1502000 J Facility Investment.pdf

SECTION J-1502000

DOCUMENTS, EXHIBITS, AND OTHER ATTACHMENTS

TABLE OF CONTENTS

ATTACHMENT NUMBER ATTACHMENT TITLE

J-1502000-01 Definitions and Acronyms J-1502000-02 References and Technical Documents J-1502000-03 Facilities Inventory J-1502000-04 Navy Shore Boiler Guide

ATTACHMENT J-1502000-01

DEFINITIONS AND ACRONYMS

Definition Description ANSI American National Standards Institute ASHRAE American Society Heating, Refrigerating and Air Conditioning Engineers CFC Chlorofluorocarbons HCFC Hydro-Chlorofluorocarbons HVAC Heating, Ventilation, and Air Conditioning IBC International Building Code IDS Intrusion Detection Systems NFPA National Fire Prevention Association OEM Original Equipment Manufacturer Preventive Maintenance

(PM)

PM consists primarily of inspection, testing, cleaning, lubrication, adjustment, calibration, and minor part and component replacement (such as filters, batteries, belts, hoses, fluids, oil and grease) as required to verify proper system operation; minimize malfunction, breakdown, and deterioration of systems and equipment; and maximize useful life.

SRM Sustainment, Restoration and Modernization IBC International Building Code

ATTACHMENT J-1502000-02

REFERENCES AND TECHNICAL DOCUMENTS

REFERENCE TITLE

ASHRAE SPC 188 Legionellosis: Risk Management for Building Water Systems NAVFACINST 11300.37 Energy and Utilities Policy Manual NAVFAC MO 200 Technical Manual Facilities Engineering Electrical NAVFAC MO-206 Maintenance and Operation of Air Compressor Plants NAVFAC MO-209 Maintenance of Steam, Hot Water, and Compressed Air Distribution Systems NAVFAC P-307 Management of Weight Handling Equipment Navy Shore Boiler Guide Navy Shore Boiler System Operation, Inspection, and Maintenance Guide OPNAV M-5090.1 (Most Current Version)

Environmental Readiness Program

OPNAV M-5090.1 (Most Current Version) Chapter 22

Clean Air Ashore

UFC 3-240-13FN Industrial Water Treatment Operation and Maintenance UFC 3-430-02FA Central Steam Boiler Plants UFC 3-430-07 Operations and Maintenance: Inspection and Certification of Boilers and

Unfired Pressure Vessels

ATTACHMENT J-1502000-03

FACILITIES INVENTORY

See Attachment J-1502000-03

ATTACHMENT J-1502000-04

NAVY SHORE BOILER GUIDE

See Attachment J-1502000-04

NAVY SHORE BOILER GUIDE

NAVY SHORE BOILER SYSTEM OPERATION, INSPECTION AND

MAINTENANCE GUIDE

CONTENTS

Page

1 PURPOSE ……………………………………………………………… 3

1.1 Action …………………………………………………………………….. 3

2 HEATING AND POWER PLANTS ……………………………………. 3

2.1 Guidance …………………………………………………………………. 3

2.2 Definitions ………………………………………………………………... 3

2.3 Applicability ……………………………………………………………… 4

3 OPERATIONS AND MAINTENANCE MANUALS …………………... 5

3.1 Background ……………………………………………………………….. 5

3.2 Standards ………………………………………………………………….. 5

3.3 Responsibilities …………………………………………………………… 6

3.3.1 FEC PW Core Boiler and UPV Lead Certifying Official (LCO)……………. 6

3.3.2 Public Works Departments (PWD’s) ………………………………………… 6

4 BOILER WATER TREATMENT …………………………………….. 6

4.1 Background ……………………………………………………………….. 6

4.2 Water Treatment ………………………………………………………….. 6

4.3 Safety ……………………………………………………………………... 7

4.4 Standards …………………………………………………………………. 7

4.5 Guidelines ……………………………………………………………….. 7

4.6 Useful Tests and Limits for the control of water for Boilers ……………. 8

4.6.1 Feedwater Limits for Watertube Boilers ………………………………… 8

4.6.2 Feedwater Limits for Water Tube Boilers 0-300 psig …………………… 9

4.6.3 Feedwater Limits for Water Tube Boilers 301-600 psig ………………… 9

4.6.4 Feedwater Limits for Industrial Firetube Boilers 0-300 psig ……………. 10

4.6.5 Boiler water Limits for Water Tube Boilers ………………………………… 10

4.6.6 ASME Boiler Water Limits for Firetube Boilers …………………………… 10

4.6.7 Shore to Ship Steam Purity Requirements ………………………………… . 11

4.6.8 Treatment for Low-Pressure Steam ………………………………………… 12

4.6.9 Treatment for Medium and High-Pressure Steam …………………………... 13

4.7 Prohibitions and Recommendations ………………………………………

4.8 Records …………………………………………………………………… 14

4.9 Responsibilities …………………………………………………………… 14

4.9.1 FEC PW Core Boiler and UPV Lead Certifying Official (LCO) …………… 14

4.9.2 Public Work Departments (PWD’s) ……………………………………... 14

5 PROPRIETARY DEVICES AND CHEMICALS …………………… 14

5.1 Discussion ……………………………………………………………… 14

5.2 General …………………………………………………………………. 14

5.3 Actions ………………………………………………………………….. 14

6 EFFICIENCY …………………………………………………………

6.1 Background ………………………………………………………………. 15

6.2 Objective …………………………………………………………………. 15

6.3 Standards …………………………………………………………………. 15

6.4 Combustion Analysis Limits ………………………………………………... 16

6.5 Responsibilities …………………………………………………………. 16

6.5.1 FEC PW Core Boiler and UPV Lead Certifying Official …………………... 16

6.5.2 NAVFAC Engineering and Expeditionary Warfare Center (EXWC) ……… 16

6.5.3 Public Works Departments (PWD’s) ………………………………………. 17

7. MINIMUM ATTENDANCE ……………………………………………… 18

7.1 Definitions ……………………………………………………………… 18

7.2 Standards …………………………………………………………………. 18

7.3 Criteria …………………………………………………………………... 19

7.3.1 Heating Boilers and Power Boilers Minimum Attendance ………………. 19

7.3.2 Power Boiler Plant Certified Boiler Operator Manning ……………………. 20

7.3.3 Alternative Fuel Fired Boiler Plants Minimum Attendance ……………… 21

7.4 Responsibilities …………………………………………………………. 21

7.4.1 NAVFAC Engineering and Expeditionary Warfare Center (EXWC) ……… 21

7.4.2 FEC PW Core Boiler and UPV Lead Certifying Official ………………….. 21

7.4.3 Public Works Departments (PWD’s) ………………………………………. 21

8. SAFETY INSPECTIONS ………………………………………………… 23

8.1 Boiler and Unfired Pressure Vessel (UPV) Inspections ………………… 23

8.2 Responsibilities ……………………………………………………………… 23

8.2.1. Naval Facilities Engineering and Expeditionary Warfare Center (EXWC) … 23

8.2.2 EXWC Boiler & Pressure Vessel Inspection and Certification Board …… 23

8.2.3 EXWC Boiler & UPV Program Manager …………………………………... 24

8.2.4 FEC PW Core Boiler and UPV Lead Certifying Official …………..………. 25

8.2.5 Public Works Departments (PWD’s) ………………………………………. 25

9. TRAINING ……………………………………………………………. 26

9.1 Background …………………………………………………………….. 26

9.2 Responsibilities …………………………………………………………. 27

9.2.1 Naval Facilities Engineering and Expeditionary Warfare Center (EXWC) .. 27

9.2.2 Public Works Departments (PWD’s) ………………………………………. 27

1. PURPOSE:

To provide updated policy and guidance for the essential operation, inspection and maintenance services that are required by NAVFAC to support its mission for shore activities while utilizing its resources in an efficient and cost effective manner.

1.1 Action.

All Navy shore activities shall comply with the policy and guidance contained herein.

2. HEATING AND POWER PLANTS

2.1 Guidance:

This Navy Shore Boiler Guide provides information and guidance on the operation, inspection and maintenance of heating and power boiler plants.

2.2 Definitions:

Boiler: is defined as a closed vessel in which water or other liquid is heated; steam or vapor is generated; steam is superheated; or in which any combination of these functions is accomplished, under pressure or vacuum, for use externally to itself, by the direct application of energy from the combustion of fuels, or from electricity. The term “boiler” shall include fired units for heating or vaporizing liquids other than water, where these units are separate from processing systems, and are complete within themselves.

Boiler Operation: is defined as the series of functions, tasks, to initiate combustion or ‘firing’ and the task of monitoring employed on boiler controls and system components to create the desired boiler function and commodity output.

Boiler Maintenance: is defined as the periodic inspection actions to check the boiler components systematically to preserve the functioning and protect the boiler from break down or other problems keeping it operating safely and efficiently.

Power Boiler: a boiler in which steam or other vapor is generated at a pressure of more than fifteen (15) pounds per square inch gauge;

High Pressure High Temperature Water Boiler: a water boiler operating at pressures exceeding one hundred sixty (160) pounds per square inch gauge or temperature exceeding two hundred fifty (250) degrees Fahrenheit;

Heating Boiler: a steam or vapor boiler operating at pressures not exceeding fifteen

(15) pounds per square inch gauge or a hot water boiler operating at pressures not exceeding one hundred sixty (160) pounds per square inch gauge or temperature not exceeding two hundred fifty (250) degrees Fahrenheit.

Domestic Hot Water Heater/Boiler (“H” or “HLW” Stamped): a vessel, which is closed except for openings through which water can flow, that includes the apparatus by which heat is generated and on which all controls and safety devices necessary to prevent pressures greater than 160 psig (1100 kPa gage) and water temperatures greater than

210°F (99°C) are provided, in which potable water is heated by the combustion of fuels, electricity, or any other heat source and withdrawn for external use.

Power Plant: the complex, including machinery, associated equipment and the structure housing it, that is used in the generation of power, especially electrical power.

Heating Plant: a facility composed of one or more pieces of equipment connected to or part of a structure and designed to provide a service such as hot water heating or hot water supply using heated oil, low pressure steam, hot water or high temperature hot water.

Cogeneration Plant: cogeneration is the process whereby a single fuel source, such as natural gas, is used to produce both electricity and thermal energy.

Central (Heating or Power) Plant: the use of a single heating or cooling plant to serve a group of buildings or facilities through a system of distribution pipework that feeds each structure or facility.

Heat Recovery Steam Generator (HRSG): a HRSG is an energy recovery heat exchanger that recovers heat from a hot gas stream. It produces steam that can be used in a process (cogeneration) or used to drive a steam turbine (combined cycle).

PH: a measure of acidity and alkalinity of a solution that is a number on a scale on which a value of 7 represents neutrality and lower numbers indicate increasing acidity and higher numbers increasing alkalinity and on which each unit of change represents a tenfold change in acidity or alkalinity and that is the negative logarithm of the effective hydrogen-ion concentration or hydrogen-ion activity in gram equivalents per liter of the solution.

Dissolved Oxygen: the amount of oxygen dissolved in a body of water as an indication of the degree of health of the water.

Conductivity: conductivity of a substance is defined as the ability or power to conduct or transmit heat, electricity, or sound. Its units are Siemens per meter [S/m] in SI and millimhos per centimeter [mmho/cm] in U.S. customary units.

Chlorides: a compound of chlorine with another element or group, especially a salt of the anion Cl or an organic compound with chlorine bonded to an alkyl group.

2.3 Applicability:

This Navy Boiler Guide applies to all boilers operated on Navy Installations and located in mechanical rooms and/or plants containing one or more boilers. Boiler Operator Licensing applied to personnel performing Boiler Operations.

3. OPERATIONS AND MAINTENANCE MANUALS

3.1 Background:

All boilers and related components shall be operated and maintained properly at all times.

Boilers shall be maintained to prevent inefficient operation and properly operated to prevent abnormal operating condition resulting in a disaster causing personal injury and property loss.

3.2 Standards:

Written maintenance and operational records in the form of a log are required for each boiler. Each attendance to the boiler for observation and maintenance shall be recorded in a log along with observations made and maintenance performed. In addition, all heating plants shall have written operating and maintenance procedures compiled into an O&M manual. For plants with capacities up to 50 million British Thermal Units per hour (MBTUH), the O&M manual should consist of plant drawings and manufacturer's maintenance and operations catalogs containing trouble-shooting guides, maintenance procedures and equipment operating procedures including start-up, shutdown, emergency and lay-up procedures. Central heating plants with capacities of 50 MBTUH and larger (including Power, Heating & Cogen Plants) and electrical generating plants shall have system oriented O&M manuals. Existing O&M manuals should be reviewed and updated every five years, or earlier in the event of a major system change. Manuals for existing plants should include:

Plant systems and equipment operating procedures including start-up, shutdown, emergency and lay-up procedures.

Plant systems and equipment maintenance procedures.

Performance test records for major equipment.

Sample operator logs.

Preventive maintenance schedules and log format for all equipment and systems.

Minimum spare parts inventory.

Trouble shooting procedures for major equipment and systems.

Clearly defined duties, responsibilities, and qualifications for all O&M positions.

File of manufacturer's equipment data and drawings.

File of manufacturer's equipment O&M procedures.

File of plant design and construction drawings.

Performance test procedures for major equipment and systems.

A Plant Equipment Manual including equipment ID or account numbers, manufacturer's name, model number

Outline of training program for all positions.

Ensure that all plant personnel and visitors are provided appropriate PPE for noise, sight, fumes, body protection and that they are available and in good usable condition. Perform inspection, testing and operation of emergency eye wash station.

Ensure that safety signs are posted for hazardous noise, high temperatures/pressure as well as MSDS sheets for chemical storage and usage.

3.3 Responsibilities

3.3.1 NAVFAC Facility Engineering Command (FEC) PW Core Boiler and UPV

Lead Certifying Official (LCO):

FEC LCO’s shall assist activities in reviewing, updating and establishing O&M manuals.

3.3.2 Public Works Departments:

Maintain O&M manuals for all heating plants and major equipment. Review adequacy and update the manuals at least once every 5 years.

4. BOILER WATER TREATMENT

4.1 Background.

The importance of good water chemistry cannot be overemphasized. Controlling the chemistry of the water and steam will extend the life of the plant, increase reliability, and reduce maintenance costs.

The primary function of a boiler water treatment program is to keep heat transfer surfaces free of deposits and scale. The secondary function is corrosion inhibition. Boiler deposits are a problem as they typically contain undesirable levels of metal oxides, mineral scale, and sludge.

Suspended solids and dissolved oxygen significantly contribute to waterside corrosion and scale.

This can be controlled through an effective testing and treatment program, regular effective blowdowns, and adherence to the guidelines set forth in this guide and UFC 3-240-13N.

Deposits and corrosion can lead to boiler tube failures that result in costly repairs and downtime.

The purpose of a boiler water treatment program is to enhance operational efficiency, safety, and reliability within a boiler system, thereby reducing unscheduled outages, improving operational efficiencies, and reducing operational and maintenance costs.

4.2 Water Treatment

Water treatment is necessary to remove the impurities that are contained in water as found in nature. Control or elimination of these impurities is necessary to combat corrosion, scale formation, and fouling of heat transfer surfaces throughout the facility and support systems.

The following are three reasons for using very pure water at the plant site:

To minimize corrosion, which is enhanced by impurities

To reduce maintenance costs resulting from corrosion

To minimize fouling of heat transfer surfaces

Corrosion products and other impurities may deposit on core surfaces and other heat transfer regions, which results in decreased heat transfer capabilities by fouling surfaces or blockage of critical flow paths. Areas of high concentrations of these impurities and corrosion products may also lead to extreme conditions of the various corrosion processes with resultant failure of components or systems.

4.3 Safety:

The basic safety goal is to be sure employers and employees know about work hazards and how to protect themselves; this should help to reduce the incidence of chemical source illness and injuries.

NAVOSH establishes uniform requirements to ensure that the hazards of all chemicals are evaluated and that this hazard information is transmitted to affected employers and employees.

Employers, therefore, must develop, implement, and maintain at the workplace a written comprehensive hazard communication program that includes provisions for container labeling, collection and availability of material safety data sheets and an employee training program.

The information must also contain a list of hazardous chemicals, the means the employer will use to inform employees of the hazards of non-routine tasks (for example, the cleaning of pressure vessels), and the hazards associated with boiler water treatment chemicals.

In addition, all covered employers must have written hazard communication program to get hazard information to their employees through labels on containers and training.

4.4 Standards:

The extent of the boiler water treatment program will depend on the type of boiler and its application, with low pressure hot water boilers needing the least attention and higher pressure boilers used for the generation of steam to ships or for electrical generation requiring the most attention. Periodic testing of feedwater, boiler water, condensate return, is necessary for assessing the effectiveness of the program. Boilers shall have raw water, boiler water and condensate samples tested, at a minimum annually, by a laboratory independent of the boiler plant for comparison to an activity analysis prepared at the same time at the plant. Significant discrepancies between the two analyses may indicate problems with the equipment, treatment chemicals, test reagents, or procedures. The activity shall take steps immediately to determine the cause of the problem and correct the situation. If an equipment problem is indicated, prompt attention shall be given to the equipment involved. UFC 3-240-13N, Industrial Water Treatment, contains further guidance and information.

4.5 Guidelines:

Frequency of Sampling.

The minimum required boiler sampling frequencies are:

Product Capacity Function Frequency

Hot Water < 5,000,000 btu/hr Heating Once / 6 months

Hot Water 5,000,000 btu/hr and Greater Heating Once / Month

HTHW 5,000,000 btu/hr and Greater Heating Once / Day

Steam Less than 5,000,000 btu/hr Heating Once / Week

Steam 5,000,000 btu/hr and Greater Heating Once / Day

Steam 5,000,000 btu/hr and Greater Electrical Gen. Once / 8 hours

4.6 Useful Tests and Limits for the control of water for Boilers:

4.6.1 Feedwater Limits for Watertube Boilers

Chemical Test Method Corrosion Deposits Carryover

Raw Water

A — Acidity or alkalinity X X

B — Hardness: calcium and magnesium X

Softened Water

A — Acidity or alkalinity X

B — Hardness: calcium and magnesium X

Feedwater

A — Acidity or alkalinity X X

B — Hardness: calcium and magnesium X

C — pH X

D — Iron X

E — Copper X

Boiler Water

A — Acidity or alkalinity X X

C — Hydroxide X X X

D — Phosphate X

E — Sulfite X

F — Nitrate X

G — Dissolved solids X X X

H — Silica X X

I — Suspended solids X X

Utilized for Prevention or Control of

USEFUL TESTS FOR THE CONTROL OF WATER FOR BOILERS

Feedwater Property p s ig

-4 p s ig p s ig p s ig p s ig p s ig p s ig p s ig

Dissolved oxygen (ppm O2) * < 0.007 < 0.007 < 0.007 < 0.007 < 0.007 < 0.007 < 0.007 < 0.007

Total iron ppm Fe (as Fe) ≤ 0.1 ≤ 0.05 ≤ 0.03 ≤ 0.025 ≤ 0.02 ≤ 0.02 ≤ 0.01 ≤ 0.01

Total copper ppm Cu (as Cu) ≤ 0.05 ≤ 0.025 ≤ 0.02 ≤ 0.02 ≤ 0.015 ≤ 0.01 ≤ 0.001 ≤ 0.001

Total Hardness ppm (as CaCO3) ≤ 0.03 ≤ 0.03 ≤ 0.02 ≤ 0.02 ≤ 0.1 ≤ 0.05 ND ND pH at 25 oC (77 oF) 8.3-10.0 8.3-10.0 8.3-10.0 8.3-10.0 8.3-10.0 8.3-9.6 8.3-9.6 8.3-9.6

Chemicals for pre-boiler system NS NS NS NS NS VAM VAM VAM

Non-volatile TOC ppm (as O2) < 1 < 1 < 0.5 < 0.5 < 0.5 < 0.2 < 0.2 < 0.2

Oily matter ppm < 1 < 1 < 0.5 < 0.5 < 0.5 < 0.2 < 0.2 < 0.2

ASME Feedwater Limits for Industrial Water Tube Boilers

* Measured before oxygen scanvenger addition

4.6.2 Feedwater Limits for Water Tube Boilers 0-300psig

4.6.3 Feedwater Limits for Water Tube Boilers 301-600psig

Feedwater Property ASME ABMA USACE

Dissolved oxygen ppm O2 * < 0.007 Note 6 NS

Total iron ppm Fe (as Fe) < 0.1 Note 6 NS

Total copper ppm Cu (as Cu) < 0.05 Note 6 NS

Total hardness ppm (as CaCO3) < 0.5 Note 6 Softened pH at 25 °C (77 °F) 8.3-10.5 Note 6 NS

Non-volatile TOC ppm (as O2) < 1 Note 6 NS

Oily matter ppm < 1 Note 6 NS

Suggested Feedwater Limits for Industrial Water Tube Boiler

0–300 psig

Notes:

1. Makeup water percentage: Up to 100% of feedwater.

* before chemical oxygen scavenger addition

3. Conditions: no superheater, turbine drives, or process restriction on steam purity.

4. Steam purity: 1.0 ppm TDS maximum.

5. NS = not specified.

6. See ABMA Standard – Boiler 401

2. Assumes existence of deaerator.

Feedwater Property ASME ABMA USACE

Dissolved oxygen ppm O2 * < 0.007 Note 6 NS

Total iron ppm Fe (as Fe) < 0.05 Note 6 NS

Total copper ppm Cu (as Cu) < 0.025 Note 6 NS

Total hardness ppm (as CaCO3) < 0.3 Note 6 Softened pH at 25 °C (77 °F) 8.3-10.5 Note 6 NS

Non-volatile TOC ppm (as O2) < 1 Note 6 NS

Oily matter ppm < 1 Note 6 NS

1. Makeup water percentage: Up to 100% of feedwater.

Suggested Feedwater Limits for Industrial Water Tube Boiler

301–600 psig

Notes:

* before chemical oxygen scavenger addition

3. Conditions: no superheater, turbine drives, or process restriction on steam purity.

4. Steam purity: 1.0 ppm TDS maximum.

5. NS = not specified.

6. See ABMA Standard – Boiler 401

2. Assumes existence of deaerator.

4.6.4 Feedwater Limits for Industrial Firetube Boilers 0-300 psig

4.6.5 Boiler Water Limits for Water Tube Boilers

4.6.6 ASME Boiler Water Limits for Firetube Boilers

Feedwater Property ASME

Dissolved oxygen ppm O2 * < 0.007

Total iron ppm Fe (as Fe) < 0.1

Total copper ppm Cu (as Cu) < .05

Total hardness ppm (as CaCO3) < 1.0 pH at 25 °C (77 °F) 8.3-10.5

Non-volatile TOC ppm (as O2) < 10

Oily matter ppm < 1

2. Assumes existence of deaerator.

3. Conditions: no superheater, turbine drives, or process restriction on steam purity.

4. Steam purity: 1.0 ppm TDS maximum.

Suggested Feedwater Limits for Industrial Firetube Boiler

0–300 psig

Notes:

* before chemical oxygen scavenger addition

1. Makeup water percentage: Up to 100% of feedwater.

Boiler Water Property 0-300 psig 301-600 psig

Silica (ppm SiO2) < 150 < 90

Total alkalinity < 1000 < 850

Free OH alkalinity NS NSSpecific conductance

(μmhos/cm) without neutralization < 7000 < 5500

Suggested Boiler Water Limits for Industrial Water Tube Boiler

0–300 psig

Boiler Water Property Limit

Silica (ppm SiO2) < 150

Total alkalinity < 700

Free OH alkalinity NS

Specific conductance (μmhos/cm) without neutralization < 7000

ASME Boiler Water Limits for Industrial Firetube Boilers

4.6.7 Shore to Ship Steam Purity Requirements

Shore to Ship Steam Purity Requirements shall meet the requirements of Naval Ships

Technical Manual (NSTM), Chapter 220, Volume 2. Steam supplied directly to ships shall be generated from feedwater that is either treated with a chemical oxygen scavenger or mechanically deaerated to 15 ppb or less of dissolved oxygen. Shore steam is treated with a neutralizing amine (morpholine or cyclohexylamine) to increase the pH of the normally acidic shore steam. Maintaining the steam in a slightly alkaline condition minimizes corrosion and will reduce the amount of suspended solids that collect in the boiler. Shore steam shall meet the following requirements:

Table 220-22-3 SHORE STEAM REQUIREMENTS

Constituent or Property Requirement pH 8.0 to 9.5

Conductivity 25μmho/cm max

Dissolved Silica 0.2 ppm max

Hardness 0.10 epm max

Total Suspended Solids 0.10 ppm max

NOTE

The use of filming amines to control steam/condensate pH is prohibited. Compliance with environmental and health regulations is the responsibility of the shore facility.

NSTM, Chapter 220-22.9 outlines the Navy and Commercial Facility Shore Steam

Certification Requirements. Shore steam provided to Navy ships shall meet the requirements of paragraph 220-22.8. Facilities providing shore steam to Navy ships are required to sample and test shore steam and provide certification to the user ships as follows:

1. Sampling and analysis requirements.

a. Shore boiler steam discharge shall be sampled daily.

b. Each pier and quay shall be sampled quarterly. Shore steam sampling piping arrangements shall comply with part 31 of the American Society for Testing Materials standards and NAVFAC P-200. Steam hoses shall be in accordance with specification

MIL-DTL-29210.

2. Shore steam certification requirements.

a. Documentation of the most recent daily analysis results shall be provided to each ship prior to shore steam hookup.

b. Daily steam analysis results shall be made available to each ship by telephone or computer. The telephone number or internet address shall be provided to each ship at the time of shore steam hookup.

c. Each ship shall be notified anytime shore steam does not meet the requirements of paragraph 220-22.8.

3. Shore steam not complying with the requirements of paragraph 220-22.8 shall not be used.

Use of shore steam that does not meet the requirements of paragraph 220-22.8 has shown to cause several problems, depending on the parameter that is out of specification. Problems include corrosion due to out of limits pH, carryover of contaminants, or damage to gaskets and the sight glass due to high suspended solids. Violation of the requirements of paragraph

220-22.8 or the above certification requirements shall be reported by message to the Type

Commander with info copy to ISIC, RMC (SGPIs), NSWCPD, and NAVSEA. See paragraph

220-23.10.

4.6.8 Treatment for Low-Pressure Steam (Use of filming amines is prohibited)

Boiler Guidelines

Cast iron Not treated

Less than 334 W (10 hp) Not treated

1. External treatment: softening.

2. Internal treatment: precipitating or solubilizing scale inhibitor, sulfite, tannin derivatives, filming surfactant, caustic supplement if necessary, neutralizing amine.

3. See Tables 3-19 through 3-20.

4. Treat same as closed hot water.

1. External treatment: softening.

2. Internal treatment: precipitating or solubilizing scale inhibitor, sulfite, tannin derivatives, filming surfactant, caustic supplement if necessary, neutralizing amine

1. External treatment: softening.

2. Internal treatment: precipitating or solubilizing scale inhibitor, sulfite, tannin derivatives, filming surfactant, caustic supplement if necessary, neutralizing amine.

3. See Tables 3-19 and 3-20.

Treatment Guidelines for Low-Pressure Steam

Boilers < 95% condensate return

Boilers with less than 95% condensate return

Boiler with 95% condensate return

4.6.9 Treatment for Medium- and High- Pressure Steam

(Use of filming amines is prohibited)

**** For boilers not producing shore-to-ship steam or feedwater, the limits on boiler water quality will vary according to the type of boiler and the nature of its service; see UFC 3-240-

13FN. In addition, boiler’s with aluminum heat exchangers PH shall be kept within the manufacturer’s recommendations, typically between the 6.5 to 8.5 range.

4.7 Prohibitions and Recommendations:

The use of filming amines is prohibited. Filming amines are difficult to control and have been found to obstruct distribution lines and heat exchangers. The use of polymers instead of tannin as a sludge conditioner is recommended. Tannin interferes with the testing of other boiler water chemicals and has largely been replaced by polymers as a sludge conditioner. The dosage of some boiler water additives such as volatile amines is restricted by the U. S. Code of Federal

Regulations Title 21 for steam used for food processing or humidification. NAVFAC policy is

Parameter Boiler Water Treatment Control

COC Maximum of 100, per ASME

General corrosion Maximum total alkalinity, per ASME guidelines, pH of 10.3–12.0. May require alkalinity builder.

Pitting corrosion 20-40 ppm sulfite for boilers up to 6205

KPa (900 psig). Specialty volatile oxygen scavengers optional for boilers 4137-

6205 KPa (600-900 psig). Also, tannin derivatives and other organic-based oxygen scavengers

Condensate corrosion Maintain pH of 7.5-9.3 using neutralizing amines or follow guidelines for filming surfactant chemistry. Specialty volatile oxygen scavengers optional.

1. Precipitating program using phosphate or carbonate with a polymer sludge conditioner. Or

2. Solubilizing program using chelants, phosphonates, or polymers. Or

3. Tannin and lignin derivatives and phosphonates and/or polymers (including acrylate-styrenesulfonate co-polymers and polymethacrylates)

Carryover control due to foaming Limit total alkalinity, per ASME guidelines, and treat with antifoam as required.

Treatment Guidelines for Medium- and High-Pressure Steam

Deposition control to prohibit, for all new construction and building renovations, the use of steam which contains amines for food processing, space humidification, and medical instrument sterilization. To ensure that boiler water additives do not come in contact with food or are contained in steam used to contain the additive laden steam within the primary distribution system.

4.8 Records:

A record log of sampling results, adjustment to chemical levels, and adjustment to equipment is considered essential for the management of an effective treatment program.

Activities shall retain water treatment logs and reports for at least three years.

4.9 Responsibilities:

4.9.1 NAVFAC Facility Engineering Command (FEC) PW Core Boiler and UPV

Lead Certifying Official (LCO):

FEC LCO shall assist activities by providing consultation services and by monitoring activity water treatment programs for effectiveness.

4.9.2 Public Works Departments:

The PWD is responsible for establishing and maintaining an effective water treatment program. Copies of water treatment logs and records shall be made available to the FEC LCO upon request.

5. PROPRIETARY DEVICES AND CHEMICALS

5.1 Discussion:

Shore activities are requested by various representatives of industry to procure and test new devices and chemicals to treat the waterside, clean the firesides, or improve the combustion efficiency of boilers. These devices and chemicals claim to treat boiler water in such a way as to eliminate the formation of scale, sludge, and corrosion in boilers and piping systems. These burner devices and fuel oil additives claim to prohibit fireside deposits and enhance burning of the fuel. New devices and chemicals shall be evaluated and approved by the FEC LCO and/or the NAVFAC Engineering and Expeditionary Warfare Center (EXWC) Boiler & UPV

Inspection Program Manager prior to procurement and installation.

5.2 General

On line installation and testing of any product that could cause operational or maintenance problems is prohibited. Proprietary devices and chemicals often have generic counterparts which are less expensive and as effective.

5.3 Actions:

The following are actions that should be taken in regards to new devices and chemicals:

The FEC LCO and/or the NAVFAC Engineering and Expeditionary Warfare

Center (EXWC) shall evaluate and approve new devices and chemicals prior to their use. Environmental and Safety Offices shall assist in evaluations.

PWDs shall request evaluation and approval of new devices and chemicals from their local FEC.

PWDs shall obtain the following information from the manufacturer or sponsor:

a. A statement defining the intended purpose and functions of the device or product.

b. A complete description of the device or chemical, including information on its application, method of operation, and the environmental conditions under which it is designed to function.

c. Detailed result of an exhaustive research and testing program by an independent agency in good standing and high repute in the engineering profession.

6. EFFICIENCY

6.1 Background:

Older boilers were designed in the days of cheap and plentiful natural gas/oil and when global warming was not an issue. Carbon dioxide is produced in larger quantities by older boilers purely because they are less fuel-efficient and burn more gas for a given amount of useful heat in a building than new boilers. A modern high efficiency or condensing boiler will extract in useful heat energy around 90% of energy available in the gas it burns. A 30-year old boiler will be closer to 60%. Therefore, it is imperative to ensure that all boiler plants are operated efficiently. Close monitoring of these boilers is necessary to ensure efficient and reliable service.

6.2 Objective:

The objective of Navy boiler plant operations is to ensure that the plants are operated at the highest level of reliability, efficiency and safety possible. To accomplish that objective, all heating and power plants shall be operated at optimum efficiency at all loads.

6.3 Standards:

During initial startup and testing of a new industrial sized boiler the test procedure from the ASME PTC 4, "Fired Steam Generators” is used to provide a means for measuring the performance of boilers. These tests typically use continuous emissions monitoring system

(CEMS) type equipment. Some larger plants in the Navy may have these CEMS systems permanently installed in the plant. The ability these systems give to maintain high efficiency should be measured against their high maintenance cost, when considering installation. The emissions data is normally very accurate in a properly operating system. The data typically includes O2, CO2, CO, SOx, NOx, and stack temperature. The CO reading should not exceed

200 ppm. Smaller heating plants and individual building boilers without CEMS must be tested periodically to maintain optimum efficiency; this is done with a portable combustion analyzer

(PCA). PCA’s use an electrochemical cell to measure each emission; with the exception of CO2 that uses an inferred device. These are less accurate but are much smaller and less expensive than CEMS. PCA analyzers vary greatly in size, cost, accuracy, and recommended time in use.

The typical model will measure O2, CO, CO2, stack temperature and have a "fuel type" select button (oil #2, oil #6, natural gas, propane, coal) with which it can calculate an approximate combustion efficiency. More complex PCAs can additionally measure NOx and SOx. Please note PCAs require a significant amount of maintenance, requiring routine calibrations of its electrochemical cells, in addition these cells need to be replaced every 12 to 18 months.

Operating boilers that are continually manned without CEMS require combustion efficiency checks and may require adjustments to combustion efficiency at least once a shift. All other operating boilers with input capacities of 400,000 btu/hr or greater require combustion efficiency measurements at least semi-annually.

6.4 Combustion Analysis Limits:

The typical combustion analysis limits for boilers at steady state conditions and at high fire are:

TYPE FUEL

Flue Gas Constituent Gas Oil

Min-Max Min-Max

CO2 8 - 10 (%) 9 - 11(%)

O2 4 - 6 (%) 4 - 7 (%)

CO 0 - 200 (ppm) 0 - 200 (ppm)

Note: Stack temperatures on the boilers shall be no more than 550°F upstream of any heat recovery devices.

Note: Always set the recommended combustion limits per the burner/boiler manufacturer’s installation / operation manual.

6.5 Responsibilities

6.5.1 NAVFAC Facility Engineering Command (FEC) PW Core Boiler and UPV

Lead Certifying Official

FEC LCO shall assist PWDs by:

Providing training opportunities on a reimbursable basis.

Reviewing operations and maintenance practices.

Field testing boilers where appropriate.

Conducting or administering studies for the purpose of improving operations and maintenance efficiency.

Providing information on boiler monitoring and other information technology to better manage boiler plants.

Performing all acceptance and commission inspections on boilers and UPV’s or assigning inspection to a qualified NAVFAC Inspector.

6.5.2 NAVFAC Engineering and Expeditionary Warfare Center (EXWC):

EXWC shall assist NAVFACENGCOM and the FEC on a reimbursable basis by:

Thermal plant design criteria and review.

Testing, trouble shooting and investigative engineering services.

Efficiency improvement training.

Boiler and UPV inspection services.

6.5.3 PWDs:

PWDs shall be responsible for:

Establishing optimum efficiency curves for all boilers.

Ensuring that the boiler plant is operated efficiently and that the prescribed efficiency tests are performed.

Accomplishing tune ups and repair/replacement of equipment to ensure the Navy's heating and power plants are efficiently operated and maintained. Depending on in-house capability, this service may need to be executed by a separate contract.

7. MINIMUM ATTENDANCE

7.1 Definitions:

Fully Automatic Boiler.

A fully automatic boiler has controls that automatically regulate and maintain proper water level within the boiler, regulate the rate of combustion in response to heat output requirements and cut off the fuel supply when a predetermined condition is reached, cut off the fuel supply in the event of low water or loss of ignition or other predetermined emergency conditions, and turn on the fuel supply and start combustion when additional heat input is required. Fully automatic boilers shall lock out on safety in case of failure to light off, lock out on safety in case of loss of ignition, provide pilot proving before opening main fuel valve on boilers with gas or oil pilots, prevent attempt to light off if the gas pressure is below a predetermined minimum on boilers with a gas pilot and provide pre-ignition and post-ignition purging on shut down on boilers with heat input in excess of 400,000 btu/hr.

Semiautomatic Boiler.

A semiautomatic boiler is a boiler equipped so that the water level in the boilers is regulated automatically, the fire is regulated automatically by the pressure and demand for steam, and the fuel supply is automatically shut off in the event of low water in the boiler or loss of ignition or other predetermined emergency conditions. Startup is not automatic.

Semiautomatic boilers shall have pilot ignition with pilot proving devices. Each burner of a multi-burner semiautomatic boiler shall be manually activated to restart following any shutdown.

Heating Boiler.

A boiler operated at pressures not exceeding 15 psig for steam, or at pressures not exceeding 160 psig and temperatures not exceeding 250 degrees F for water.

Power Boiler.

A boiler operated at a pressure of more than 15 psig for steam, or pressure of more than

160 psig and a temperature of more than 250 degrees F for hot water.

Central Power Plant.

A central power boiler plant that exports a heated medium and/or electricity to more than one facility/building at a pressure of more than 15 psig for steam, or pressure of more than 160 psig and a temperature of more than 250 degrees F for hot water.

Boiler Central Monitoring System.

Central monitoring system is a remote monitoring system that may be used whenever feasible to reduce the frequency of visits to boiler plant(s) using fully automatic controls. A licensed operator shall perform the monitoring. Paragraph 7.2 below outlines the parameters that must be followed if central monitoring systems are to be used.

Boiler Room.

Any room in a building where a boiler is located.

7.2 Standards:

To reduce the possibility of property losses, personnel injuries and unnecessary fuel and maintenance costs, boiler plants must be operated in a safe and efficient manner by properly trained and certified operators. To ensure safe and efficient boiler operation all heating and power boilers shall receive operational attendance by qualified licensed operators on a constant or periodic basis. Operators shall be able to detect and correctly respond to equipment malfunctions or irregularities that could disrupt service, cause a hazard, or damage equipment.

The frequency and degree of attendance can vary depending on plant capacity, operating pressure, extent of automatic controls employed, and the application of remote monitoring systems. Central monitoring systems maybe used whenever feasible to reduce the frequency of visits to boiler plants using fully automatic controls. If central monitoring systems are used the following parameters shall be followed:

a. The boiler shall have an established water treatment program following the guidance outlined in UFC 3-240-13FN, Industrial Water Treatment.

b. Monitoring shall be performed by a properly licensed operator.

c. Boiler shall have redundant feed pumps to supply water to the boiler.

d. Remote boiler shutdown switches shall be located at each boiler room door and at the remote monitoring station.

e. Power Boiler Plants utilizing gas or liquid fuels shall have a fuel rich condition shutdown procedure.

f. Boiler shall be equipped with water level transmitter viewable from a location outside the boiler room.

g. A bound log book shall be maintained in the boiler room.

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h. A licensed operator shall be dispatched immediately to boiler room if alarm annunciates a safety shutdown occurrence from central monitoring location.

i. Boiler shall have Emergency and Standard Operating Procedures posted at the boiler.

The SOP’s must include testing of all safety devices on the boiler at scheduled intervals.

j. Remote monitoring shall have network failure alarm. Network failure requires operator to return to the boiler room immediately. The following items shall be available to be viewed remotely when the building is not occupied by a licensed operator:

Water level (water pressure and temperature for high temp hot water “(HWH)”

Stack temperature if oil fired

Video camera installed to view boiler front

k. The following alarms will shut down the boiler immediately and give indication to the licensed operator monitoring the boiler:

Low water level (high or low pressure and high or low temperature for HWH)

Low gas/oil pressure

High gas/oil pressure

High Temperature/High Steam Pressure

Pilot failure

Flame failure

Remote energizing of boiler controls is prohibited without an operator or mechanic in attendance at the boiler. Any control shall be such that no flame safeguard or burner management component is remotely controlled.

7.3 Criteria:

7.3.1 Heating Boilers and Power Boilers Minimum Attendance:

The minimum attendance for electric, oil, and gas fired heating boilers and power boilers using fully automatic controls are:

Output Heating Boiler (BTU/hr) Attendance

Up to 400,000 Once / Month

400,000 to 5,000,000 (Hot Water) Once / 2-Weeks

Over 5,000,000 (Hot Water) Once / Week

400,000 and up 3,400,000 (Steam) Weekly

3,400,000 and Up (Steam) Daily

Output Power Boiler (BTU/hr) Without Central Monitoring With Central Monitoring

(See Notes 2, 3, 4)

HTWH (High Temp. Hot Water) Once / Day Once / Day

Up to 3,400,000 Once / Day Once / Week

3,400,000 to 14,000,000 Once / 8 hours Once / Day

14,000,000 to 21,000,000 Once / 4 hours Once / 12 hours

21,000,000 and Up Continuous Continuous

The following explanations apply to the above tables:

Notes:

(1) Where two or more boilers are operating in a single plant/facility/boiler room, the minimum attendance shall be based on the capacity of the largest operating boiler or one half of the sum of the combined capacities of all operating boilers, whichever is greater.

(2) If central monitoring fails or is down for maintenance, follow “the without central monitoring” guidelines

(3) A single Power Boiler over 14,000,000 Btu/hr input utilizing Central Monitoring

System, the licensed operator minimum attendance will be once every12 hours.

(4) A single Power Boiler less than 14,000,000 Btu/hr input utilizing a Central

Monitoring system, the licensed operator minimum attendance must not be less than paragraph 12-7.3.1 tables above.

(5) One boiler horse power equals 33,475 BTUH.

7.3.2 Power Boiler Plant Certified Boiler Operator Manning:

The operator manning required for all Power Boiler Plants/Facility/Boiler Rooms and non-fully automatic boilers is:

GAS-FIRED BOILERS

No. of Operating Boilers in Plant 1 2 3 4 5 6 7 8

Output Capacity Number of Plant Boiler Room Personnel / Shift

Up to 21,000,000 BTUH 1 1 1 1 1 1 1 1

Up to 40,000,000 BTUH 1 1 1 1 1 1 1 2

Up to 60,000,000 BTUH 1 1 1 1 1 1 2 2

Up to 80,000,000 BTUH 1 1 1 1 2 2 2 2

Up to 100,000,000 BTUH 1 1 1 1 2 2 2 2

Up to 125,000,000 BTUH 1 1 1 1 2 2 2 2

Up to 150,000,000 BTUH 1 1 2 2 2 2 3 3

Up to 200,000,000 BTUH & Over 1 1 2 2 2 2 3 3

OIL-FIRED BOILERS

No. of Operating Boilers in Plant 1 2 3 4 5 6 7 8

Output Capacity Number of Plant Boiler Room Personnel / Shift

Up to 21,000,000 BTUH 1 1 1 1 1 2 2 2

Up to 25,000,000 BTUH 1 1 1 1 1 2 2 2

Up to 40,000,000 BTUH 1 1 1 2 2 2 2 2

Up to 60,000,000 BTUH 1 1 1 2 2 2 2 2

Up to 80,000,000 BTUH 1 1 2 2 2 2 2 2

Up to 100,000,000 BTUH 1 1 2 2 2 2 2 2

Up to 125,000,000 BTUH 1 2 2 2 2 2 3 3

Up to 150,000,000 BTUH 1 2 2 2 2 2 3 3

Up to 200,000,000 BTUH & Over 2 2 2 2 2 2 3 3

Notes:

(1) The output capacity is the average peak demand, not the peak capacity. This average should be taken over the last five-year period of the plant's operation. The minimum staffing listed pertains only to boiler operator attendance. It does not include additional staffing which shall be required for maintenance (excluding low level preventative maintenance) and repair of the boiler and auxiliary equipment or tasks such as boiler water treatment and testing. These additional tasks are not part of the activities required to meet the minimum attendance requirements listed in tables above.

(2) For Central Power Boiler Plants with central monitoring, attendance may be reduced by one but will never be less than one.

7.3.3 Alternative Fuel Fired Boiler Plants Minimum Attendance:

Due to the unique operation and maintenance requirements of individual plants and their relative small number, minimum staffing will be determined on a site-specific basis with the concurrence of EXWC PW5.

7.4 Responsibilities

7.4.1 NAVFAC Engineering and Expeditionary Warfare Center (EXWC):

NAVFAC EXWC shall monitor compliance with the minimum attendance, operator qualification and staffing requirements via the FEC LCO’s.

7.4.2 NAVFAC Facility Engineering Command (FEC) PW Core Boiler and UPV

The FEC LCOs shall assist the PWDs in attaining compliance with the requirements.

7.4.3 PWDs:

To ensure safe and efficient boiler plant operation, PWDs shall meet the following requirements:

Boiler personnel that perform boiler attendance as required in paragraph 7.3.1 & 7.3.2 will be trained, licensed and certified in accordance with applicable existing Federal, State, local, or host nation standards. In the absence of Federal, State, local, or host nation certification requirements for boiler plant operators, boiler operators within the oversight of the PWBL Facilities Management & Sustainment (FM&S) Product Line shall, as a minimum, successfully complete the Fifth Class Power Engineer

Certification Program of the National Institute for the Uniform Licensing of Power

Engineers, Inc. (www.niulpe.org), or successfully complete the Facility Operating

Engineer Third Class Certification Program of the American Society of Power

Engineer, Inc. (ASOPE). Boiler operators, whom are part of central boiler plants under the purview of Public Works Business Line (PWBL) Utilities Management shall, as a minimum, successfully complete the Fourth Class Power Engineer Certification

Program of the National Institute for the Uniform Licensing of Power Engineers, Inc.

(www.niulpe.org), or successfully complete the Third Class Power Plant Operating

Engineer Certification Program of the American Society of Power Engineer, Inc.

(ASOPE).

To eliminate or minimize boiler and UPV problems on all contracts involving boiler or

UPV installations, PWD’s shall coordinate Design & SOW Reviews, Contractor

Submittal Reviews and Acceptance Inspections with the NAVFAC FEC LCO or local

NAVFAC Inspector. The requesting activity is responsible for providing the funds to accomplish the reviews and inspections.

For Foreign Regions that use BOS Contractor and Host Nation Employees which operate boilers, boiler personnel shall be trained and licensed by the Host Nation Government agency. If no applicable licensed agency is available in the Activity Area of

Responsibility (AOR), contact the region NAVFAC FEC Public Works (PW) Core Boiler and Unfired Pressure Vessel (UPV) Lead Certifying Official (LCO) for training and license requirements.

An operator shall be in continuous attendance when boilers without fully automatic controls are in operation.

The attendance for oil and gas fired boilers using fully automatic controls shall not be less than the criteria listed in tables above.

The staffing for continuously manned boiler plants with either automatic or semiautomatic controls shall not be less than what is contained in tables above.

A set of standard operating procedures including safety practices should be established for and posted at each boiler plant. Automatic controls and safety devices shall be checked only by licensed operator when periodic visits are made. This should include operation of flame failure devices and observing normal programming controls for proper sequence, timing, scavenging, etc. Attendance visits shall be of sufficient duration to observe a complete operational cycle and perform preventive maintenance on the equipment. An operational log shall be kept on the boiler containing the name of the attendant, date, time, observations made, checks of programming, flame failure and low water cut off devices, meter reading, operational changes and maintenance performed during each visit.

Requests for waivers for boilers that have controls not meeting the definition of a fully automatic or a semiautomatic boiler shall be made to the geographic FEC LCO’s.

Requests shall state the condition of the boiler, corrective action planned and the time frame necessary to comply with the criteria. No steaming boiler shall be operated unattended without low water and loss of ignition cut off devices.

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