves and Controls —Appendix I-2460 , I-3355

Engineering Design — RB-4220Equipment operation — RB-2110Erosion — RB-4000 , RB-5000 , RB-6000 ,

RB-7000 , RB-9000 , Appendix 3

Estimating Remaining Service Life andInspection Intervals — RB-9000

Evidence of leakage Boilers — RB-5430; Pressure Vessels — RB-6220; Piping — RB-7330Examination — RC-2050 , RC-3030 ,

Appendix 9-5630Examples or Repairs/Alterations —

Appendix 6Exfoliation — RB-4110Exhibits — RA-2151 , RA-2255Exit and Egress — Appendix I-2341 , I-3351Expansion Tanks — RB-6440 ,

Appendix I-3691 , I-3692External Inspections Boilers — RB-5410; Pressure Vessels — RB-6220 ,

Appendix H-3200; Piping — RB-7310; Graphite — Appendix 8-2000; FRP — Appendix 9-5500

F

Failure Mechanisms — RB-4000Fatigue — RB-4410Federal Railroad Administration (FRA) —

Appendix 3-1200Feedwater — RB-5525 , RB-5605 ,

Appendix C-2041 , C-6090 , Appendix I-2410 , I-3640

Fiber Reinforced — Appendix 9Field Repairs for Relief Devices —

Appendix 4 , RA-2255Firebox — RB-5523 , RB-5609 , Appendix 3 ,

Appendix C-6090Fire Damage — Appendix H-3570Flanges — RB-5524 , RD-2030Forced Flow Steam Generators —

Appendix I-2860

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Forms — Appendix 5; Distribution — RC-2072 , RC-3052; Registration — RC-1150 , RC-1151; Guide for completing — Appendix 5Fractures — Appendix 8-5020Fuel — Appendix I-2420 , I-3420

Fusible Plugs — Appendix 3-2020 ,Appendix C-2020 , C-2034

G

Gages — RB-5526 , RB-6251 , RB-6460 ,RB-7351 , RC-1120 , Appendix 3-2020 , 3-3610 , Appendix C-2030 , C-6090 , Appendix I-2721 , I-3711 , I-3712 , I-3721

Galvanic Corrosion — RB-4110

Glossary — Appendix 4 , Appendix D-1020Graphite Pressure Equipment —Appendix 8

Grooving — RB-4110

H

Heat Treatment — RC-1100 , RD-1000 , RE-1200 , Appendix 3-3200 , Appendix B , Appendix C-6070 , RC-1100

High Temperature Water —

Appendix I-3842 , I-3843Hydrogen Attack — RB-4440Hydrogen Embrittlement — RB-4450

I

Illegible Nameplates — RE-1064Inquiries — Appendix 1Inservice Inspection — Part RB ,

Appendix 3 , Appendix 8 , Appendix 9 ,

Appendix C , Appendix H , Appendix I , Appendix KInspection and Test Frequencies —

RB-8410Inspection and Test Methods — RB-3000Installation Condition — RB-8300Installation Requirements — Appendix I

Interface with Owners Repair/ Replacement Program — RA-2370Intergranular Corrosion — RB-4120Internal Inspections — RB-5420 , RB-6230 ,

RB-7320 , Appendix H-3300Interrupted Service — RB-9130

Insulation Material/Insulation — RB-5430 , RB-6220 , RB-7330 , Appendix H-3200

Inspector — RB-1000 , RB-2000 , RB-3000 , RB-4000 , RB-5000 , RB-6000 , RB-8000 , RB-9120 , RC-1000 , RC-2000 , RC-3000 , RD-2000 , RD-3000 , Appendix6-2000 , Appendix 8 , Appendix 9 ,Appendix C-2000 , C-6000 , Appendix I-2900 , I-4900 , AppendixK-1020 , K-2043 , K-3030 , K-4020

J

Jurisdiction — Foreword , Introduction , RA-1010 , RA-2100 , RB-1030 , RB-2230 ,RB-3110 , RB-6500 , RB-8300 , Part RC , RD-1020 , RD-2020 , RD-2040 , RD-3000 , RE-1023 , Appendix 7 , Appendix 8-3000 , Appendix 9 , Appendix C , Appendix I , Appendix J

Jurisdictional Authority — Foreword ,RB-9130 , Appendix 9-3030 ,

Appendix H-1000 , Appendix I-2950 , Appendix J

Jurisdictional Participation — RA-2212Jurisdictional Precedence — Introduction

K

Knuckles — RD-2020 , Appendix 3

LLadders and Runways — Appendix I-2342 ,

I-3352Lamination — RB-4460 , Appendix 9Lap Joints/Seams — RB-4480 , Appendix 3 ,

Appendix C

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INDEX

Leakage — RB-5410 , RB-5430 , RB-5430 , RB-5525 , RB-5600 , RB-6220 , RB-6430 , RB-6440 , RB-7310 , Appendix 3 ,Appendix 8-1020 , Appendix 9-3030 , 9-5420 , 9-5510 , Appendix C-6090 ,Appendix H-3200 , H-3560 ,

Appendix K-1031 , K-1032Leak Testing — RB-3220 , RC-2051Level Indicating Devices —

Appendix I-4710Lift Assist Testing — RE-2030Lighting — Appendix I-2450 , I-3354Line Corrosion — RB-4110Liquid Ammonia Vessels — RB-6450Liquid Penetrant — RB-3130Liquid Pressure Testing — RB-3210 ,

RC-2051 , RC-3031Loadings — Appendix I-3311Local PWHT — RD-1100Locomotive Boilers — Appendix 3Low Water Fuel Cutoff — RB-5528 ,


M

Magnetic Particle — RB-3120Materials — RC-1040 , RE-1040 ,

Appendix 9-1050 , Appendix C-6030;

Preparation — RB-3300; QC Program — Part RA; Selection — RB-4240Metallographic — RB-3170Methods Repair/Alteration,

Examination/Testing — RC-2051 ,RC-3031;

Inspection and Test — RB-3000; Locomotive Inspection —

Appendix 3-2010 , Appendix 3-4000; Repair — RD-2000

Minimum Thickness — RD-3020Mudring — Appendix 3-3330 , 3-3340

N

Nameplates — RB-1030 , RC-1141 , RC-2060 , RC-3040 , RE-1060 , Appendix 2 ,Appendix 7-3000 , Appendix 8-3000 ,8-4000 , Appendix 9-1130 , 9-1140 , 9-2070 ,

9-3040 , Appendix E-2000 , E-3000National Board “R” Symbol Stamp —

RA-2110 , RA-2130 , RA-2140 , RC-1050 ,Appendix 2-2000 , Appendix 8-3000 , Appendix 9-1060

Nondestructive Examination — RB- 3100 ,RB-6500 , RC-1110 , RC-2051 , RC-3031 ,RD-1020 , Appendix 3-2010 ,Appendix 9-1090 , Appendix C-6080 , Appendix H-3400 , Appendix K-1050

“NR” Accreditation — RA-2300“NR” Symbol Stamp — RA-2340

Nuclear Valves (repair) — RA-2214“NV” Stamped Pressure Relief Devices —

Appendix 7

O

Oil Heaters — Appendix I-3610Operating Systems — Appendix I-2600 ,

I-3600Overheating — RB-4470 , Appendix 3-2020

Owner-User Inspection Organization— RA-1010 , RA-2110 , RC-1070

P

Patches — RD-2060 , Appendix 3-3320Performance Qualification — RC-1093 ,

RE-1130Performance Testing — RE-2000Permissible Mounting (SV) —


Personnel Safety — RB-2000 , RB-2100Pilot Operated Safety Relief Valves —

Appendix E-3000Piping — RB-5520 , RB-7000 , RB-8520 ,

Appendix C-2041 , Appendix I Pitting Corrosion — RB-4110Pneumatic Testing — RC-2051 , RC-3031

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Post-Inspection Activities — RB-2230Postweld Heat Treatment — RC-1102 ,

RC-1103 , RD-1000 , RE-1220 , Appendix 3-3200 , Appendix C-6070

Potable Water Heaters — Appendix I-3000 Preheating — RC-1101 , RD-1000 , RE-1210 ,

Appendix BPre-Inspection Activities — RB-2220 ,

RB-5200Preparation of Forms — RC-2071 , RC-3051 ,

Appendix 9-2081 , 9-3051Preservation — Appendix 3-4040Pressure Control — Appendix I-3714Pressure Gages — RB-5526 , RC-1120 ,

Appendix 3-2020 , Appendix 9-1110 ,Appendix C-2035 , Appendix I-2720 ,I-3721

Pressure Relief Devices — RB-5527 , RB-8000 , Appendix I-4800 , I-5800

Pressure-Reducing Valves — Appendix G , Appendix I-2880

Pressure TestingAlterations — RC-3031;

Inservice — RB-3210; Installation — Appendix I-2920 , I-3910 ,

I-4900; FRP Vessels — Appendix 9-2060 , 9-3030; Graphite — Appendix 8-3000; Repairs — RC-2051;

Yankee Dryers — Appendix K-1060Pressure Vessels FRP — Appendix 9; Graphite — Appendix 8; Inspection — RB-6000; Installation — Appendix I-4000; LP Gas (Propane) — Appendix H; Relief — RB-8520; Yankee Dryers — Appendix KProcess Variables (corrosion) — RB-4210Provisions for Expansion/support —

RB-7340

Pumps — Appendix I-2413

Q

Quality Systems — RA-2150 , RA-2250 , RA-2350 , Appendix J-1030

Qualifications NDE — RC-1110;

PRV Personnel — RE-3000; Welders Performance — RC-1093 ,

RE-1130FRP Performance — Appendix 9-1072; Inspector — Appendix 9-5300; Quick-Actuating Closures — RB-6460

R

“R” Symbol Stamp — RA-2140Radiography — RB-3150Reference to other Codes and Standards —

Introduction , RB-1040 , RB-5602 ,Appendix 3 , Appendix 9 , Appendix C

Re-ending — RD-2050 , Appendix 3-3110Registration of “R” Forms — RC-1150 ,

RC-2073 , RC-3053Remaining Life — RB-6600 , RB-9000Removal of Stamping — RC-1141 ,

Appendix 9-1140Renewal of “VR” Certificate — RA-2223Repair — RA-2214 , RA-2370 , Part RC ,

Part RD , Appendix 3 , Appendix 8 ,Appendix 9 , Appendix C- 6000 , Appendix J-1050 , Appendix K-2000

Replacement Parts — RC-1050 , RE-1050 ,Appendix 9-1060 , Appendix C-6040 ,Appendix K-2020

Replacement Stamping — RB-1030 , RE-1064 , Appendix 5 (NB-136)

Rerating — RC-3022 , RD-3010 , Appendix 9-3023 ,

Return Pipe Connections —Appendix I-3660

Return to Service — Appendix 3-4060Rivets — RB-6220 , RB-9130 , RD-2020 ,

RD-2040 , Appendix 3 , Appendix C-4020Rupture Discs — RB-8530Routine Repairs — RC-2031 ,

Appendix 8-3010 , Appendix 9-2040

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S

Safety — RB-2000 , RB-8100 , Appendix9-5440

Safety Devices — RB-6252 , RB-7352 , Appendix C-2030

Safety Valve Capacity —Appendix GSafety/Safety Relief Valves — RB-8000 ,

Appendix IScale and Sludge — RB-5605 , RB-5608Scope of Activities (Accreditation) —

RA-2000 , RA-2151 , RA-2255 , RA-2360Seal Welding — RD-2040 , Appendix 3-3040Seams and Joints — Appendix 3-3400

Thermometer — Appendix I-3732Thinning — Appendix KTraining — RE-3000 , Appendix J-1010Tubes — RB-5000 , RC-2031 , RD-2000 ,

Appendix 3 , Appendix 6-2000 , Appendix 8 , Appendix C-6090

Tubesheet — RB-5000 , RD-2000 , Appendix 3 , Appendix 8 , Appendix C-6090

Threaded Connections/Openings —Appendix 3-3500 , Appendix I-3833 ,I-3854

Threaded Stays, Bolts, Studs —RD 2000 Appendix 3 3020 3 3070