BOILERS Administrative Rules of the Texas Department of Licensing and Regulation 16 Texas Administrative Code, Chapter 65

TABLE OF CONTENTS

65.1. 65.10. 65.20. 65.30. 65.40. 65.50. 65.60. 65.65. 65.70. 65.80. 65.90.

AUTHORITY..................................................................................................................................................1 DEFINITIONS. ...............................................................................................................................................1 LICENSING/CERTIFICATION/REGISTRATION REQUIREMENTS........................................................3 EXEMPTIONS................................................................................................................................................7 METRICATION POLICY. .............................................................................................................................7 REPORTING REQUIREMENTS ...................................................................................................................7 RESPONSIBILITIES OF THE DEPARTMENT............................................................................................8 BOILER BOARD..........................................................................................................................................11 RESPONSIBILITIES OF THE LICENSEE/CERTIFICATE HOLDER/REGISTRANT.............................11 FEES. ............................................................................................................................................................14 SANCTIONS. ...............................................................................................................................................15

65.100. TECHNICAL REQUIREMENTS.................................................................................................................15 EXHIBITS

EXHIBIT 1. .................................................................................................................................................................35 EXHIBIT 3. .................................................................................................................................................................39 EXHIBIT 4. .................................................................................................................................................................40 EXHIBIT 5A. ..............................................................................................................................................................41 EXHIBIT 5B................................................................................................................................................................42 EXHIBIT 5C................................................................................................................................................................43 EXHIBIT 5D ...............................................................................................................................................................44 EXHIBIT 6. .................................................................................................................................................................45

65.1.

AUTHORITY.
(Amended effective January 30, 2000, 25 TexReg 385; amended effective December 1, 2003, 28 TexReg 10452)

The sections in this chapter are promulgated under the authority of the Texas Health and Safety Code, Chapter 755 and the Texas Occupations Code, Chapter 51. 65.10. DEFINITIONS.
(Amended effective August 1, 1996, 21 TexReg 6619; amended effective July 20, 1999, 24 TexReg 5467; amended effective March 27, 2002, 27 TexReg 2223; amended effective December 1, 2003, 28 TexReg 10452; amended effective December 8, 2005, 30 TexReg 8061; amended effective September 1, 2006, 31 TexReg 6717; amended effective December 1, 2007, 32 TexReg 8476)

The following words and terms, when used in this chapter, shall have the following meanings, unless the context clearly indicates otherwise. (1) (2) (3) Alteration--A substantial change in an original design. Approved--Approved by the executive director. ASME Code--The American Society of Mechanical Engineers Boiler and Pressure Vessel Code with addenda, code cases, and interpretations adopted by the council of the society. Authorized inspector--An inspector employed by an inspection agency holding a commission issued by the executive director. Board--The board of boiler rules. Boiler--Any heating boiler, nuclear boiler, power boiler, unfired steam boiler or process steam generator. Boiler external piping--The piping which begins where the ASME Section I or Section VIII, Division 1 o r2 boiler proper or separately fired superheater terminates at: (A) (B) (C) the first circumferential joint for welding end connections; or the face of the first flange in bolted flange connections; or the first threaded joint in that type of connection; and which extends up to and including the valve or valves required by ASME.

(4)

(5) (6)

(7)

(8)

Certificate inspection--The required internal or external boiler inspection, the report of which is used by the chief inspector to decide whether to issue a certificate of operation. Certificate of operation--A certificate issued by the executive director to allow the operation of a boiler. Chief inspector--The inspector appointed in accordance with the Health and Safety Code, 755.023. Code--ASME Code. Commission--The Texas Commission of Licensing and Regulation. Condemned boiler--A boiler inspected and declared unfit for further service by the chief inspector, the deputy inspector, or the executive director. Department--Texas Department of Licensing and Regulation. Deputy inspector--An inspector appointed by the executive director. Electric boiler--A boiler in which the source of heat is electricity. Page 1-R January 1, 2008

(9)

(10) (11) (12) (13)

(14) (15) (16)

Chapter 65, Boilers

(17) (18)

Executive Director--The executive director of the department. Existing installation--Any boiler constructed, installed, placed in operation, or contracted for before June 3, 1937. External inspection--An inspection of the exterior of a boiler and its appurtenances that is made, if possible, while the boiler is in operation. Heating boiler--A steam heating boiler, hot water heating boiler, hot water supply boiler, or potable water heater, that is directly fired with oil, gas, solar energy, electricity, coal, or other solid or liquid fuel. High-temperature water boiler--A water boiler designed for operation at pressures exceeding 160 pounds per square inch gage (1100 kilopascals) or temperatures exceeding 250 degrees Fahrenheit (121 degrees Celsius). Hot water heating boiler--A boiler designed for operation at a pressure not exceeding 160 pounds per square inch gage (1100 kilopascals) or temperatures not exceeding 250 degrees Fahrenheit (121 degrees Celsius) at or near the boiler outlet. Hot water supply boiler--A boiler designed for operation at pressures not exceeding 160 pounds per square inch gage (1100 kilopascals) or temperatures not exceeding 250 degrees Fahrenheit (121 degrees Celsius) at or near the boiler outlet if the boilers: heat input exceeds 200,000 British thermal units per hour (58.6 kilowatts); water temperature exceeds 210 degrees Fahrenheit (99 degrees Celsius); or nominal water-containing capacity exceeds 120 gallons (454 Liters). Inspection agency--An authorized inspection agency providing inspection services. Inspector--The chief inspector, a deputy inspector, or an authorized inspector. Internal inspection--A complete and thorough inspection of the interior waterside and fireside areas of a boiler as construction allows. Metric (SI)--An international system of measurement. Metrication--The process of converting between US customary units and metric (SI) units. Modular boiler--A steam or hot water heating assembly consisting of a group of individual boilers called modules, intended to be installed as a unit, with a single inlet and single outlet. Modules may be under one jacket or may be individually jacketed. Multiple pressure steam generator--A boiler consisting of several sections of heat exchange surface designed for different pressure levels. National Board--The National Board of Boiler and Pressure Vessel Inspectors. National Board Inspection Code--The manual for boiler and pressure vessel inspectors published by the National Board. New installations--A boiler constructed, installed, or placed in operation after June 3, 1937. Nominal--The accepted ASME standard used to designate a size or capacity of an item. Nonstandard boiler--A boiler that does not qualify as a standard boiler. Nuclear boiler--A nuclear power plant system, including its pressure vessels, piping systems, pumps, valves, and storage tanks, that produces and controls an output of thermal energy from nuclear fuel and the associated systems essential to the function of the power system. Page 2-R January 1, 2008

(19)

(20)

(21)

(22)

(23)

(24) (25) (26)

(27) (28) (29)

(30)

(31) (32)

(33) (34) (35) (36)

Chapter 65, Boilers

(37)

Owner or operator--Any person, firm, or corporation owning or operating boilers within the State of Texas. Portable power boiler--A boiler primarily intended for use at a temporary location. Potable water heater --A boiler designed for operation at pressures not exceeding 160 pounds per square inch gage (1100 kilopascals) and water temperatures not exceeding 210 degrees Fahrenheit (99 degrees Celsius) if the boilers: heat input exceeds 200,000 British thermal units per hour (58.6 kilowatts) or nominal water-containing capacity exceeds 120 gallons (454 liters). Power boiler--A high-temperature water boiler or a boiler in which steam is generated at a pressure exceeding 15 pounds per square inch gage (103 kilopascals) for a purpose external to the boiler. Preliminary order--A written order issued by the chief inspector or any deputy inspector to require repairs or alterations to render a boiler safe for use or to require that operation of the boiler be discontinued. A Repair Requirement form that is signed by the chief inspector or a deputy inspector is a Preliminary Order. Process steam generator--An evaporator, heat exchanger, or vessel in which steam is generated by the use of heat resulting from the operation of a processing system that contains a number of pressure vessels, such as used in the manufacture of chemical and petroleum products. Reinstalled boiler--A boiler removed from its original setting and reinstalled at the same location or at a new location without change of ownership. Repair--The work necessary to return a boiler to a safe and satisfactory operating condition without changing the original design. Rules--The rules promulgated and enforced by the commission in accordance with the Health and Safety Code, Section 755.032 and Occupations Code, Chapter 51. Safety appliance--A safety device such as a safety valve or a safety relief valve for a boiler provided to diminish the danger of accidents. Secondhand boiler--A boiler of which both the location and ownership have changed. Special inspection--An inspection by the chief inspector or deputy inspector other than those in the Health and Safety Code, Sections 755.025, 755.026, and 755.027. Standard boiler--A boiler that bears a Texas stamp, the stamp of a nationally recognized engineering professional society, or the stamp of any jurisdiction that has adopted a standard of construction equivalent to the standard required by the executive director. Steam heating boiler--A boiler designed for operation at pressures not exceeding 15 pounds per square inch gage (103 kilopascals). Unfired steam boiler--An unfired pressure vessel in which steam is generated. The term does not include: vessels known as evaporators or heat exchangers; or vessels in which steam is generated by using the heat that results from the operation of a processing system that contains a number of pressure vessels, as used in the manufacture of chemical and petroleum products.

(38) (39)

(40)

(41)

(42)

(43)

(44)

(45)

(46)

(47) (48)

(49)

(50)

(51)

65.20.

LICENSING/CERTIFICATION/REGISTRATION REQUIREMENTS.
(Amended effective August 1, 1996, 21 TexReg 6619; amended effective March 1, 1998, 23 TexReg 1564; amended effective April 13, 1999, 24 TexReg 2934; amended effective July 20, 1999, 24 TexReg 5467; amended effective March 27, 2002, 27 TexReg 2223; amended effective December 1, 2003, 28 TexReg 10452; amended effective September 1, 2005, 30 TexReg 4971; amended effective December 8, 2005, 30 TexReg 8061)

(a)

Inspection of all boilers.

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(1)

All boilers not exempted by the Texas Health and Safety Code Ann. Section 755.022 shall be inspected in accordance with the Texas Health and Safety Code Ann. Section 755.025 and/or Section 755.026, or with requirements specified under the applicable rules. Boilers shall be inspected by the inspection agency that has accepted responsibility for the inspection. All other boilers shall be inspected by the chief inspector or deputy inspector.

(2)

(b)

Notice to owners or operators of boilers. (1) All boilers, unless otherwise exempted, shall be prepared for initial inspection, regular inspections, or hydrostatic tests, whenever necessary, by the owner or operator when notified by the chief inspector, deputy inspector, or authorized inspector. The owner or operator shall prepare each boiler, in accordance with Section 65.70(h) for an internal inspection and shall prepare for and apply the hydrostatic tests whenever necessary on the date specified by the chief inspector, deputy inspector, or authorized inspector. This date shall not be less than seven days after the date of notification. No inspection shall be made by the chief inspector or any deputy inspector on a Saturday, Sunday, or legal holiday except in case of an accident or other emergency.

(2)

(3)

(c)

Registration. (1) The procedure for an owner or operator to follow in registering a boiler with the department shall be as follows. (A) At the time of purchase, installation, or prior to commencing service, the owner or operator shall notify the inspection agency that the time for assigning the state number and the initial inspection is imminent. The inspection agency will register the boiler within 30 days of the owner or operator notification. If there is no inspection agency, the owner or operator shall notify the department. The chief inspector will provide to the owner/operator, within three working days of the notification, a form to apply for a temporary operating permit. The chief inspector shall, within five working days of receipt of the completed request for temporary operating permit, respond to the owner or operator and deputy inspector. The deputy inspector shall, within 30 days of receipt of the approved request, register the boiler. The owner or operator shall apply to the department for certification prior to any boiler operation. Application for certification is defined as the completed first inspection report. The inspector shall file the application with the executive director within 30 days of the inspection. Before the certification can be approved, the completed application and certificate/inspection fee must be received and accepted by the department. If the boiler has not been registered with the National Board, the owner or operator shall apply to the executive director for a variance. Any person, owner, or operator may request a variation from a rule or decision. The request for variation shall specify how the equivalent safety is to be maintained. The executive director, after investigation and such hearing as he may direct, may, on his own motion, grant such variation from the terms of any rule or decision.

(B)

(C)

(D)

(E)

(2)

The procedure for an owner or operator to follow in registering with the department portable or stationary nonstandard boilers used solely for exhibition, instruction, education, show, display, or demonstration shall be as follows. (A) The owner or operator shall apply to the department for certification as a special designed boiler prior to any boiler operation. Upon receipt of the request to register a portable or stationary nonstandard boiler, the chief Page 4-R January 1, 2008

(B) Chapter 65, Boilers

inspector will, within five working days of receipt of the request, notify the deputy inspector. The deputy inspector shall file the application within 30 days of the inspection. (C) Before the certification can be approved, the completed application and certificate/inspection fee must be received and accepted by the department.

(d)

External inspection. External inspections shall be performed as part of the application for an extension to the inspection interval in the Health and Safety Code, 755.026. Otherwise, it shall be conducted in conjunction with the annual internal inspection required in the Health and Safety Code, 755.025. Extension of interval between internal inspections. (1) For the interval between internal inspection to be extended as provided for in the Health and Safety Code, 755.026, the following procedure must be followed. (A) Not less than 30 days prior to the expiration date of the current certificate, the owner or operator shall submit to the executive director a separate request for each boiler, stating the desired length of extension, the date of the last internal inspection, and a statement certifying that records are available showing compliance with the Health and Safety Code, 755.026. Upon receipt of the owner's or operator's request and statement that records have been kept as required by the Health and Safety Code, 755.026, the executive director shall confirm the records and ensure the extension period is not exceeded. The executive director shall then notify the owner or operator and the inspection agency having jurisdiction of the maximum extension period that may be approved. The inspection agency shall then review all records, make an external inspection, and submit to the executive director, along with the external inspection report, a statement confirming compliance with the Health and Safety Code, 755.026, and the recommended extension period, not to exceed the approved maximum. Upon completion of subparagraphs (A)-(C) of this paragraph, a new certificate of operation may be issued for the extended period of operation, provided all fees have been paid.

(e)

(B)

(C)

(D)

(2)

An additional extension for up to 120 days may be allowed as provided for in the Health and Safety Code, 755.026, when it is established an emergency exists. (A) Prior to the expiration date of the current certificate the owner or operator shall submit to the executive director a request stating an emergency exists with an explanation of the emergency and the date of the last internal inspection. The request shall be submitted along with the inspection agency's report of external inspection, confirming compliance with the Health and Safety Code, 755.026, and the recommended period of extension. Upon receipt of the request and the accompanying report of external inspection, the executive director shall confirm the records and ensure the extension requirements are met. The executive director shall then notify the owner or operator and the inspection agency having jurisdiction of the approved period of extension. Upon completion of the previously stated requirements, a new certificate of operation may be issued for the extended period of operation, provided all fees have been paid as required.

(B)

(C)

(f)

Procedure for appeal of executive director decisions. (1) Any person aggrieved by a decision of the executive director may notify the executive director of the grievance in writing. An appeal pursuant to this subsection is governed by Chapter 2001, Government Code, the Administrative Procedure Act.

(2)

(g)

Examination for a commission. Deputy inspectors and authorized inspectors shall be qualified in accordance Page 5-R January 1, 2008

Chapter 65, Boilers

with the Health and Safety Code, 755.023 and 755.024, respectively. (1) Deputy inspectors. (A) The Texas commission examination is mandatory under the following conditions for: (i) (ii) new issuance - inspectors applying for the initial issuance; reinstatement - inspectors seeking reinstatement with a time lapse of more than 12 months.

(B)

Examinations shall be scheduled by the chief inspector and held at the office of the Texas Department of Licensing and Regulation or any other location selected by the chief inspector. If the applicant is successful in obtaining a score of 70%, a commission will be issued by the executive director. An applicant who fails to pass the examination will be permitted to take another examination after a suitable period of instruction determined by the chief inspector.

(C)

(D)

(2)

Authorized inspectors. (A) The Texas commission examination is mandatory under the following conditions for: (i) new issuance - inspectors applying for the initial issuance who are not designated by the employing inspection agency to perform ASME code new construction inspection only; reinstatement - inspectors seeking reinstatement with a time lapse of 12 months or more without any type of inspection activity and are not designated by the employing inspection agency to perform ASME code new construction inspections only.

(ii)

(B)

Application for examination for a commission as an inspector shall be in writing upon a form to be furnished by the executive director stating the education of the applicant, a list of employers, period of employment, and position(s) held with each employer. Applicants for a commission shall submit with their initial application an examination fee as required in 65.80(c) of this title (relating to Fees). This examination fee must be received by the department before an applicant can take the examination. An applicant who repeats the examination because of an unsuccessful first attempt shall submit an examination fee for each time the examination is repeated. If the applicant's qualifications meet the approval of the executive director, he shall be given a written examination dealing with the construction, installation, maintenance, repair, and inspection of boilers. Examinations shall be scheduled by the chief inspector and held at the office of the Texas Department of Licensing and Regulation or any other location selected by the chief inspector. If the applicant is successful in obtaining a score of 70%, a commission will be issued by the executive director. An applicant who fails to pass the examination will be permitted to take another examination after a suitable period of instruction determined by the employing agency. The record of an applicant's examination shall be made accessible to the applicant and his employers.

(C)

(D)

(E)

(F)

(G)

(H)

(3)

Notification of examination results. Not later than the 30th day after the date on which an examination Page 6-R January 1, 2008

Chapter 65, Boilers

is administered to an applicant for a commission as an inspector of boilers, the executive director shall notify each examinee of the results of the examination. (4) Additional manual copies. A commissioned inspector shall be issued an initial Texas Boiler Law and Rules manual.

65.30.

EXEMPTIONS.

The provisions of these rules shall not apply to those boilers exempted by the Health and Safety Code, Section 755.022. 65.40. (a) METRICATION POLICY.
(New section effective December 1, 2007, 32 TexReg 8476)

The following provides policy guidelines for the use of US customary units and metric (SI) units. Throughout Chapter 65, metric (SI) units are identified and placed in parentheses after the US customary units in the text and any associated exhibits. There are two rationales when converting between US customary units and metric (SI) units: (1) Soft conversions A soft conversion is an exact conversion. (A) (B) (2) Example: 200,000 Btu/hr = 58.56208 kW Example: 120 gallons = 454.24944 liters

(b)

Hard conversions A hard conversion is simply performing a soft conversion and then rounding off within the intended specific range. (A) (B) Example: 200,000 Btu/hr = 58.6 kW Example: 120 gallons = 454 liters

(c)

Repairs and alterations, when performed, shall be to the specified units used in the original code of construction. If the original units are US customary units, then the repair or alteration shall be to US customary units, and if the original units are metric (SI) units, then the repair or alteration shall be to the metric (SI) units. The selected units shall be used consistently throughout each repair or alteration and all aspects of the work required (i.e. materials, design, procedures, testing, documentation and stamping). The following procedure shall be used when converting between US customary units and metric (SI) units: (1) (2) (3) (4) All conversions will be done using a soft conversion. Soft conversions will be reviewed for accuracy. Depending upon a specified value in Chapter 65, an appropriate degree of precision shall be identified. A rounding up or down may apply to each conversion to determine the degree of precision needed for each application.

(d)

65.50.

REPORTING REQUIREMENTS
(Amended effective August 1, 1996, 21 TexReg 6619; amended effective April 13, 1999, 24 TexReg 2934; amended effective July 20, 1999, 24 TexReg 5467; amended effective September 1, 2005, 30 TexReg 4971; amended effective December 8, 2005, 30 TexReg 8061)

(a)

Manufacturer's data reports. Manufacturer's data reports shall be filed by the manufacturer with the chief inspector and the National Board. Risks and Inspection Agreements. All inspection agencies shall notify the chief inspector, of all boiler risks or inspection agreements written, canceled, or not renewed within 30 days of the effective date. Immediate notification shall be made of all boiler risks rejected or suspended or inspection agreements cancelled or not Page 7-R January 1, 2008

(b)

Chapter 65, Boilers

renewed because of unsafe conditions. The inspection agency shall immediately notify the chief inspector and submit a report of the defects. Notification may be made electronically or manually using the format provided by the department. This notification shall list, by Texas boiler number, all objects affected by the notice. (c) Inspection report forms. At the time of the first inspection of any boiler covered by the provisions of the Health and Safety Code, Chapter 755, a complete report shall be submitted manually or electronically using the format provided by the department. Subsequent inspection reports shall be submitted manually or electronically using the format provided by the department. The reports shall be submitted within 30 days of the date of the inspection. External inspections shall be reported manually or electronically using the format provided by the department when hazardous conditions affecting the safety of the boiler are found to exist or to document the inspection required for extension of the internal inspection interval. Boiler installation. Any person, firm, or corporation performing a boiler installation in the state will certify compliance with the Texas Boiler Law and Rules by filing a boiler installation report and manufacturers data report on new boilers (and when available, on second hand boilers) with the chief inspector within 30 days of completion. The appropriate form will be provided by the chief inspector upon request. Defective conditions disclosed at time of external inspection. If there is evidence of a leak or crack, the covering of the boiler shall be removed to satisfy the inspector as to the safety of the boiler. If the covering cannot be removed at that time, he may order the operation of the boiler discontinued until such time as the covering can be removed and proper examination made. Boiler accidents. (1) In case of a serious accident, such as an explosion, the owner/operator shall immediately notify the chief inspector and authorized inspector. Neither the boiler nor any of the parts thereof shall be removed or disturbed, except for the purpose of saving human life or preventing further damage, before an inspection and investigation has been made by the chief inspector, deputy inspector, or authorized inspector. The authorized inspector shall notify the chief inspector before beginning an inspection and investigation of serious boiler accidents. To the extent necessary to conduct an inspection and subsequent investigation of a boiler accident, the owner/operator shall provide the chief inspector or deputy inspector free access to the boiler and accident area. The owner/operator shall provide the chief inspector or deputy inspector and authorized inspector with fragments, parts, appurtenances, documents, and records necessary to conduct an investigation of the accident. The chief inspector shall investigate, or cause to be investigated, each boiler accident to the extent necessary to reasonably determine the cause of the boiler accident. The authorized inspector shall submit a report of the boiler accident to the chief inspector. The report shall be submitted on a form supplied by the department. The chief inspector shall file a final report detailing the cause for the boiler accident, including a recommendation to prevent a recurrence of a similar boiler accident.

(d)

(e)

(f)

(2)

(3)

(4)

(5)

(g)

Repair and alteration report forms. All repair and alteration report forms shall be filed, by the organization making the repair or alteration, with the chief inspector within 90 days following the repair or alteration. Interagency reporting. Deputy fire marshals under the State Board of Insurance and inspectors under the Department of Health, who during routine inspections encounter boilers which are unregistered, or in the opinion of the inspector unsafe, shall report these boilers on forms provided by the department within five working days. In the case of unsafe boilers, immediate notification shall also be made to the office of the chief inspector. RESPONSIBILITIES OF THE DEPARTMENT
(Amended effective March 1, 1998,23 TexReg 1564; amended effective July 20, 1999, 24 TexReg 5467; amended effective December 1, 2003, 28 TexReg 10452; amended effective September 1, 2005, 30 TexReg 4971; amended effective December 8, 2005, 30 TexReg 8061)

(h)

65.60.

(a)

Inspector's duties. Inspectors shall be regularly employed as an inspector and shall not engage in the sale of any article or device relating to boilers, pressure vessels, or other appurtenances. Page 8-R January 1, 2008

Chapter 65, Boilers

(b)

Commissions. (1) Deputy inspectors. (A) A commission as a deputy inspector and an identifying commission card shall be issued by the executive director to an inspector who has successfully passed the examination as set forth in 65.20(g) of this title (relating to Licensing/Certification/Registration Requirements). The identifying commission card shall be returned to the chief inspector when the inspector to whom the commission was issued is no longer employed by the department. If a commission and/or identifying commission card is lost or destroyed, a replacement shall be issued without examination upon request. Annual renewal of a commission shall be accomplished by the department and a new identifying commission card will be issued. In lieu of the examination provided for in 65.20(g) of this title (relating to Licensing/Certification/Registration Requirements), a commission may be issued to an inspector holding a certificate of competency as an inspector of boilers and pressure vessels for a jurisdiction that has a standard written examination substantially equal to that of the State of Texas.

(B)

(C)

(D)

(2)

Authorized inspector. (A) Upon the request of an inspection agency, authorized to do business in this state, a commission as an authorized inspector and an identifying commission card shall be issued by the executive director to an inspector in the employ of such inspection agency provided the inspector has successfully passed the examination as set forth in 65.20(g) of this title. The identifying commission card shall be returned to the chief inspector when the inspector to whom the commission was issued is no longer in its employ. An inspector, commissioned as provided in this section, shall be entitled to another commission upon leaving the employ of one inspection agency and entering the employ of another such agency without examination, provided the executive director is notified immediately of such reemployment and provided that a commission reinstatement fee and new application are submitted. If a commission and/or identifying commission card is lost or destroyed, a replacement shall be issued without examination upon request and receipt of the replacement fee as stated in 65.80(c) of this title (relating to fees). Annual renewal of a commission is required and shall be received by the department not less than 30 days prior to the expiration date. Upon receipt of a written request and the renewal fee as stated in 65.80(c) of this title (relating to fees), a new identifying commission card will be issued. In lieu of the examination provided for in 65.20(g) of this title (relating to Licensing/Certification/Registration Requirements), a commission may be issued to an inspector holding a certificate of competency as an inspector of boilers and pressure vessels for a jurisdiction that has a standard written examination substantially equal to that of the State of Texas. Written requests for new issuances, renewals, or reinstatements will specify if the scope of work to be performed will be ASME code inspections only, inservice inspections only, or both. When a request is for new issuance or reinstatement as described in 65.20(g)(2)(A)(i) and (ii) of this title (relating to Licensing/Certification/Registration Requirements), the inspector will attend a mandatory indoctrination period of one and one-half days prior to issuance of the commission.

(B)

(C)

(D)

(E)

(F)

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(c)

Assignment of boiler numbers and identification. (1) Texas boiler numbers shall be issued as a decal to all inspection agencies and deputy inspectors as requested in writing. Only numbers issued by the chief inspector shall be assigned to boilers. Only the official decal and corrosion-resistant metal tags supplied by the chief inspector may be used. Only one Texas boiler number shall be assigned to a boiler. Reassignment of Texas boiler numbers shall be made with the approval of the chief inspector. During the first inspection of all boilers, the inspector shall stamp, except as provided for in paragraphs (3) and (4) of this subsection, the Texas boiler number as near to the original American Society of Mechanical Engineers (ASME) code symbol stamping and required information as practicable. All numbers shall be given on the first inspection report, including the National Board registration number and manufacturer's serial number. The stamping shall consist of the letters TX and directly below the TX shall be stamped the Texas boiler number with a five point star stamped immediately adjacent to the first and last digit of the Texas boiler number. All stamping shall be accomplished by low stress steel dies 5/16 inch (8 millimeters) high. The stamping shall be arranged as shown in Exhibit 3. In addition, the corrosion-resistant metal tag shall be applied, as permanently as practicable, to the external jacket or other covering where the surface temperature exceeds 200 degrees Fahrenheit (93.3 degrees Celsius), or the Texas boiler number decal shall be applied where the surface does not exceed 200 degrees Fahrenheit (93.3 degrees Celsius). The tag or decal shall be located on the boiler so that identification is easily obtained from the most accessible operating control side or information label side. Potable water heaters ASME code symbol stamped HLW, cast iron sectional boilers, water tube boilers with cast headers, and other types of boilers that will be damaged by direct impression stamping are exempt from the stamping requirements of paragraph (2) of this subsection. These boilers shall be identified with the Texas boiler number decal or corrosion-resistant tag. Portable or stationary nonstandard boilers shall be identified by the Texas boiler number as described in paragraph (2) of this subsection with an exception that the Texas boiler number decal shall not be applied. The letters "TEXAS SPECIAL" or "TX SPCL" shall identify portable or stationary nonstandard boilers and shall be stamped directly above the Texas boiler number. The Texas boiler number or other boiler identifying numbers shall not be concealed by lagging or paint. No person except the chief inspector or deputy inspector shall deface or remove such numbers, except as approved by the chief inspector.

(2)

(3)

(4)

(5)

(6)

(d)

Condemned boilers. (1) Any boiler, stamped or identified with the corrosion-resistant metal tag, having been inspected and declared unsafe by the chief inspector or deputy inspector, shall be stamped by the inspector with an X on the star on either side of the Texas boiler number, as shown by the following facsimile, which will designate a condemned boiler: TX X123456X Any boiler, identified with the Texas boiler number decal, having been inspected and declared unsafe by the chief inspector or deputy inspector, shall be altered by the inspector by removing the star on either side of the Texas boiler number, as shown in Exhibit 4. This will designate a condemned boiler.

(2)

(e)

Interagency requirements. The department shall provide for those inspectors described in 65.50(h) the following: (1) (2) (3) current copies of the boiler rules; training in the recognition of unregistered or unsafe boilers; forms to identify, as a minimum, the owner/operator, location, number, and types of boilers; and Page 10-R January 1, 2008

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(4) 65.65.

current roster of the department's headquarters and regional enforcement staff.

BOILER BOARD.
(Amended effective March 1, 1998, 23 TexReg 1564; amended effective July 20, 1999 24 TexReg 5467; amended effective December 1, 2003, 28 TexReg 10452)

(a)

The purpose of the Boiler Board is to advise the commission in the adoption of definitions and rules relating to the safe construction, installation, inspection, operating limits, alteration, and repair of boilers and their appurtenances. Recommendations of the board will be transmitted to the commission by the executive director. Expenses reimbursed to board members shall be limited to authorized expenses incurred while on board business and traveling to and from board meetings. The least expensive method of travel should be used. Expenses paid to board members shall be limited to those allowed by the State of Texas Travel Allowance Guide and Texas Department of Licensing and Regulation policies governing travel allowances for employees. RESPONSIBILITIES OF THE LICENSEE/CERTIFICATE HOLDER/REGISTRANT.
(Amended effective December 1, 2003, 28 TexReg 10452; amended effective December 8, 2005, 30 TexReg 8061; amended effective September 1, 2006, 31 TexReg 6717; amended effective December 1, 2007, 32 TexReg 8476)

(b) (c)

(d)

65.70.

(a)

New installations. (1) No boiler, except reinstalled boilers and those exempted by the Health and Safety Code, 755.022, shall be installed in this state unless it has been constructed, inspected, and stamped in conformity with the applicable section of the ASME code and registered with the National Board of Boiler and Pressure Vessel Inspectors, and is approved, registered, and inspected in accordance with the requirements of these rules. Cast iron sectional boilers need not be registered with the National Board. A boiler having the standard stamping of another state that has adopted a standard of construction equivalent to the standard of the State of Texas, or a special-designed boiler, may be accepted by the executive director. Any person desiring to install such a boiler shall make application for the installation and shall file with this application the manufacturer's data report covering the construction of the boiler in question. New boilers, including reinstalled boilers, shall be installed in accordance with the requirements of the latest revision of the applicable section of the ASME code and these rules. These boilers shall be inspected within 30 days of the owner or operator notification. Secondhand boilers shall meet all the requirements for new installations, including code construction and stamping requirements.

(2)

(3)

(4)

(b)

Existing installations. (1) The maximum allowable working pressure for standard boilers shall be determined in accordance with the applicable provisions of the edition of the ASME code under which they were constructed and stamped. In no case shall the maximum allowable working pressure of an existing nonstandard boiler be increased to a greater pressure than would be allowed for a new boiler of same construction. The age limit of any boiler of nonstandard construction installed prior to the date this law became effective shall be 30 years, except after a thorough internal and external annual inspection and annual hydrostatic pressure test of one and one-quarter times the allowable working pressure held for a period of at least 30 minutes, during which no distress or leakage develops. At no time, while applying the hydrostatic pressure test, shall the pressure exceed one and one-quarter times the allowable working pressure by more than 6%. Any boiler having other than a lap-riveted longitudinal joint may be continued in operation without reduction in working pressure. The age limit of any nonstandard boiler Page 11-R January 1, 2008

(2)

(3)

Chapter 65, Boilers

having lap-riveted longitudinal joints and operating at a pressure in excess of 50 psig (345 kilopascals) shall be 20 years; this type of boiler, when removed from the existing setting, shall not be reinstalled for a pressure in excess of 15 psig (103 kilopascals); and a reasonable time for replacement shall be given at the discretion of the executive director. (4) Shipment of portable or stationary nonstandard boilers into this state for use is prohibited unless application has been made for approval as a portable or stationary nonstandard boiler used for exhibition, instruction, education, show, display, or demonstration. The request to register a portable or stationary nonstandard boiler should include a sufficient description of the materials, methods of construction, drawings, and such other design information as required by the chief inspector to establish the maximum allowable working pressure. As an alternative, the chief inspector may require a proof test of the portable or stationary nonstandard boiler in accordance with the edition of the Code determined to be most applicable for the method of construction. In any case where a boiler is moved and reinstalled, the fittings and appliances must comply with the ASME code. The maximum allowable working pressure on the shell of an existing steam heating boiler shall not exceed 15 psig (103 kilopascals). For a hot water heating boiler, the working pressure shall not exceed 160 (1100 kilopascals) psig or a temperature of 250 degrees Fahrenheit (121 degrees Celsius). The maximum allowable working pressure on the shell of an existing riveted heating boiler shall be determined in accordance with the National Board Inspection Code covering existing installations for riveted boilers.

(5)

(6)

(c)

Attendance on boilers. A boiler in operation shall be under the supervision of and checked at suitable intervals by a competent attendant, regardless of whether or not it is equipped with automatic feed water regulator, fuel and damper regulator, high-and-low-water alarm, or any other form of automatic control. A competent attendant shall be a person who is familiar with the operation of the boiler and who has been properly instructed in its safe operation. Care of boiler room. (1) The boiler room shall be free from accumulation of rubbish and materials that obstruct access to the boiler, its setting, or firing equipment. The storage of flammable material or gasoline-powered equipment in the boiler room is prohibited. The roof over boilers designed for indoor installations shall be free from leaks and maintained in good condition. Adequate drainage shall be provided. All exit doors shall open outward. Two or more exits remote from each other should be provided. It is recommended that the ASME Code, Section VI, covering recommended rules for the care and operation of heating boilers be used as a guide for proper and safe operating practices. It is recommended that the ASME Code, Section VII, recommended rules for care and operation of power boilers, be used as a guide for proper and safe operating practices.

(d)

(2) (3)

(4) (5) (6)

(7)

(e)

Foundations and levels. (1) All boilers shall be kept reasonably level and must be provided with a substantial foundation such as steel, concrete, brick, or stone. The boiler mud rim or bottom of a vertical boiler setting shall not be less than six inches (152 millimeters) from the ground. The locomotive-type boiler mud rim or wet bottom shall have the foundation of its setting not less than 12 inches (305 millimeters) from the floor or ground. All boiler mud rims shall be accessible to the inspector. Boilers that are not level and do not have substantial foundations may be removed from service until such provisions are provided. Page 12-R January 1, 2008

(2)

Chapter 65, Boilers

(3)

Supports for boilers shall be masonry or structural steel of sufficient strength and rigidity to safely support the boiler. There shall be no vibration in either the boiler or its connecting piping.

(f)

Clearance. (1) All boilers and their appurtenances shall be so located that adequate space will be provided for the proper operation, inspection, maintenance, and repair. The minimum manufacturers recommended clearances shall be maintained, except for portable boilers. A minimum of one foot (305 millimeters) shall be maintained between the bottom of scotchtype boilers and the foundation or floor.

(2)

(g)

Safety appliances. (1) General. No one shall remove (except temporarily for repair), fail to replace after removal, displace, damage, destroy, carry off, tamper with, or fail to use any safety appliance. When the safety appliance has been removed for repairs and the seal broken, such appliance shall not be replaced on the boiler until it is in proper working order. Such appliance shall not be set at a pressure in excess of the working pressure stated on the certificate of operation. The seal shall be replaced prior to returning the boiler to service. Dismantled boiler. When a boiler is dismantled or moved, all safety appliances must conform to the requirements governing new installations prior to a return to service.

(2)

(h)

Preparation for inspection. (1) The owner or operator shall prepare a boiler for internal inspection in the following manner. (A) (B) Water shall be drawn off and the boiler thoroughly washed. All manhole and handhole plates, washout plugs, and plugs in water column connections shall be removed as necessary for complete inspection. The furnace and combustion chambers shall be thoroughly cooled and cleaned. All grates of internally fired boilers shall be removed. Brickwork shall be removed as required by the inspector in order to determine the condition of the boiler, headers, furnace, supports, or other parts. The pressure gage shall be removed for cleaning of the siphon and testing, if necessary. The low-water cutoff device shall be dismantled, cleaned, and prepared for inspection. Before removing the manhole or handhole covers and entering any part of the boiler connected to a common header with other boilers any leakage of steam or hot water shall be eliminated. The nonreturn and stop valves must be closed, tagged, and preferably padlocked, and drain valves between the two valves opened. The feedwater valves must be closed, tagged, and preferably padlocked. After draining the boiler, the blowdown valves shall be closed and preferably padlocked. Blowdown lines, where practicable, shall be disconnected between pressure parts and valves. All vent and drain lines shall be opened.

(C) (D)

(E) (F) (G)

(2)

If the boiler is jacketed so that the seams of shells, drums, or domes cannot be seen, enough of the jacketing, setting wall, or other form of casing or housing shall be removed to permit inspection to determine the safety of the boiler, provided such information cannot be determined by other means. Portable or stationary nonstandard boilers shall be prepared for inspection as described in this section with the following additional requirements. (A) External lagging and insulation shall be removed and ultrasonic thickness measurements Page 13-R January 1, 2008

(3)

Chapter 65, Boilers

shall be performed for the first inspection and at five-year intervals for subsequent inspections. (B) Other examinations as required by the chief inspector or deputy inspector shall be performed to determine the condition of the boiler. Any other inspections or examinations shall be performed as determined by the chief inspector as a condition for registration.

(C)

(i)

Boiler stamping. Restamping or nameplate replacement shall be in accordance with the National Board Inspection Code and jurisdictional requirements. Heating systems. Potable water heaters (HLW stamped boilers) shall not be incorporated into a hot water heating system as a hot water heating boiler. Modular boilers. (1) All modular steam heating and hot water heating boilers that meet all of the requirements of ASME Section IV, HG-716 shall be registered with a single Texas boiler number. All the information that is required for each section of the modular boiler shall be included on the application for certification in the conditions block.

(j)

(k)

(2)

(l)

Multiple pressure steam generators. (1) A multiple pressure steam generator that meets the requirements of PG-106.12 shall be registered with a single Texas boiler number. All the information that is required in PG-106.12.6 that is included on the manufacturers master data report shall be provided in the conditions block on the application for certification. All previously registered multiple pressure steam generators with multiple Texas boiler numbers shall remain as they were originally registered and a separate inspection report will be completed for each boiler number.

(2)

(3)

(m)

Stacked boiler. The owner or operator of boilers that are to be stacked, shall submit to this Department the manufacturers designed or fabricated stacking rack information for approval from the chief inspector. FEES.
(Amended effective October 1, 1995, 20 TexReg 7278; amended effective August 1, 1996,, 21 TexReg 6619; amended effective March 1, 1998, 23 TexReg 1564; amended effective January 30, 2000, 25 TexReg 385; amended effective April 18, 2000, 25 TexReg 3247; amended effective September 1, 2001, 26 TexReg 6010; amended effective March 27, 2002, 26 TexReg 2223; amended effective September 1, 2003, 28 TexReg 7363; amended effective January 1, 2008, 32 TexReg 9963)

65.80.

(a)

Certificate/inspection fees. (1) Inspection by authorized inspector. The owner or operator or his/her agent shall make a $70 payment for the certificate of operation fee. Inspection by deputy inspector. The owner or operator shall make payment of the appropriate fee as shown below. (A) (B) The inspection fees for all boilers other than heating boilers shall be $140. The inspection fees for heating boilers shall be: (i) (ii) those without a manhole--$110; and those with a manhole--$140.

(2)

Chapter 65, Boilers

Page 14-R

January 1, 2008

(3)

All fees must be paid in full to the Texas Department of Licensing and Regulation, P. O. Box 12157, Austin, Texas 78711 before a certificate of operation will be issued.

(b)

Special inspections. The fee for a special inspection is $1,200. A prepayment of $1,200 shall be received by the department at least five working days before the department can initiate the requested special inspection. Prepayment shall be made by certified check or money order made payable to the Texas Department of Licensing and Regulation. Texas Commission fees. (1) (2) (3) (4) Exam - $25, re-exam - $25. New - $25, renewal - $10. Reinstatement - $25. Replacement: (A) (B) (C) (5) certificate only - $10; identifying commission card only - $10; certificate and identifying commission card - $25.

(c)

Late renewal fees for commissions issued under this chapter are provided under <*>60.83 of this title (relating to Late Renewal Fees).

(d) 65.90. (a)

Exam administration fees: The National Board exam fee is $25. SANCTIONS.
(Amended effective December 1, 2003, 28 TexReg 10452)

Boilers improperly prepared for inspection or test. If a boiler has not been properly prepared for an internal inspection or a hydrostatic test as set forth in these sections, the inspector may decline to make the inspection or witness the test, and the certificate of operation shall be withheld until the owner or operator complies with all requirements. If a person violates the Texas Health and Safety Code Annotated, Chapter 755 (Vernon 1999), or a rule, or order of the Executive Director or Commission relating to this Code and Chapter, proceedings may be instituted to impose administrative sanctions and/or recommend administrative penalties in accordance with this Code, or the Texas Occupations Code, Chapter 51 (Vernon 1999) and 16 Texas Administrative Code, Chapter 60 (1999) of this title (relating to the Texas Department of Licensing and Regulation). Suspension or revocation of a commission. (1) An inspector's commission may be suspended or revoked by the executive director after due investigation and hearing for the inspector's incompetence, untrustworthiness, or willful falsification in his application or in an inspection report made by him or others. A person whose commission has been suspended is entitled to apply for reinstatement after 90 days from the date of such suspension. Any commission that is revoked shall be treated as a new application for a commission and can be filed no sooner than one year after the effective date of revocation.

(b)

(c)

(2)

65.100.

TECHNICAL REQUIREMENTS.
(Amended effective March 1, 1998, 23 TexReg 1564; amended effective April 13, 1999, 24 TexReg 2934 amended effective July 20, 1999, 24 TexReg 5467; amended effective January 30, 2000, 25 TexReg 385; repealed effective June 9, 2002, 27 TexReg 4685; new section effective June 9, 2002, 27 TexReg 4685; amended effective December 1, 2003, 28 TexReg 10452; amended effective December 8, 2005, 30 TexReg 8061; amended effective September 1, 2006, 31 TexReg 6717; amended effective December 1, 2007, 32 TexReg 8476)

Chapter 65, Boilers

Page 15-R

January 1, 2008

(a)

Conditions not covered by rules. (1) Any owner or operator of boilers or any deputy inspector, authorized inspector, or interested party may submit in writing an inquiry to the executive director for an opinion or clarification. All conditions not specifically covered by these requirements shall be treated as new installations or be referred to the chief inspector for instruction.

(2)

(b)

General safety. (1) If, in the judgment of the inspector, a boiler is unsafe for operation at the pressure previously approved, the pressure shall be reduced and proper repair made, or the boiler shall be removed from service. Before internal access is made to a boiler by an inspector, the inspector shall deem the environment within the boiler to be safe for occupancy.

(2)

(c)

Ventilation. (1) The boiler room must have an adequate and uninterrupted air supply to assure proper combustion and ventilation. The combustion and ventilation air may be supplied by either an unobstructed opening or by power ventilators or fans. The opening shall be sized on the basis of one square inch (645 square millimeters) of free area for each 2,000 Btu/hour (.586 kilowatts) input of the combined burners located in the boiler room. The power ventilator or fans shall be sized on the basis of 0.2 cfm. (5.6 liters per minute) for each 1,000 Btu/hour (.29 kilowatts) fuel input for the combined burners located in the boiler room. The boiler and the fans shall be interlocked so that the burners will not operate unless an adequate number of fans are in operation.

(2)

(3)

(4)

(5)

(d)

Location of discharge outlets. The discharge of safety valves and safety relief valves, blowdown pipes, and other outlets shall be located to prevent injury to personnel. Electric steam boilers. (1) A cable at least as large as one of the incoming power lines to the generator shall be provided for grounding the generator shell. This cable shall be permanently fastened on some part of the generator and shall be grounded in an approved manner. A suitable screen or guard shall be provided around high-voltage bushings, and a sign posted warning of high voltage. This screen or guard shall be so located that it will be impossible for anyone working around the generator to accidentally come in contact with the high voltage circuit. In electric boilers of the submerged-electrode type, the water gage glass shall be located to indicate the water levels both at start-up and under maximum load conditions as established by the manufacturer. Electric boilers of the resistance-element type shall have at least one gage glass. The lowest visible water level in the gage glass shall be at least 1 inch (25 millimeters) above the lowest permissible water level as determined by the manufacturer. Each boiler of this type shall be equipped with an automatic low-water cutoff to cut off the power supply before the surface of the water falls below the visible level in the gage glass. Tubular gage glasses on electric boilers shall be equipped with protective rods or shields. The minimum safety valve or safety relief valve relieving capacity for electric boilers shall be 3 1/2 pounds (24 kilopascals) of steam per hour per kilowatt input. Page 16-R January 1, 2008

(e)

(2)

(3)

(4)

(5) (6)

Chapter 65, Boilers

(7)

All electric boilers shall be internally examined through the electric heating element, removable cover, inspection opening or handhole as construction allows.

(f)

Atmospheric vents, gas vents, bleed or relief lines for power boilers, unfired steam boilers and process steam generators with supplemental firing (extensions only, where applicable). (1) Gas pressure regulators not incorporating integral vent limiters, and all other gas train components requiring atmospheric air pressure to balance a diaphragm or other similar device, shall be provided with a connection for a vent line. These lines shall be sized in accordance with the component manufacturers instructions. The vent or relief line shall be at least the same size as the vent outlet of the device. (A) Where there is more than one gas pressure regulator at a location, each gas pressure regulator shall have a separate vent. The vent lines may be manifolded in accordance with accepted engineering practices to minimize back pressure in the event of a diaphragm failure (see paragraphs (2) and (3) following). A gas pressure regulator shall not be vented into the boiler flue or exhaust system.

(B) (2)

Atmospheric vent lines, when manifolded, shall be connected into a common atmospheric vent line having a cross-sectional area not less than the area of the largest vent line plus 50% of the areas of the additional vent lines. Atmospheric vent lines shall not be connected to any common or manifolded gas vent, bleed, or relief lines. Gas pressure relief valves may discharge into common manifolding only with other gas vent, bleed, or relief lines. When manifolded, the common vent line shall have a cross-sectional area not less than the area of the largest vent line plus 50% of the areas of the additional vent lines. Vent and relief lines shall be piped to the outdoors at a safe point of discharge so there is no possibility of discharged gas being drawn into the air intake, ventilating system, or openings of any structure or piece of equipment and shall extend sufficiently above any structure so that gaseous discharge does not present a fire hazard. A means shall be provided at the terminating point to prevent blockage of the line by foreign material, moisture, or insects.

(3)

(4)

(5)

(g)

Power boilers, excluding unfired steam boilers and process steam generators. (1) Safety valves and safety relief valves. (A) The use of weighted-lever safety valves, or safety valves having either the seat or disk of cast iron, is prohibited. Each boiler shall have at least one safety valve and, if it has more than 500 square feet (47 square meters) of water heating surface or has electric power input more than 1,100 kilowatts, it shall have two or more safety valves. Safety valves or safety relief valves shall be connected so as to stand in the upright position, with spindle vertical. The opening or connection between the boiler and the safety valve or safety relief valve shall have at least the area of the valve inlet. The valve or valves shall be connected to the boiler, independent of any other steam connection, and attached as close as practicable to the boiler without unnecessary intervening pipe or fittings. No valve(s) of any description shall be placed between the required safety valve or safety relief valve or valves and the boiler, nor in the discharge pipe between the safety valve or safety relief valve or valves and the atmosphere. When a discharge pipe is used, it shall be at least full size of the safety valve discharge and fitted with an open drain to prevent water Page 17-R January 1, 2008

(B)

(C)

(D)

(E)

Chapter 65, Boilers

lodging in the upper part of the safety valve or discharge pipe. When an elbow is placed on a safety valve discharge pipe, it shall be located close to the safety valve outlet. The discharge pipe shall be securely anchored and supported. In the event multiple safety valves discharge into a common pipe, the discharge pipe shall be sized in accordance with ASME Code, Section I, PG-71. All safety valve or safety relief valve discharges shall be located or piped to a safe point of discharge clear from walkways or platforms. (F) The safety valve capacity of each boiler must allow the safety valve or valves to discharge all the steam that can be generated by the boiler without allowing the pressure to rise more than 6.0% above the highest pressure to which any valve is set, and to no more than 6.0% above the maximum allowable working pressure. For forced-flow steam generators with no fixed steam and waterline, power-actuated relieving valves may be used in accordance with ASME Code, Section I, PG-67. One or more safety valves on every boiler shall be set at or below the maximum allowable working pressure. The remaining valve(s) may be set within a range of 3.0% above the maximum allowable working pressure, but the range of setting of all the safety valves on a boiler shall not exceed 10% of the highest pressure to which any valve is set. When two or more boilers, operating at different pressures and safety valve settings, are interconnected, the lower pressure boilers or interconnected piping shall be equipped with safety valves of sufficient capacity to prevent overpressure, considering the maximum generating capacity of all boilers. In those cases where the boiler is supplied with feedwater directly from water mains without the use of feeding apparatus (not to include return traps), no safety valve shall be set at a pressure higher than 94% of the lowest pressure obtained in the supply main feeding the boilers.

(G)

(H)

(I)

(2)

Feedwater supply. (A) Each boiler shall have a feedwater supply, which will permit it to be fed at any time while under pressure, except for automatically fired miniature boilers that meet all of the following criteria: (i) (ii) (iii) the boiler is M stamped per ASME Code, Section I; the boiler is designed to be fed manually; the boiler is provided with a means to prevent cold water from entering into a hot boiler; and the boiler is equipped with a warning sign visible to the operator not to introduce cold feedwater into a hot boiler.

(iv)

(B)

A boiler having more than 500 square feet (47 square meters) of water heating surface shall have at least two means of feeding, one of which should be a pump, injector, or inspirator. A source of feed directly from water mains at a pressure of at least 6.0% greater than the set pressure of the safety valve with the highest setting may be considered as one of the means of feeding. Boilers fired by gaseous, liquid, or solid fuel in suspension may be equipped with a single means of feeding water, provided means are furnished for the immediate shutoff of heat input if the feedwater is interrupted. Feedwater shall not be discharged close to riveted joints of shell or furnace sheets or directly against surfaces exposed to products of combustion or to direct radiation from the fire. Feedwater piping to the boiler shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler. When two or more boilers are fed from a common source there shall also be a stop valve on the branch to each boiler between the check valve and the source of supply. Whenever a globe valve is used on the feedwater Page 18-R January 1, 2008

(C)

(D)

Chapter 65, Boilers

piping, the inlet shall be under the disk of the valve. (E) In all cases where returns are fed back to the boiler by gravity, there shall be a check valve and stop valve in each return line, the stop valve to be placed between boiler and the check valve, and both shall be located as close to the boiler as is practicable. It is recommended that no stop valve be placed in the supply and return pipe connections of a single boiler installation. Where deaerating heaters are not used, it is recommended that the temperature of the feedwater be not less than 120 degrees Fahrenheit (49 degrees Celsius) to avoid the possibility of setting up localized stress. Where deaerating heaters are used, it is recommended that the minimum feedwater temperature be not less than 215 degrees Fahrenheit (102 degrees Celsius) so that dissolved gases may be thoroughly released.

(F)

(3)

Water level indicators. (A) Each boiler, except forced-flow steam generators with no fixed steam and waterline, and high temperature water boilers of the forced circulation type that have no steam and waterline, shall have at least one water gage glass. Except for electric boilers of the electrode type, boilers with a maximum allowable working pressure (MAWP) over 400 psig (three megapascals) shall be provided with two water gage glasses, which may be connected to a single water column or connected directly to the drum. Two independent remote level indicators may be provided instead of one of the two required gage glasses for boiler drum water level indication, when the MAWP is above 400 psig (three megapascals). When both remote level indicators are in reliable operation, the remaining gage glass may be shut off, but shall be maintained in serviceable condition. In all installations where direct visual observations of the water gage glass(es) cannot be made, two remote level indicators shall be provided at operational level. The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (diameter nominal 15). No outlet connections, except for damper regulator, feedwater regulator, drains, steam gages, or apparatus of such form as does not permit the escape of an appreciable amount of steam or water therefrom, shall be placed in the pipes connecting a water column or gage glass to a boiler. The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (diameter nominal 20). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (diameter nominal 20) and shall be piped to a safe point of discharge. Connections from the boiler to remote level indicators shall be at least 3/4 inch nominal pipe size (diameter nominal 20), to and including the isolation valve, and at least 1/2 inch (13 millimeters) OD tubing from the isolation valve to the remote level indicator. These connections shall be completely independent of other connections for any function other than water level indication.

(B)

(C)

(D)

(E)

(F)

(G)

(H)

(4)

Low-water fuel cutoff and water feeding devices. (A) All automatically fired steam boilers, except boilers having a constant attendant, who has no other duties while the boiler is in operation, shall be equipped with approved low-water fuel cutoffs. These devices shall be installed in such a manner that they cannot be rendered inoperative by the manipulation of any manual control or regulating apparatus. The lowwater fuel cutoff devices shall be tested regularly by lowering the water level in the boiler sufficiently to shut off the fuel supply to the burner when the water level reaches the lowest safe level for operation. The low-water cutoff shall be rated for a pressure and temperature equal to or greater than the maximum allowable working pressure and temperature of the Page 19-R January 1, 2008

Chapter 65, Boilers

boiler. (B) When a low-water fuel cutoff and feedwater pump control are combined in a single device, an additional separate low-water fuel cutoff shall be installed. The additional control shall be wired in series electrically with the existing low-water fuel cutoff. When a low-water fuel cutoff is housed in either the water column or a separate chamber it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (diameter nominal 20). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the lower-water fuel cutoff device. If a water feed device is utilized, it shall be constructed to prevent feedwater from entering the boiler through the water column or separate chamber of the low-water fuel cutoff.

(C)

(D)

(5)

Pressure gages. (A) Each boiler shall have a pressure gage that is easily readable. The dial of the pressure gage shall be graduated to approximately double the pressure at which the safety valve is set, but in no case, less than one and one-half times this pressure. The pressure gage shall be connected to the steam space, to the water column, or its steam connection. A valve or cock shall be placed in the gage connection adjacent to the gage. An additional valve or cock may be located near the boiler providing it is locked or sealed in the open position. No other shutoff valves shall be located between the gage and the boiler. The pipe connection shall be of ample size and arranged so that it may be cleared by blowing down. For a steam boiler, the gage or connection shall contain a siphon or equivalent device which will develop and maintain a water seal that will prevent steam from entering the gage tube. Each boiler must have a valved connection at least 1/4 inch nominal pipe size (diameter nominal 8) connected to the steam space for the exclusive purpose of attaching a test gage when the boiler is in service to test the accuracy of the pressure gage.

(B)

(6)

Stop valves. (A) Each steam outlet from a boiler (except safety valve connections) shall be fitted with a stop valve located as close as practicable to the boiler. When a stop valve is located that allows water to accumulate, ample drains shall be provided. The drain shall be piped to a safe location and shall not be discharged on the boiler or its setting. When boilers provided with manholes or other similar opening that permits access for human occupancy and that are connected to a common steam main, the steam connection from each boiler shall be fitted with two stop valves with an ample drain between them. The discharge of the drain shall be visible to the operator while manipulating the valves and shall be piped clear of the boiler setting. The stop valves shall consist preferably of one automatic nonreturn valve (set next to the boiler) and a second valve of the outside-screw-and-yoke type.

(B)

(C)

(7)

Blowdown connection. (A) The construction of the setting around each blowdown pipe shall permit free expansion and contraction. These setting openings must be sealed without restricting the movement of the blowdown piping. All blowdown piping, when exposed to furnace heat, shall be protected by firebrick or other heat-resisting material, and constructed to allow the piping to be inspected readily or easily. Each boiler shall have a blowdown pipe, fitted with a valve or cock, in direct connection with the lowest water space. The piping shall be run full size without the use of a reducer or Page 20-R January 1, 2008

(B)

(C)

Chapter 65, Boilers

bushings and shall not be galvanized. Cocks shall be of gland or guard type and suitable for the pressure allowed. The use of globe valves shall be in accordance with ASME code. (D) When the maximum allowable working pressure exceeds 100 psig (700 kilopascals), the piping shall be at least schedule 80 steel and shall not be galvanized. Each blowdown pipe shall be provided with two valves or a valve and cock, such valves and cocks shall be adequate for design conditions of the boiler. All fittings between the boiler and blowdown valve shall be of steel or extra-heavy malleable iron. In case of renewal of blowdown pipe or fittings, they shall be installed in accordance with the requirements of the applicable section of the ASME code. It is recommended that blowdown tanks be designed, constructed, and installed in accordance with National Board recommended rules for boiler blowoff equipment.

(E)

(F)

(8)

Boiler external piping. All boiler external piping, as referenced in the ASME code, shall be examined for compliance to the boilers code of construction and shall be documented in the appropriate block on the inspection report.

(h)

Unfired steam boilers. (1) (2) Unfired steam boilers referred to in Section 65.10 are shown in Exhibits 5C and 5D. Unfired steam boilers shall be constructed in accordance with the American Society of Mechanical Engineers (ASME), Section I, or ASME, Section VIII, Division 1. Safety valves and safety relief valves (A) The use of weighted-lever safety valves, or safety valves having either the seat or disk of cast iron, is prohibited. Each ASME Code, Section VIII, Division 1 unfired steam boiler shall have at least one pressure relieving device. Safety valves for ASME, Section VIII, Division 1 unfired steam boilers shall be V or UV stamped. ASME, Section VIII, Division 1 does not require that the relief device be attached directly to the boiler. (i) The installation of isolation valves between the unfired steam boiler and the safety valve is permitted for systems designed and installed as depicted in Exhibit 5C. Full-area stop valves may be installed on the inlet side of a safety valve as shown in Exhibit 5C. A full-area stop valve may be installed on the discharge of the safety valve when connected to a common header. Stop valves shall be car sealed or locked in the open position. One or more safety valves on every unfired steam boiler shall be set at or below the maximum allowable working pressure. The remaining valves, if any, shall be set within the range specified and have the capacity required by the applicable ASME code.

(3)

(B)

(ii)

(iii)

(C)

Each ASME Code, Section I unfired steam boiler shall have one safety valve and if it has more than 500 square feet (47 square meters) of water heating surface it shall have two or more safety valves. ASME Code, Section I safety valves shall be V stamped. (i) The valve or valves shall be connected to the boiler, independent of any other steam connection, and attached as close as practicable to the boiler without unnecessary intervening pipe or fittings.

(ii) No valves of any description shall be placed between the required safety valve or safety relief valve or valves and the boiler, nor on the discharge pipe between the safety valve or safety relief valve and the atmosphere. Chapter 65, Boilers Page 21-R January 1, 2008

(iii)

The safety valve capacity of each unfired steam boiler must allow the safety valve or valves to discharge all the steam that can be generated by the boiler without allowing the pressure to rise more than 6.0% above the highest pressure to which any valve is set, and to no more than 6.0% above the maximum allowable working pressure.

(D)

When a discharge pipe open to the atmosphere is used, it shall be at least full size of the safety valve discharge and fitted with an open drain to prevent water lodging in the upper part of the safety valve or discharge piping. The drain or drains shall be piped to a safe point of discharge. When an elbow or fitting is installed on the discharge pipe it shall be located close to the safety valve outlet. The discharge pipe shall be securely anchored and supported. All safety valve discharges shall be located or piped to a safe point of discharge clear from walkways or platforms. When two or more unfired steam boilers operating at different pressures and safety valve settings are interconnected, the lower pressure boilers or interconnected piping shall be equipped with safety valves of sufficient capacity to prevent overpressure, considering the maximum generating capacity of all boilers. Safety valve and safety relief valve mountings. (i) For ASME Code, Section I installations, safety valves or safety relief valves shall be connected so as to stand in the upright position, with spindle vertical. The opening or connection between the boiler and the safety valve or safety relief valve shall have at least the area of the valve inlet. For ASME Code, Section VIII, Division 1 installations, safety valves or safety relief valves normally should be installed in the upright position with spindle vertical. Where space or piping configurations preclude such an installation, the valve may be installed in other than the vertical position, provided that: (I) (II) the valve design is satisfactory for such position; the media is such that material will not accumulate at the inlet of the valve; and drainage of the discharge side of the valve body and discharge piping is adequate.

(E)

(F)

(ii)

(III)

(4)

Feedwater supply. (A) Each unfired steam boiler shall have a feedwater supply which will permit it to be fed at any time while under pressure. Feedwater piping to the unfired steam boiler constructed to ASME Code, Section I shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler. When two or more boilers are fed from a common source there shall also be a stop valve on the branch to each boiler between the check valve and the source of supply. Whenever a globe valve is used on the feedwater piping, the inlet shall be under the disk of the valve. Where deaerating heaters are not used, it is recommended that the temperature of the feedwater be not less than 120 degrees Fahrenheit (49 degrees Celsius) to avoid the possibility of setting up localized stress. Where deaerating heaters are used, it is recommended that the minimum feedwater temperature be not less than 215 degrees Fahrenheit (102 degrees Celsius) so that dissolved gases may be thoroughly released.

(B)

(C)

(5)

Water level indicators.

Chapter 65, Boilers

Page 22-R

January 1, 2008

(A)

ASME Code, Section I unfired steam boilers with a maximum allowable working pressure (MAWP) of 400 psig (three megapascals) or less shall have at least one gage glass. For a MAWP over 400 psig (three megapascals) shall have two required gage glasses. When two gage glasses are required one of the gage glasses may be replaced by two independent remote level indicators that are maintained in simultaneous operation while the boiler is in service. Each steam drum of an ASME Code, Section VIII, Division 1 unfired steam boiler, irrespective of pressure and temperature, shall be provided with one direct reading water level indicator (water gage glass) or two independent remote level indicators that are maintained in simultaneous operation while the boiler is in service. In all installations where direct visual observations of the water gage glass(es) cannot be made, two remote level indicators shall be provided at operational level. The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (diameter nominal 15). No outlet connections, except for feedwater regulators, drains, steam gages, or apparatus of such form as does not permit the escape of an appreciable amount of steam or water therefrom, shall be placed in the pipes connecting a water column or gage glass to a boiler. The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (diameter nominal 20). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (diameter nominal 20) and shall be piped to a safe point of discharge. Connections from the unfired steam boiler to remote level indicators shall be at least 3/4 inch nominal pipe size (diameter nominal 20), to and including the isolation valve, and at least 1/2 inch (13 millimeters) OD tubing from the isolation valve to the remote level indicator. These connections shall be completely independent of other connections for any function other than water level indication.

(B)

(C)

(D)

(E)

(F)

(G)

(6)

Low-water cutoffs, alarms and feed regulating devices. (A) The owner/operator is responsible for the design and installation of any low water protection devices as required to prevent damage to the unfired steam boiler. All installed low water cutoffs, alarms and feeding devices shall be designed for pressure and temperature equal or greater than the maximum allowable working pressure of the unfired steam boiler. When a low-water cutoff, and/or alarm is housed in either the water column or a separate chamber, it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (diameter nominal 20). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the low-water cutoff and/or alarm device. Should an unfired steam boiler be installed in a system without a local and constant attendant, and it is not a fail safe design, it shall be provided with a low-water cutoff as required for power boilers.

(B)

(C)

(7)

Pressure gages. (A) Each unfired steam boiler shall have a pressure gage that is easily readable. The dial of the pressure gage shall be graduated to approximately double the pressure at which the safety valve is set, but in no case, less than one and one-half times this pressure. The pressure gage shall be connected to the steam space, to the water column, or its steam connection. A valve or cock shall be placed in the gage connection adjacent to the gage. An additional valve or cock may be located near the boiler providing it is locked or sealed in the open position. No other shutoff valves shall be located between the gage and the boiler. The pipe connection shall be of ample size and arranged so that it may be cleared by blowing down. The gage or connection shall contain a siphon or equivalent device which will develop and maintain a water seal that will prevent steam from entering the gage tube. Page 23-R January 1, 2008

Chapter 65, Boilers

(B)

Each unfired steam boiler must have a valved connection at least 1/4 inch nominal pipe size (diameter nominal 8) connected to the steam space for the exclusive purpose of attaching a test gage when the boiler is in service to test the accuracy of the pressure gage.

(8)

Stop valves. (A) Each steam outlet from an ASME Code, Section I unfired steam boiler shall be fitted with a stop valve located as close as practicable to the boiler. When a stop valve is located such that it allows water to accumulate, ample drains shall be provided. The drain shall be piped to a safe location and shall not be discharged on the boiler or its setting. When boilers that are provided with manholes or other similar openings that permit access for human occupancy are connected to a common steam main, the owner or operator shall ensure that the boiler to which entry is being made is completely isolated from the steam main. This may be accomplished with the use of two stop valves with an ample drain between them, with a full isolation blind or removal of piping such that the boiler is no longer connected to the steam main.

(B)

(C)

(i)

Process steam generators. (1) (2) Some process steam generators referred to in Section 65.10 are shown in Exhibits 5A and 5B. The steam collection or liberation drums of a process steam generator shall be constructed in accordance with the American Society of Mechanical Engineers (ASME) Section VIII, Division 1 or Division 2, and shall be stamped with the U or U2 symbol. As an alternate the process steam generator may be constructed to ASME Code, Section I. When the owner/operator elects to construct a process steam generator to ASME Code, Section I, the limits as shown in Exhibits 5A and 5B are as defined in the rules of ASME Section I. Safety valves and safety relief valves. (A) The use of weighted-lever safety valves, or safety valves having either the seat or disk of cast iron is prohibited. Each ASME Code, Section VIII, Division 1 or Division 2 steam collection or liberation drum of a process steam generator shall have at least one safety valve designed for steam service with the V or UV stamp. The valve body drain shall be open and piped to a safe point of discharge. (i) The installation of full-area stop valves between the steam collection or liberation drum of a process steam generator and the safety valve is permitted as depicted in Exhibit 5A and 5B. A full-area stop valve may be installed on the discharge of the safety valve when connected to a common header. Stop valves shall be car sealed or locked in the open position. One or more safety valves on every steam collection or liberation drum of a process steam generator shall be set at or below the maximum allowable working pressure. The remaining valves, if any, shall be set within the range specified and have the capacity required by the applicable ASME code.

(3)

(4)

(B)

(ii)

(C)

Each ASME Code, Section I process steam generator shall have one safety valve and if it has more than 500 square feet (47 square meters) of water heating surface it shall have two or more safety valves. ASME Code, Section I safety valves shall be V stamped. (i) The valve or valves shall be connected to the steam collection or liberation drum of the process steam generator, independent of any other steam connection, and Page 24-R January 1, 2008

Chapter 65, Boilers

attached as close as practicable to the steam collection or liberation drum without unnecessary intervening pipe or fittings. (ii) No valves of any description shall be placed between the required safety valve or safety relief valve or valves and the steam collection or liberation drum, nor on the discharge pipe between the safety valve or safety relief valve and the atmosphere. The safety valve capacity of each process steam generator must allow the safety valve or valves to discharge all the steam that can be generated by the process steam generator without allowing the pressure to rise more than 6.0% above the highest pressure to which any valve is set, and to no more than 6.0% above the maximum allowable working pressure.

(iii)

(D)

When a discharge pipe open to the atmosphere is used, it shall be at least full size of the safety valve discharge and fitted with an open drain to prevent water lodging in the upper part of the safety valve or discharge piping. The drain or drains shall be piped to a safe point of discharge. When an elbow or fitting is installed on the discharge pipe it shall be located close to the safety valve outlet. The discharge pipe shall be securely anchored and supported. All safety valve discharges shall be located or piped to a safe point of discharge clear from walkways or platforms. When two or more steam collection or liberation drums of process steam generators, operating at different pressures and safety valve settings are interconnected, the lower pressure process steam generator(s) or interconnected piping shall be equipped with safety valves of sufficient capacity to prevent overpressure, considering the maximum generating capacity of all of process steam generators. Safety valve and safety relief valve mountings. (i) For ASME Code, Section I installations, safety valves or safety relief valves shall be connected so as to stand in the upright position, with spindle vertical. The opening or connection between the boiler and the safety valve or safety relief valve shall have at least the area of the valve inlet. For ASME Code, Section VIII, Division 1 or Division 2 installations, safety valves or safety relief valves normally should be installed in the upright position, with spindle vertical. Where space or piping configurations preclude such an installation, the valve may be installed in other than the vertical position, provided that: (I) (II) the valve design is satisfactory for such position; the media is such that material will not accumulate at the inlet of the valve; and drainage of the discharge side of the valve body and discharge piping is adequate.

(E)

(F)

(ii)

(III)

(5)

Feedwater supply. (A) Each steam collection or liberation drum of a process steam generator shall have a feedwater supply which will permit it to be fed at any time while under pressure. Feedwater piping to a process steam generator constructed to ASME Code, Section I shall be provided with a check valve near the process steam generator and a stop valve or cock between the check valve and the process steam generator. When two or more process steam generators are fed from a common source there shall also be a stop valve on the branch to each process steam generator between the check valve and the source of supply. Whenever a globe valve is used on the feedwater piping, the inlet shall be under the disk of the valve.

(B)

Chapter 65, Boilers

Page 25-R

January 1, 2008

(C)

Where deaerating heaters are not used, it is recommended that the temperature of the feedwater be not less than 120 degrees Fahrenheit (49 degrees Celsius) to avoid the possibility of setting up localized stress. Where deaerating heaters are used, it is recommended that the minimum feedwater temperature be not less than 215 degrees Fahrenheit (102 degrees Celsius) so that dissolved gases may be thoroughly released.

(6)

Water level indicators. (A) ASME Code, Section I process steam generators with a MAWP of 400 psig (three megapascals) or less shall have at least one gage glass. For a MAWP over 400 psig (three megapascals) shall have two required gage glasses. When two gage glasses are required one of the gage glasses may be replaced by two independent remote level indicators that are maintained in simultaneous operation while the process steam generator is in service. Each steam collection or liberation drum of an ASME Code, Section VIII, Division 1 or Division 2 process steam generator, irrespective of pressure and temperature, as shown in Exhibit 5A and 5B shall be provided with one direct reading water level indicator (water gage glass) or two independent remote level indicators that are maintained in simultaneous operation while the process steam generator is in service. In all installations where direct visual observations of the water gage glass(es) cannot be made, two remote level indicators shall be provided at operational level. The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (diameter nominal 15). No outlet connections, except for feedwater regulator, drains, steam gages, or apparatus of such form as does not permit the escape of an appreciable amount of steam or water therefrom, shall be placed on the pipes connecting a water column or gage glass on the steam collection or liberation drum of a process steam generator. The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (diameter nominal 20). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (diameter nominal 20) and shall be piped to a safe point of discharge. Connections from the steam collection or liberation drum of a process steam generator to remote level indicators shall be at least 3/4 inch nominal pipe size diameter nominal 20), to and including the isolation valve, and at least 1/2 inch (13 millimeters) OD tubing from the isolation valve to the remote level indicator. These connections shall be completely independent of other connections for any function other than water level indication.

(B)

(C)

(D)

(E)

(F)

(G)

(7)

Low-water cutoffs, alarms and feed regulating devices. (A) The owner/operator is responsible for the design and installation of any low water protection devices as required to prevent damage to the process steam generator. All installed low water cutoffs, alarms and feeding devices shall be designed for a pressure and temperature equal to or greater than the maximum allowable working pressure and temperature of the process steam generator steam collection or liberation drum. When a low-water cutoff, and/or alarm is housed in either the water column or a separate chamber, it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (diameter nominal 20). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the low-water cutoff and/or alarm device. Should a steam collection or liberation drum of a process steam generator be installed in a system without a local and constant attendant, and it is not a fail safe design, it shall be provided with a low-water cutoff as required for power boilers.

(B)

(C)

(8)

Pressure gages. Page 26-R January 1, 2008

Chapter 65, Boilers

(A)

Each steam collection or liberation drum of a process steam generator shall have a pressureindicating device that is easily readable from the primary operating station. The range shall be graduated to approximately double the pressure at which the safety valve is set, but in no case, less than one and one-half times this pressure. The pressure-indicating device shall be connected to the steam space, or to the water column, or its steam connection. A valve or cock shall be placed in the gage connection adjacent to the gage. An additional valve or cock may be located near the steam collection or liberation drum of the process steam generator. No other shutoff valves shall be located between the gage and the steam collection or liberation drum of the process steam generator. The pipe connection shall be of ample size and arranged so that it may be cleared by blowing down or flushing. The pressure-indicating device shall be provided with a siphon or equivalent device, which will develop and maintain a water seal that will prevent steam from entering the pressure-indicating device. Each steam collection or liberation drum of a process steam generator must have a valved connection at least 1/4 inch nominal pipe size (diameter nominal 8) connected to the steam space for the purpose of attaching a test gage when the process steam generator is in service to test the accuracy of the pressure-indicating device.

(B)

(9)

Stop valves. (A) Each steam outlet from a ASME Code, Section I process steam generator shall be fitted with a stop valve located as close as practicable to the steam collection or liberation drum of the process steam generator. When a stop valve is located that allows water to accumulate, ample drains shall be provided. The drain shall be piped to a safe location and shall not be discharged on the process steam generator or its setting. When boilers that are provided with manholes or other similar openings that permit access for human occupancy are connected to a common steam main, the owner or operator shall ensure that the boiler to which entry is being made is completely isolated from the steam main. This may be accomplished with the use of two stop valves with an ample drain between them, with a full isolation blind or removal of piping such that the boiler is no longer connected to the steam main.

(B)

(C)

(j)

Nuclear boilers. (1) Nuclear boilers shall be inspected inservice by the owner or operator in accordance with ASME Boiler and Pressure Vessel Code, Section XI. The owner or operator shall engage the services of an inspection agency, qualified in accordance with American National Standards Institute/American Society of Mechanical Engineers (ANSI/ASME) N626.1, licensed by the Texas State Board of Insurance, and authorized to provide inspection services by the executive director. The chief inspector shall assign, after receipt of the completed N-3 owner's data report, a state serial number to the nuclear boiler. (A) All N-5 data reports for piping systems and N-3 owner's data reports shall be filed with the chief inspector. National Board registration described in Section 65.50(a) or Section 65.20(c)(1)(D) is not required.

(2)

(3)

(B)

(4)

The certificate of operation will be issued after receipt of the preservice inspection summary report and prior to commercial service. The summary report shall include all activities required by ASME Code, Section XI, except for the results of examinations or test of items obtainable only during power ascension testing. These items shall be filed as an amendment to the summary report within 60 days of the completion of the power ascension testing. The items identified to be submitted in the Page 27-R January 1, 2008

Chapter 65, Boilers

amendment shall be agreed upon by mutual consent as provided for in paragraph (11) of this subsection prior to power ascension testing and issuance of the certificate of operation. (5) The inservice inspection plan shall be submitted to the chief inspector by the owner or operator prior to commercial service. The chief inspector shall review the inservice inspection plan and select those items necessary to verify compliance with the Health and Safety Code, Chapter 755 and ASME Code, Section XI. Items selected for verification shall be from within the verification boundary of the nuclear boiler consisting of the components and component supports of the systems illustrated in Exhibit 6. The chief inspector shall, upon reasonable notification by the owner or operator of inservice inspection activities to be accomplished during any outage on items selected in subsection (h) of this section, coordinate with the owner or operator the verification activities. The chief inspector shall review and maintain summary reports of the inservice inspections that are submitted by the owner or operator in accordance with ASME Code, Section XI. Repairs and/or replacements shall conform to the requirements of ASME Code, Section XI. The owner or operator shall, in case of serious accidents to a nuclear boiler involving a breach of the pressure boundary integrity of components included in Exhibit 6 immediately notify the chief inspector by the most expeditious means available and apprise him of the nature of the accident. The chief inspector shall assess the nature of the accident, formulate inspection activities as required, and coordinate these activities with the owner or operator and as necessary with other state and federal agencies having jurisdiction. If exceptions or situations arise which are not specifically addressed in this section or other sections of the Boiler Law and Rules, or in ASME Code, Section XI, the owner or operator shall contact the chief inspector for guidance or interpretation.

(6)

(7)

(8)

(9) (10)

(11)

(k)

Heating boilers. (1) Steam heating. (A) Safety valves. (i) Each steam boiler shall have one or more officially rated safety valves of the spring pop type adjusted and sealed to discharge at a pressure not to exceed 15 psig (103 kilopascals). Seals shall be attached in a manner to prevent the valve from being taken apart without breaking the seal. The safety valves shall be arranged so that they cannot be reset to relieve at a higher pressure than the maximum allowable working pressure of the boiler. A body drain connection below seat level shall be provided. For valves exceeding 2 1/2 inch nominal pipe size (diameter nominal 65), the drain hole or holes shall be tapped not less than 3/8 inch nominal pipe size (diameter nominal 10). For valves 2 1/2 inch nominal pipe size (diameter nominal 65) or less, the drain hole shall not be less than 1/4 inch (6 millimeters) in diameter. Each safety valve 3/4 inch nominal pipe size (diameter nominal 20) or over used on a steam boiler shall have a substantial lifting device which will positively lift the disk from its seat at least 1/16 inch (1.6 millimeters) when there is no pressure on the boiler. The seats and disks shall be of suitable material to resist corrosion. No safety valve for a steam boiler shall be smaller than 1/2 inch nominal pipe size (diameter nominal 15). No safety valve shall be larger than 4 1/2 inches nominal pipe size (diameter nominal 115). The inlet opening shall have an inside diameter approximately equal to, or greater than, the seat diameter. The minimum relieving capacity of valve or valves shall be governed by the capacity marking on the boiler. Page 28-R January 1, 2008

(ii)

(iii)

(iv)

Chapter 65, Boilers

(v)

The minimum valve capacity in pounds per hour shall be the greater of that determined by dividing the maximum Btu output 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 the pounds of steam generated per hour per square foot of boiler heating surface as given in Table 1 of Exhibit 2. For cast iron boilers, the minimum valve capacity shall be determined by the maximum output method. In every case, the safety valve capacity for each steam boiler shall be such that with the fuel burning equipment installed, and operated at maximum capacity, the pressure cannot rise more than five psig (35 kilopascals) above the maximum allowable working pressure. Safety valve piping. No valve shall be placed between the safety valve and the boiler or on the discharge pipe between the safety valve and the atmosphere. When a discharge pipe is used, it shall be full size and fitted with an open drain to prevent water from lodging in the upper part of the safety valve or relief valve or in the discharge pipe. When an elbow is placed on the safety valve discharge pipe, it shall be located close to the valve outlet. The discharge pipe shall be securely anchored and supported, independent of the valve. Safety valves and safety relief valves shall be installed on the boiler with their spindles vertical. The opening or connection between the boiler and any safety valve or safety relief valve shall have at least the area of the valve inlet.

(vi)

(vii)

(B)

Feedwater connections. (i) Feedwater, or water treatment shall be introduced into a boiler through the return piping system or through an independent feedwater connection which does not discharge against parts of the boiler exposed to direct radiant heat from the fire. Feedwater, or water treatment shall not be introduced through openings or connections provided for inspection or cleaning, safety valve, surface blowoff, water column, water gage glass, pressure gage, or temperature gage. Feedwater pipe shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler or return pipe system.

(ii)

(C)

Low-water fuel cutoffs and water feeding devices. (i) All automatically fired steam boilers, except boilers having a constant attendant, who has no other duties while the boiler is in operation, shall be equipped with approved automatic low-water fuel cutoffs installed in such a manner that they cannot be rendered inoperative by the manipulation of any manual control or regulating apparatus. The low-water fuel cutoff devices shall be tested regularly by lowering the water level in the boiler sufficiently to shut off the fuel supply to the burner when the water level reaches the lowest safe level for operation. The MAWP of all low water fuel cutoff devices shall be set at or above the boiler stamped MAWP. When low-water fuel cutoff and feedwater pump controls are combined in a single device, an additional separate low-water fuel cutoff shall be installed. The additional control shall be wired in series electrically with the existing low-water fuel cutoff. When a low-water fuel cutoff is housed in either the water column or a separate chamber it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (diameter nominal 20). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the low-water fuel cutoff device.

(ii)

(iii)

(iv)

Chapter 65, Boilers

Page 29-R

January 1, 2008

(v)

If a water feed device is utilized, it shall be constructed to prevent feedwater from entering the boiler through the water column or separate chamber of the low-water fuel cutoff.

(D)

Pressure gages. (i) Each steam heating boiler shall have a pressure gage connected to the device exterior to the boiler. The gage shall be of sufficient capacity to keep the gage tube filled with water and arranged so that the gage cannot be shut off from the boiler except by a cock with tee or lever handle placed in a pipe near the gage. The handle of the cock shall be parallel to the pipe in which it is located when the cock is open. The scale on the dial of a steam heating boiler pressure gage shall be graduated to not less than 30 psig (207kilopascals) nor more than 60 psig (414 kilopascals). The travel of the pointer from zero to 30 psig (207 kilopascals) pressure shall be at least three inches.

(ii)

(E)

Stop valves. (i) Single steam heating boilers. When a stop valve is used in the supply pipe connection of a single steam heating boiler, there shall be one used in the return pipe connection. Supply and return line. Each supply and return line to a steam heating boiler, which may be entered while adjacent boilers are in operation, shall be fitted with either two stop valves with ample drain between or a stop valve and figure 8 blank. The blank shall be installed between the stop valve and the boiler. Type of stop valve. When stop valves over two inches in size are used, they shall be of the outside screw-and-yoke rising stem type or of such other type as to indicate at a distance whether it is closed or open by the position of its stem or other operating mechanism. The wheel may be carried either on the yoke or attached to the stem. If the valve is of the plug cock type, it shall be fitted with a slow opening mechanism and an indicating device and the plug shall be held in place by a guard or gland.

(ii)

(iii)

(F)

Bottom blowdown or drain valve. (i) Bottom blowoff valve. Each steam heating boiler shall have a bottom blowoff connection fitted with a valve or cock connected to the lowest water space practicable with a minimum size as shown in Table 2 of Exhibit 2 in Figure 65.100(k)(1)(A)(v). The discharge piping shall be full size to the point of discharge. Boilers having a capacity of 25 gallons (95 liters) or less are exempt from these requirements. Drain valve. Each boiler shall have one or more drain connections, fitted with valves or cocks connecting to the lowest water containing spaces. The minimum size of the drain piping, valves, and cocks shall be 3/4 inch nominal pipe size (diameter nominal 20). The discharge piping shall be full size to the point of discharge. When the blowoff connection is located at the lowest water containing space, a separate drain connection is not required. Minimum pressure rating. The minimum pressure rating of valves and cocks used for blowoff or drain purposes shall be at least equal to the pressure stamped on the boiler, but in no case less than 30 psig (207 kilopascals). The temperature rating of such valves and cocks shall not be less than 250 degrees Fahrenheit (121 degrees Celsius).

(ii)

(iii)

(G) Chapter 65, Boilers

Water gage glasses. Page 30-R January 1, 2008

(i)

Each steam heating boiler shall have one or more water gage glasses attached to the water column or boiler by means of valved fittings not less than 1/2 inch nominal pipe size (diameter nominal 15). The lower fitting shall have a drain valve of the straightway type with opening not less than 1/4 inch (6 millimeters) diameter to facilitate cleaning. Gage glass replacement shall be possible under pressure. Transparent material, other than glass, may be used for the water gage provided that the material will remain transparent and has proved suitable for the pressure, temperature, and corrosive conditions encountered in service.

(ii)

(2)

Hot water heating. (A) Safety relief valves. (i) Each hot water heating boiler shall have at least one officially rated safety relief valve set to relieve at or below the maximum allowable working pressure of the boiler. When more than one safety relief valve is used on a hot water heating boiler, the additional valve or valves shall be officially rated and may have a set pressure within a range not to exceed six psig (42 kilopascals) above the maximum allowable working pressure of the boiler up to and including 60 psig (414 kilopascals), and 5.0% for those having a maximum allowable working pressure exceeding 60 psig (414 kilopascals). Safety relief valves shall be spring loaded. Safety relief valves shall be set and sealed so that they cannot be reset without breaking the seal. A body drain connection below seat level shall be provided. For valves exceeding 2 1/2 inch nominal pipe size (diameter nominal 65), the drain hole or holes shall be tapped not less than 3/8 inch nominal pipe size (diameter nominal 10). For valves of 2 1/2 inch nominal pipe size (diameter nominal 65) or less, the drain hole shall not be less than 1/4 inch (6 millimeters) diameter. Each safety relief valve shall have a substantial lifting device which will positively lift the disk from its seat at least 1/16 inch (1.6 millimeters) when there is no pressure on the boiler. Seats and disks of safety relief valves shall be made of a suitable material to resist corrosion. No materials likely to fail due to deterioration or vulcanization, when subjected to saturated steam temperature corresponding to capacity test pressure, shall be used for any part. No safety relief valve shall be smaller than 3/4 inch nominal pipe size (diameter nominal 20) nor larger than 4 1/2 inch nominal pipe size (diameter nominal 115) except that boilers having a heat input not greater than 15,000 Btu/hr (4.4 kilowatts) may be equipped with a rated safety relief valve of 1/2 inch nominal pipe size (diameter nominal 15). The inlet opening shall have an inside diameter approximately equal to, or greater than, the seat diameter. In no case shall the minimum opening through any part of the valve be less than 1/4 inch (6 millimeters) diameter or its equivalent area. The required steam relieving capacity, in pounds per hour, of the pressure relieving device or devices on a boiler shall be the greater of that determined by dividing the maximum output in Btu 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 of steam generated per hour per square foot of boiler heating surface as given in Table 1 Exhibit 2 as shown in Figure 65.100(k)(1)(A)(v). For cast iron boilers the minimum valve capacity shall be determined by the maximum output method.

(ii)

(iii)

(iv)

(v)

(vi)

(vii)

Chapter 65, Boilers

Page 31-R

January 1, 2008

(viii)

In every case, the safety relief valve capacity for each boiler with a single safety relief valve shall be such that, with the fuel burning equipment installed and operated at maximum capacity, the pressure cannot rise more than 10% above the maximum allowable working pressure. When more than one safety relief valve is used, the overpressure shall be limited to 10% above the set pressure of the highest set valve. Safety relief valve piping. No valve shall be placed between the safety relief valve and the boiler or on the discharge pipe between the safety relief valve and the drain. When a discharge pipe is used, it shall be full size and fitted with an open drain to prevent water from lodging in the upper part of the safety relief valve or in the discharge pipe. When an elbow is placed on the safety relief valve discharge pipe, it shall be located close to the valve outlet. The discharge pipe shall be securely anchored and supported, independent of the valve. Safety relief valves and safety valves shall be installed on the boiler with their spindles vertical. The opening or connection between the boiler and any safety relief valve or safety valve shall have at least the area of the valve inlet.

(ix)

(x)

(B)

Makeup water connections. (i) Makeup water, or water treatment shall be introduced into a boiler through the return piping system or through an independent makeup water connection which does not discharge against parts of the boiler exposed to direct radiant heat from the fire. Makeup water, or water treatment shall not be introduced through openings or connections provided for inspection or cleaning, safety relief valve, pressure gage, or temperature gage. Makeup water pipe shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler or between the check valve and the piping system.

(ii)

(C)

Low-water fuel cutoffs and water feeding devices. (i) All automatically fired hot water heating boiler shall have an automatic low-water fuel cutoff that has been designed for hot water service, and it shall be so located as to automatically cut off the fuel supply when the surface of the water falls to a level below the normal waterline established. The MAWP of all low water fuel cutoff and flow sensing devices shall be set at or above the boiler stamped MAWP. When low-water fuel cutoff and feedwater pump controls are combined in a single device, an additional separate low-water fuel cutoff shall be installed. The additional control shall be wired in series electrically with the existing low-water fuel cutoff. When a low-water fuel cutoff is housed in either the water column or a separate chamber it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (diameter nominal 20). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the low-water fuel cutoff device. As there is no normal water line to be maintained in a hot water heating boiler, any location of the low-water fuel cutoff above the lowest safe water level established by the boiler manufacturer is satisfactory. All automatically fired hot water heating boilers, when installed in a forced circulation system and not under continuous attendance, shall be equipped in the manner described in this subsection. A coil-type boiler or a water-tube boiler Page 32-R January 1, 2008

(ii)

(iii)

(iv)

(v)

(vi)

Chapter 65, Boilers

requiring forced circulation to prevent overheating of the coils or tubes shall have a flow sensing device which is listed by a nationally recognized testing agency to prevent burner operation at a flow rate inadequate to protect the boiler unit against overheating. (vii) If a water feed device is utilized, it shall be constructed to prevent feedwater from entering the boiler through the water column or separate chamber of the low-water fuel cutoff.

(D)

Pressure gages. (i) Each hot water heating boiler shall have a pressure or altitude gage connected to it or to its flow connection which cannot be shut off from the boiler except by a cock with tee or lever handle placed in a pipe near the gage. The handle of the cock shall be parallel to the pipe in which it is located when the cock is open. The scale on the dial of the pressure or altitude gage shall be graduated to not less than 1 1/2 nor more than 3 1/2 times the pressure at which the safety relief valve is set. The gage shall be provided with effective stops for the indicating pointer at the zero point and at the maximum pressure point. Piping and tubing for pressure or altitude gage connections shall be of nonferrous metal when smaller than 1 inch nominal pipe size (diameter nominal 25).

(ii)

(iii)

(E)

Stop valves. (i) Stop valves shall be located at an accessible point in the supply and return pipe connections near the boiler nozzle of a single hot water heating boiler installation to permit draining the boiler without emptying the system. When the boiler is located above the system and can be drained without draining the system, stop valves may be eliminated. Type of stop valve. When stop valves over two inches in size are used, they shall be of the outside screw-and-yoke rising stem type or of such other type as to indicate at a distance whether it is closed or open by the position of its stem or other operating mechanism. The wheel may be carried either on the yoke or attached to the stem. If the valve is of the plug cock type, it shall be fitted with a slow opening mechanism and an indicating device and the plug shall be held in place by a guard or gland.

(ii)

(iii)

(F)

Drain valve. (i) Each hot water heating boiler shall have one or more drain connections, fitted with valves or cocks connecting to the lowest water containing spaces. The minimum size of the drain piping, valves, and cocks shall be 3/4 inch nominal pipe size (diameter nominal 20). The discharge piping shall be full size to the point of discharge. When the blowoff connection is located at the lowest water containing space, a separate drain connection is not required. Minimum pressure rating. The minimum pressure rating of valves and cocks used for blowoff or drain purposes shall be at least equal to the pressure stamped on the boiler, but in no case less than 30 psig (207 kilopascals). The temperature rating of such valves and cocks shall not be less than 250 degrees Fahrenheit (121 degrees Celsius).

(ii)

(G)

Provisions for thermal expansion. (i) Heating systems with open expansion tank An indoor overflow from the upper portion of the expansion tank shall be provided in addition to an open vent, the Page 33-R January 1, 2008

Chapter 65, Boilers

indoor overflow to be carried within the building to a suitable plumbing fixture or basement. (ii) Closed heating system - If the system is of closed type, an airtight tank or other suitable air cushion that is consistent with the volume and capacity of the system shall be installed. If the system is designed for a working pressure of 30 psi (207 kilopascals) or less, the tank shall be suitably designed for a minimum hydrostatic pressure of 75 psi (520 kilopascals). Expansion tanks for systems designed to operate above 30 psig (207 kilopascals) shall be constructed in accordance with the ASME Code, Section VIII, Division 1. Alternatively, a tank built to ASME Section X requirements may be used if the pressure and temperature ratings of the tank are equal to or greater than the pressure and temperature ratings of the system. Provision shall be made for draining the tank without emptying the system, except for pre-pressurized tanks.

(3)

Hot water supply. (A) Safety relief valves. (i) Each hot water supply boiler shall have at least one officially rated safety relief valve set to relieve at or below the maximum allowable working pressure of the boiler. When more than one safety relief valve is used on a hot water supply boiler, the additional valve or valves shall be officially rated and may have a set pressure within a range not to exceed six psig (42 kilopascals) above the maximum allowable working pressure of the boiler up to and including 60 psig (414 kilopascals), and 5.0% for those having a maximum allowable working pressure exceeding 60 psig (414 kilopascals). Safety relief valves shall be spring loaded. Safety relief valves shall be set and sealed so that they cannot be reset without breaking the seal. A body drain connection below seat level shall be provided. For valves exceeding 2 1/2 inch nominal pipe size (diameter nominal 65), the drain hole or holes shall be tapped not less than 3/8 inch nominal pipe size (diameter nominal 10). For valves of 2 1/2 inch nominal pipe size (diameter nominal 65) or less, the drain hole shall not be less than 1/4 inch (6 millimeters) diameter. Each safety relief valve shall have a substantial lifting device which will positively lift the disk from its seat at least 1/16 inch (1.6 millimeters ) when there is no pressure on the boiler. Seats and disks of safety relief valves shall be made of a suitable material to resist corrosion. No materials likely to fail due to deterioration or vulcanization, when subjected to saturated steam temperature corresponding to capacity test pressure, shall be used for any part. No safety relief valve shall be smaller than 3/4 inch nominal pipe size (diameter nominal 20) nor larger than 4 1/2 inch nominal pipe size (diameter nominal 115) except that boilers having a heat input not greater than 15,000 Btu/hr (4.4 kilowatts) may be equipped with a rated safety relief valve of 1/2 inch nominal pipe size (diameter nominal 15). The inlet opening shall have an inside diameter approximately equal to, or greater than, the seat diameter. In no case shall the minimum opening through any part of the valve be less than 1/4 inch (6 millimeters) diameter or its equivalent area. The required steam relieving capacity, in pounds per hour, of the pressure relieving device or devices on a boiler shall be the greater of that determined by dividing the maximum output in Btu 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 of Page 34-R January 1, 2008

(ii)

(iii)

(iv)

(v)

(vi)

(vii)

Chapter 65, Boilers

steam generated per hour per square foot of boiler heating surface as given in Table 1 Exhibit 2 as shown in Figure 65.100(k)(1)(A)(v). For cast iron boilers the minimum valve capacity shall be determined by the maximum output method. (viii) In every case, the safety relief valve capacity for each boiler with a single safety relief valve shall be such that, with the fuel burning equipment installed and operated at maximum capacity, the pressure cannot rise more than 10% above the maximum allowable working pressure. When more than one safety relief valve is used, the overpressure shall be limited to 10% above the set pressure of the highest set valve. Safety relief valve piping. No valve shall be placed between the safety relief valve and the boiler nor on the discharge pipe between the safety relief valve and the drain. When a discharge pipe is used, it shall be full size and fitted with an open drain to prevent water from lodging in the upper part of the safety relief valve or in the discharge pipe. When an elbow is placed on the safety relief valve discharge pipe, it shall be located close to the valve outlet. The discharge pipe shall be securely anchored and supported, independent of the valve. Safety relief valves and safety valves shall be installed on the boiler with their spindles vertical. The opening or connection between the boiler and any safety relief valve or safety valve shall have at least the area of the valve inlet.

(ix)

(x)

(B)

Makeup water connections. (i) Makeup water, or water treatment shall be introduced into a boiler through the return piping system or through an independent makeup water connection which does not discharge against parts of the boiler exposed to direct radiant heat from the fire. Makeup water, or water treatment shall not be introduced through openings or connections provided for inspection or cleaning, safety relief valve, pressure gage, or temperature gage. Makeup water pipe shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler or between the check valve and the piping system.

(ii)

(C)

Low-water fuel cutoffs and water feeding devices. (i) All automatically fired hot water supply boiler shall have an automatic low-water fuel cutoff that has been designed for hot water service, and it shall be so located as to automatically cut off the fuel supply when the surface of the water falls to a level below the normal waterline established. The MAWP of all low water fuel cutoff and flow sensing devices shall be set at or above the boiler stamped MAWP. When low-water fuel cutoff and feedwater pump controls are combined in a single device, an additional separate low-water fuel cutoff shall be installed. The additional control shall be wired in series electrically with the existing low-water fuel cutoff. When a low-water fuel cutoff is housed in either the water column or a separate chamber it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (diameter nominal 20). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the low-water fuel cutoff device. As there is no normal water line to be maintained in a hot water supply boiler, any location of the low-water fuel cutoff above the lowest safe water level established by the boiler manufacturer is satisfactory. Page 35-R January 1, 2008

(ii)

(iii)

(iv)

(v)

Chapter 65, Boilers

(vi)

All automatically fired hot water heating boilers, when installed in a forced circulation system and not under continuous attendance, shall be equipped in the manner described in this subsection. A coil-type boiler or a water-tube boiler requiring forced circulation to prevent overheating of the coils or tubes shall have a flow sensing device which is listed by a nationally recognized testing agency to prevent burner operation at a flow rate inadequate to protect the boiler unit against overheating. If a water feed device is utilized, it shall be constructed to prevent feedwater from entering the boiler through the water column or separate chamber of the low-water fuel cutoff.

(vii)

(D)

Pressure gages. (i) Each hot water supply boiler shall have a pressure or altitude gage connected to it or to its flow connection which cannot be shut off from the boiler except by a cock with tee or lever handle placed in a pipe near the gage. The handle of the cock shall be parallel to the pipe in which it is located when the cock is open. The scale on the dial of the pressure or altitude gage shall be graduated to not less than 1 1/2 nor more than 3 1/2 times the pressure at which the safety relief valve is set. The gage shall be provided with effective stops for the indicating pointer at the zero point and at the maximum pressure point. Piping and tubing for pressure or altitude gage connections shall be of nonferrous metal when smaller than 1 inch nominal pipe size (diameter nominal 25).

(ii)

(iii)

(E)

Stop valves. (i) Stop valves shall be located at an accessible point in the supply and return pipe connections near the boiler nozzle of a single hot water supply boiler installation to permit draining the boiler without emptying the system. When the boiler is located above the system and can be drained without draining the system, stop valves may be eliminated. Type of stop valve. When stop valves over two inches in size are used, they shall be of the outside screw-and-yoke rising stem type or of such other type as to indicate at a distance whether it is closed or open by the position of its stem or other operating mechanism. The wheel may be carried either on the yoke or attached to the stem. If the valve is of the plug cock type, it shall be fitted with a slow opening mechanism and an indicating device and the plug shall be held in place by a guard or gland.

(ii)

(iii)

(F)

Drain valve. (i) Each hot water supply boiler shall have one or more drain connections, fitted with valves or cocks connecting to the lowest water containing spaces. The minimum size of the drain piping, valves, and cocks shall be 3/4 inch nominal pipe size (diameter nominal 20). The discharge piping shall be full size to the point of discharge. When the blowoff connection is located at the lowest water containing space, a separate drain connection is not required. Minimum pressure rating. The minimum pressure rating of valves and cocks used for blowoff or drain purposes shall be at least equal to the pressure stamped on the boiler, but in no case less than 30 psig (207 kilopascals). The temperature rating of such valves and cocks shall not be less than 250 degrees Fahrenheit (121 degrees Celsius).

(ii)

Chapter 65, Boilers

Page 36-R

January 1, 2008

(G)

Provisions for thermal expansion. If a system is equipped with a check valve or pressure reducing valve in the cold water inlet line, consideration should be given to the installation of an airtight expansion tank or other suitable air cushion. Otherwise, due to the thermal expansion of the water, the safety relief valve may lift periodically. If an expansion tank is provided, it shall be constructed in accordance with the ASME Code, Section VIII, Division 1 or Section X. Except for pre-pressurized tanks, which should be installed on the cold water side, provisions shall be made for draining the tank without emptying the system.

(4)

Potable water heaters. (A) Safety relief valves. (i) Potable water heaters (tank type) shall have at least one officially rated pressure temperature safety relief valve of the automatic reseating type set to relieve at or below the maximum allowable pressure of the heater. No safety relief valve shall be smaller than 3/4 inch nominal pipe size (diameter nominal 20). The relief valve shall have a capacity equal to or exceeding the rated burner input of the heater. The relieving capacity for electric water heaters shall be 3,500 Btu/hr (1.0 kilowatts) per kilowatt of input. The ASME Btu rating on the valve shall be used to determine the relieving capacity. Relief valves shall be connected directly to the heater within the top six inches of the tank. Relief valves may be installed vertically or horizontally. The center line of the horizontal connection shall be no lower than four inches from the top of the shell. Relief valves shall not be connected to an internal pipe in the heater, or to a cold water feed line connected to the heater. Safety relief valve piping. No valve shall be placed between the safety relief valve and the boiler nor on the discharge pipe between the safety relief valve and the drain. When a discharge pipe is used, it shall be full size and fitted with an open drain to prevent water from lodging in the upper part of the safety relief valve or in the discharge pipe. When an elbow is placed on the safety relief valve discharge pipe, it shall be located close to the valve outlet. The discharge pipe shall be securely anchored and supported, independent of the valve.

(ii)

(iii)

(iv)

(v)

(vi)

(vii)

(B)

Water supply. (i) Water supply shall be introduced into a water heater through an independent water supply connection. Water shall not be introduced through openings or connections provided for cleaning, safety relief valves, drains, pressure gage or temperature gage. If the water supply pressure to a hot water heater exceeds 75% of the set pressure of the safety relief valve, a pressure reducing valve is required.

(ii)

(C)

Flow sensing device. (i) All automatically fired potable water heater, when installed in a forced circulation system and not under continuous attendance, shall be equipped in the manner described in this subsection. A coil-type boiler or a water-tube boiler requiring forced circulation to prevent overheating of the coils or tubes shall have a flow sensing device which is listed by a nationally recognized testing agency to prevent burner operation at a flow rate inadequate to protect the boiler unit against overheating. Page 37-R January 1, 2008

Chapter 65, Boilers

(ii)

The MAWP of all flow sensing devices shall be set at or above the boiler stamped MAWP.

(D)

Gages. (i) Temperature gages. Each hot water heater shall have a thermometer located and connected at or near the outlet that is easily readable. The thermometer shall at all times indicate the temperatures of the water in the hot water heater. Pressure gages. Each hot water heater that is of the coil type or water tube shall have a pressure gage that is graduated to not less than 1 1/2 or more than 3 1/2 times the pressure at which the safety relief valve is set.

(ii)

(E)

Stop valves. Stop valves should be placed in the supply and discharge pipe connections of the hot water heater installation to permit draining the heater without emptying the system. Drain valves. Each hot water heater shall have a bottom drain pipe connection fitted with a valve or cock connected to the lowest water space practical. The minimum size bottom drain shall be 3/4 inch nominal pipe size (diameter nominal 20). Provisions for thermal expansion. If a system is equipped with a check valve or pressure reducing valve in the cold water inlet line, consideration should be given to the installation of an airtight expansion tank or other suitable air cushion. Otherwise, due to the thermal expansion of the water, the safety relief valve may lift periodically. If an expansion tank is provided, it shall be constructed in accordance with the ASME Code, Section VIII, Division 1 or Section X. Except for pre-pressurized tanks, which should be installed on the cold water side, provisions shall be made for draining the tank without emptying the system.

(F)

(G)

(l)

Repairs and alterations. (1) Repairs and alterations shall conform to the current edition of the National Board Inspection Code (NBIC) and addenda; and shall be acceptable to the inspector, except that repairs and alterations may be performed by the following provided the intended work is within the scope of the issued certificate of authorization: (A) holders of a certificate of authorization from the National Board of Boiler and Pressure Vessel Inspectors for use of the R repair symbol stamp; or owner/operators of boilers who have been issued a certificate of authorization by the Texas Department of Licensing and Regulation. (i) Issuance of the certificate of authorization will be made upon submission of an application, on forms provided by the department. Review of the applicant's program and facilities initially and at subsequent three-year intervals will be done. (I) The review will determine the applicant has a documented program to control repairs and/or alterations conforming to minimum requirements established by the department. The review will require demonstration of the applicant's ability to perform repairs and/or alterations by implementing on representative work the requirements of the written program.

(B)

(ii)

(II)

(2)

Non-welded repairs. (A) Replacement parts made of plate material used for pressure retaining shall require material test reports (MTR). Traceability to the MTR must be maintained at all times. Page 38-R January 1, 2008

Chapter 65, Boilers

(B)

Replacement parts fabricated by welding shall be certified, stamped with the appropriate ASME Code symbol and inspected by an authorized inspector as required by the ASME Code. When a non-welded repair involves the replacement of cast or forged parts that are identified with the ASME Code symbol at the time of casting or forging, these parts shall be replaced with cast or forged parts that are identified with the ASME Code symbol or so certified by the manufacturer to be in accordance with the original code of construction. All other materials shall not require MTRs, provided the material is identified with the material specification, grade, lot and rating as required by the material or product specification and the ASME Code. When used parts are utilized for non-welded repairs, it is the repair entitys responsibility to ensure the parts are identified as required above.

(C)

(D)

(E)

(m)

Lap seam cracks. The shell or drum of a boiler in which a typical lap seam crack is discovered along a longitudinal riveted lap-type joint shall be immediately and permanently discontinued for use under pressure. A lap seam crack is the typical crack frequently found in lap seams, which extends parallel to the longitudinal joint and is located either between or adjacent to rivet holes. Hydrostatic pressure tests. (1) When there is a question or doubt about the extent of a defect found in a boiler, the inspector may require a hydrostatic pressure test. In preparing a boiler for a hydrostatic pressure test, the boiler shall be filled with water to the stop valve and all air vented off. If the boiler to be tested is connected with other boilers that are under pressure, such connections shall be blanked off unless they have double stop valves on all connection pipes with a drain between. During a hydrostatic pressure test of a boiler, the safety valve or valves shall be removed or each valve disc shall be held to its seat by means of a testing clamp and not by screwing down the compression screw under the spring. The metal temperature for the pressure test shall not be less than 60 degrees Fahrenheit (16 degrees Celsius) unless the owner provides information on the toughness characteristics of the material for a lower test temperature, but the maximum metal temperature shall not exceed 120 degrees Fahrenheit (50 degrees Celsius) unless a higher temperature is specified and is acceptable to the inspector. When a hydrostatic pressure test is to be applied after inspection, the pressure shall be as follows. (A) For all cases involving the question of tightness, the pressure shall be no more than the set pressure of the safety valve or valves having the lowest setting. For all cases involving the question of safety, the pressure applied shall not exceed the lesser of that which was required by the original code of construction, or the pressure equal to that which results in an applied stress no greater than 90% of the specified minimum yield stress at test temperature of the material as published by ASME Code, Section II, Part D, current edition and addenda.

(n)

(2)

(3)

(4)

(5)

(B)

(o)

Authority to set and seal safety appliances. All safety and safety relief valves for ASME Sections I, IV, and VIII Division 1 boilers must be repaired, tested, set, and sealed by one of the following, provided the scope of the issued certificate of authorization covers the work to be performed: (1) an organization holding a valid V, HV, or UV certificate of authorization, as appropriate, issued by the American Society of Mechanical Engineers (ASME); or an organization holding a valid VR certificate of authorization issued by the National Board of Boiler and Pressure Vessel Inspectors; or Page 39-R January 1, 2008

(2)

Chapter 65, Boilers

(3)

an organization holding a valid owner/operator certificate of authorization issued by the department. Such authorization may be granted or withheld by the executive director. (A) If authorization is granted and proper administrative fees as provided for in Section 65.80(b) are paid, a certificate of authorization will be issued, expiring on the triennial anniversary date. The certificate shall indicate authorization to repair ASME Sections I, IV, or VIII valves, as verified by testing and as covered by the repair organization's quality control manual. The certificate will be signed by the executive director and the chief inspector. The applicant should apply to the department for renewal of authorization and reissuance of the certificate six months prior to the date of expiration. The owner/operator certificate of authorization is renewable every three years. Before issuance or renewal of the certificate of authorization, the repair organization and its facilities are subject to a review and demonstration of its quality control system by an inspector. Before the owner/operator certificate of authorization may be issued or renewed, two valves which have been repaired by the applicant must successfully complete operational verification tests as follows: (i) (ii) visual examination to ensure the quality of material and workmanship; verification that critical parts meet the valve manufacturer's specifications. Critical parts that are replaced must be fabricated to the valve manufacturer's specifications. Critical parts which require repair shall meet the valve manufacturer's specifications; tightness tests and verification; set pressure test and verification.

(B)

(C)

(D)

(iii) (iv) (E)

The purpose of the tests is to ensure that the function and operation of the valves meet the requirements of the applicable section of the ASME Code to which they are manufactured. Should any of the valves fail to meet the applicable requirements, the test shall be repeated on two valves for each valve that failed. Failure of any of these valves shall cause the applicant to investigate and document the cause of failure and state what corrective action has been taken to prevent future recurrences. Retest of the original valve is acceptable. Following proper implementation of this corrective action and after satisfactory performance, permission to receive the certificate of authorization will be granted. Field repairs are defined as any repair conducted outside a fixed repair shop location. Field repairs may be conducted with the aid of mobile facilities with repair capabilities with or without testing capabilities. Field repairs may be conducted in owner/operator facilities without the use of mobile facilities. Organizations that obtain the owner/operator certificate of authorization for in-shop/plant repairs may also perform field repairs to safety and safety relief valves provided that: (i) (ii) (iii) qualified technicians perform such repairs; an acceptable quality control system covering field repairs is maintained; periodic audits of the work carried out in the field are made by quality control personnel of the certificate of authorization holder to ensure that the requirements of the quality control system are met.

(F)

(G)

Provided the provisions in paragraph (F)(i)-(iii) of this paragraph are met, verification testing of field repaired valves shall not be required. Organizations that perform field repairs only must demonstrate their field repair capabilities Page 40-R January 1, 2008

(H) Chapter 65, Boilers

to an inspector before the certificate of authorization may be issued or renewed. Two valves must be repaired in the field and successfully complete verification tests as described in subparagraph (D) of this paragraph. A quality control manual as required in subparagraph (J) of this paragraph must be prepared describing all field repair activities. (I) Repair of a safety and safety relief valve is considered to be the replacement, remachining, or cleaning of any part, lapping of seat and disc, or any other operation which may affect the flow passage, capacity, function, or pressure retaining integrity. Disassembly, reassembly, and/or adjustments which affect the safety or safety relief valve function are also considered a repair. The initial installation, testing, and adjustments of a new safety valve or a safety relief valve in a boiler are not considered a repair. In general, the quality control system shall describe and explain what documents and procedures the owner/operator will use to validate a valve repair. Before issuance or renewal of the owner/operator certificate of authorization, the applicant must meet all requirements, including an acceptable written quality control system. The basic elements of a written quality control system shall be those described in Exhibit 1. (i) The written quality control system shall also include provisions for making revisions, enabling the system to be kept current as required. A review of the applicant's quality control system will be performed by an inspector. The review will include a demonstration of the implementation of the applicant's quality control system. Each applicant to whom a certificate of authorization is issued shall maintain thereafter a controlled copy of the accepted quality control manual with the inspector. Except for changes which do not affect the quality control program, revisions to the quality control manual shall not be implemented until such revisions are acceptable to the inspector.

(J)

(ii)

(iii)

(K)

It is essential that owner/operator valve repair organizations ensure that personnel making repairs to safety and safety relief valves are knowledgeable and qualified. The owner/operator shall provide documented training with minimum qualification requirements for the valve repair position. Specific requirements to be included in an individual's training are as follows: (i) (ii) (iii) working knowledge of the organization's quality control manual; working knowledge of the applicable requirements; and working knowledge of the technical aspects and mechanical skills for valves being repaired or tested.

(L)

Performance testing of repaired valves. (i) For shop valves, a test stand shall be used. The test stand shall be of a size and design to ensure clean, consistent, and repetitive pop action and response to blowdown adjustment, if possible. Test gages shall be connected to the test stand in such a manner as to indicate true pressure at the inlet of the valve being tested. Test gages shall be maintained and calibrated, at least every 90 days, to a minimum of one-half of 1.0% accuracy over the upper 80% of full scale range. The use of digital gages is acceptable. All calibrations shall be documented and traceable to national standards. Valves marked for liquid service shall be set according to the applicable manufacturer's specification. Valves marked for steam service or having special internal parts for steam should be tested with steam. However, valves for steam service may be tested with air or Page 41-R January 1, 2008

(ii)

(iii)

Chapter 65, Boilers

nitrogen for correct opening (popping), pressure setting, and, if possible, blowdown adjustment, provided the differential in popping pressure between steam and air or nitrogen, as specified in the quality control manual, are applied to the popping point. (iv) (v) Valves which are repaired in place shall be tested to demonstrate set pressure. For valves which are repaired in place, a device (hydraulic, pneumatic, etc.) may be used to apply an auxiliary lifting load on the spring to a valve for testing purposes and/or making adjustments. Calibrated testing equipment shall be used and detailed testing procedures followed. In such cases, the manufacturer's recommendations shall be used to establish blowdown.

(M)

When a safety or safety relief valve is repaired, a metal repair tag, as described in the quality control manual, shall be attached to the valve. As a minimum, the information on the tag will include the valve identification number, set pressure, date of repair, and certificate of authorization number.

Chapter 65, Boilers

Page 42-R

January 1, 2008

1.0

Basic Elements of a Written Quality Control System

Exhibit 1

1.1 This outline sets the requirements of the Boiler Section for a written quality control system for repairers of ASME safety and safety relief valves. 1.2 Control Copy

A controlled copy of the written quality control system shall be submitted to the inspector. Revisions shall also be submitted for acceptance prior to being implemented. 1.3 Sample Forms

Forms used in the quality control system shall be included in the manual with a written description. Forms exhibited should be marked SAMPLE and completed in a manner typical of actual valve repair procedures. 1.4 Individuality Important

It is extremely important that the manual describe and the operation implement the system of each individual firm while meeting the requirements of the owner/operator certification program. 1.5 Quality Control Manual Requirements

It is essential that each valve repair organization develop its own quality control system which meets the requirements of each organization. Some of these requirements are, but not limited to: 1.5.1 Title Page

The title page shall include the name and address of the company to which the certificate of authorization is to be issued. 1.5.2 Revision Log

A revision log is required to assure revision control of the quality control manual. The log should contain sufficient space for date, description and section of revision, company approval, and chief inspector or authorized inspector acceptance. 1.5.3 Contents Page

The contents page should list and reference, by paragraph and page number, the subjects and exhibits contained therein. 1.5.4 Statement of Authority and Responsibility

A statement of authority and responsibility shall appear on company letterhead, dated and signed by an officer of the company verifying that only ASME Code stamped safety and safety relief valves will be repaired and returned to a condition equivalent to the standards for new valves. To ensure this is attained, the requirements of the written quality control system shall include as a minimum:

Chapter 65, Boilers Exhibit 1

Page 43

January 1, 2008

1.5.4.1 the title of the individual responsible to ensure that the quality control system is followed and has the authority and organizational freedom to effect the responsibility; 1.5.4.2 if there is disagreement in the implementation of the written quality control system, the matter is to be referred to a higher authority in the company for resolution; and 1.5.4.3 the title of the individual authorized to approve revisions to the written quality control system and the method by which such revisions are to be submitted to the authorized inspector for acceptance before implementation. 1.5.5 Organization Chart

The organization chart shall include all departments or divisions within the company that perform functions affecting the quality of the valve and show the relationship. 1.5.6 Scope of Work

The scope of work section should clearly indicate the scope and type of valve repairs the organization is capable of and intends to carry out, and should include the types and sizes of valves which can be repaired. In addition, the testing media (steam, air, water, etc.) and pressure ranges should be included. The scope can be limited by engineering, machine tools, welding processes, heat treatment facilities, testing facilities, nondestructive examination (NDE) techniques, or qualified personnel. 1.5.7 Drawings and Specification Control

The drawings and specification control system shall provide procedures assuring that applicable drawings, specifications, and instructions required are used for valve repair, inspection, and testing. Specific reference should be made to the materials used for the repair of various valve parts (PG-73.2.3, Section I and UG-136(b)(3), Section VIII Division 1 of the ASME Code). Mechanical requirements shall comply with the ASME Code. applicable Code section. 1.5.8 Material and Part Control See

The material and part control section shall describe purchasing of parts from the valve manufacturer, if applicable, and of material with request for mill test certification as required. It shall also describe receiving, storage, and issuing. 1.5.8.1 all material. 1.5.8.2 other records as required. State the title of the individual responsible for certification and State the title of the individual responsible for the purchasing of

Chapter 65, Boilers Exhibit 1

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January 1, 2008

1.5.8.3 All incoming material and parts shall be checked for conformance with the purchase order, and where applicable, the material specifications or drawings. Indicate how material or part is identified and how identity is maintained by the quality control system. 1.5.8.4 All critical parts shall be fabricated to the valve manufacturer's specifications. Critical parts are defined as any part which may affect the flow passage, capacity, or valve function. 1.5.8.5 When the original manufacturer's nameplate is missing or illegible, or when valve parts are no longer available from the manufacturer, a system will be in place to provide positive valve identification or replacement. 1.5.9 Repair and Inspection Program

The repair and inspection program section shall include reference to a document (such as a report, traveler, or check list) which outlines the specific repair and inspection procedures used in the repair of safety and safety relief valves. Provisions shall be made to retain this document for a period of at least five (5) years as a part of quality control traceability documents. 1.5.9.1 Each valve or group of valves shall be accompanied by the document referred to above for processing through the plant. 1.5.9.2 The document referred to above should include material check, reference to items such as the welding procedures specifications (WPS), fitup, NDE technique, heat treatment, and pressure test methods to be used. There should be a space for "sign-offs" at each operation to verify that each step has been properly performed. 1.5.9.3 The system shall include a method of controlling the repair or replacement of critical valve parts. The method of identifying each spring shall be indicated. 1.5.10 Welding, NDE, and Heat Treatment

The quality control manual is to indicate the title of the person(s) responsible for the development and approval of the welding procedure specifications and their qualifications and the qualifications of welders and welding operators. It is essential that only welding procedure specifications and welders or welding operators qualified to the requirements of the ASME Boiler and Pressure Vessel Code, Section IX, be used in the valve repair. Similarly, NDE and heat treatment techniques must be covered in the quality control manual. This section should also include outside contracting for services and qualifications. 1.5.11 Valve Testing and Setting

The system shall include provisions that every valve shall be tested, set, and all external adjustments sealed according to the requirements of the applicable ASME Code section. The seal shall identify the repair organization. Abbreviations or initials shall be permitted, provided such identification is acceptable to the authorized inspector.

Chapter 65, Boilers Exhibit 1

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January 1, 2008

1.5.12

Valve Repair Tags

An effective system shall be established to ensure proper tagging of each valve. The manual shall include a description of the tag or a drawing. 1.5.13 Calibration of Measurement and Test Gages

The calibration of measurement and test gage system shall include the periodic calibration of measuring instruments and pressure gages. Pressure gages used for setting valves are to be checked periodically (indicate frequency) by authorized quality control personnel. The method of gage testing is to be indicated and results recorded. Periodically, all master gages shall be calibrated, preferably but not necessarily, to measuring equipment traceable to the National Bureau of Standards. 1.5.14 Training of Valve Repair Personnel

The certificate holder shall describe a system of providing and documenting in-house training for persons repairing, testing, setting, and sealing safety valves and safety relief valves. This training shall include and document the following as a minimum: 1.5.14.1 control manual; 1.5.14.2 a general working knowledge of the applicable requirements; a general working knowledge of the organization's quality

1.5.14.3 a general working knowledge of the manufacturer's technical bulletin for valves being repaired, tested, set, and sealed.

Chapter 65, Boilers Exhibit 1

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January 1, 2008

Exhibit 3

TX 124608

Chapter 65, Boilers Exhibit 3

Page 47

January 1, 2008

Exhibit 4

TEXAS DEPARTMENT OF
REPORT ALL SERIOUS ACCIDENTS TO: LICENSING AND REGULATION

TX

123456

CHIEF INSPECTOR
P. O. BOX 12157 AUSTIN, TEXAS 78711

Chapter 65, Boilers Exhibit 4

Page 48

January 1, 2008

Limits of Jurisdictional Boundaries of the Steam Collection or Liberation Drum Pressure Gauge Syphon Vent and/or Instrument Connection (typical) First flange or circumferential joint for welding end connection (typical)

Single safety valve per ASME Sect. VIII Stop valve per ASME Sect. VIII (Allowed only if S.V. discharges into closed system) Valve shall be car sealed or locked in the open position Stop valve per ASME Sect. VIII Valve shall be car sealed or locked in the open position Steam collection or liberation drum of a Process Steam Generator ASME Section VIII

Superheater

Steam
other disposition Blinding point
Level Controller

Sight Glass Blinding point

Process Heater or Similar Source of Heat Process Heat Exchanger (Heat source)

Blinding point Blowdown and drain

Manway

Blinding point

Process Feed water Fluid

Process Steam Generator feed pump

Economizer Process Heater or Similar Source of Heat

Process Steam Generator Heat Source Process heater or similar source of heat

Alternate source of feedwater

EXHIBIT " 5A" PROCESS STEAM GENERATORS

Chapter 65, Boilers Exhibit 5A

Page 49

January 1, 2008

Steam header or other disposition

Process Fluid

Superheater Superheater

Blinding point

First flange or circumferential joint for welding end connection (typical)

Single safety valve per ASME Section VIII Stop valve per ASME Section VIII (Allowed only if S.V. discharges into closed system) Valve shall be car sealed or locked in the open position Stop valve per ASME Section VIII Valve shall be car sealed or locked in the open position Process Fluid Steam collection or liberation drum of a Process Steam Generator ASME Section VIII Blinding point

Process heater or similar source of heat

Pressure Gauge Syphon Vent and/or Instrument Connection (Typical) Sight Glass and or Level Controllers (Typical)

Limits of Jurisdictional Boundaries of the Steam Collection or Liberation Drum

Blowdown and Drain

Process Fluid Blinding point Limits of jurisdiction for Process Steam Generator

Process Steam Generator feed water pump Blinding point (typical)

Blinding point

Alternate source of feed water

EXHIBIT "5B" PROCESS STEAM GENERATORS

Chapter 65, Boilers Exhibit 5B

Page 50

January 1, 2008

First flange or circumferential joint for welding end connection (typical) Steam Header or Other Disposition

Vent and Instrumentation Single safety valve per ASME Sect. VIII Stop valve per ASME Sect. VIII (Required only if S.V. discharges into closed system) Valve shall be car sealed or locked in the open position Stop valve per ASME Sect. VIII Valve shall be car sealed or locked in the open position

Blinding Point

Pressure Gauge Syphon Instrument Connection Limits of Jurisdictional Boundaries of the Unfired Steam Boiler Level Indicator Steam Drum of Unfired Steam Boiler Constructed to ASME Section VIII

Level Controller

Header

Blinding Point

Blinding Point Gas Turbine Exhaust or other similar heat source Ductwork

Risers and Downcomers Ductwork Exhaust Stack Mud Drum or Header

Alternate Source

Primary Feedwater Source

Blowdown and Drain

EXHIBIT " 5C" UNFIRED STEAM BOILER

Chapter 65, Boilers Exhibit 5C

Page 51

January 1, 2008

Blinding Point Steam Header or Other Disposition

Vent Safety valve(s) per ASME Sect. 1

Pressure Gauge Syphon Instrument Connection Limits of Jurisdictional Boundaries of the Unfired Steam Boiler Level Indicator Steam Drum of Unfired Steam Boiler Complete Boiler Constructed to ASME Section 1 Level Controller

Alternate Feed Water Source

Primary Feedwater Source Boundaries of Feedwater System per ASME Section I

Typical Blinding Points

Header

Risers and Downcomers Ductwork Ductwork Exhaust Stack

Gas Turbine Exhaust or other similar heat source

Mud Drum or Header

Blowdown and Drain

EXHIBIT " 5D" UNFIRED STEAM BOILER

Chapter 65, Boilers Exhibit 5D

Page 52

January 1, 2008

Chapter 65, Boilers Exhibit 6

Page 53

January 1, 2008