BASE CHARLESTON Pressure Vessel Inspections SOW_Final.pdf

Scope of Work & Specifications

Boiler & Unfired Pressure Vessel Inspections

Located at

U.S. Coast Guard Base

Charleston, SC

July 2025

Commanding Officer

United States Coast Guard

Base Charleston, FED

1050 Register Street

Charleston, SC 29405

John Difrancesco Jr.

Facilities Engineering Department

TABLE OF CONTENTS

1.0 GENERAL REQUIREMENTS

1.1 Scope of Services

1.2 Personnel Qualifications

1.3 Type, Location, and Task List of Vessel Inspections

1.4 Scheduling Work and Site Access

2.0 EXECUTION OF WORK

2.1 General

2.2 External Inspection and Operational Test

2.3 Internal Inspections

2.4 Leak Tightness Testing

2.5 Wall Thickness Testing

2.6 Specific Items Associated with Inspections

2.7 Conditions Found Report

2.8 Closing Conference

2.9 Reporting Equipment Certification

2.10 Determination of Payment and Invoicing

3.0 ATTACHMENTS

3.1 Certificate to Operate

3.2 Forms NB-6 and NB-7, along with example detailed equipment checklist.

1.0 GENERAL REQUIREMENTS:

Scope of Services: This Scope of Services is written to acquire the services of inspectors that are commissioned by the National Board Inspection Code (NBIC) to perform inspections and repairs of boilers and unfired pressure vessels located at USCG Base Charleston 1050 Register St, 196

Tradd Street, and 1164 Thornback Street, Charleston, SC.

The Contractor shall provide all labor, services, materials, tools, equipment, travel and subsistence required to inspect, test and certify fired pressure vessels (boilers of various types and sizes) and unfired pressure vessels (compressed air tanks) in accordance with this Scope of Services and the standards published in the NBIC.

The contractor shall be responsible for complete mechanical take-down (preparation) of pressure vessels in preparation for Internal Inspections and Investigative Tests. Such work shall include system isolation and draining.

The contractor shall be responsible for repairs (costing under $100 per system) required to render certifications and any repairs resulting from damage to aged parts incident to the take-down and shall be responsible for reassembly of all systems into certified, operational order following inspections.

The base year shall be one (1) year from the time the written Notice to Proceed is issued with an option to renew for a period of four (4) additional years at the discretion of the

Contracting Officer.

1.2 Personnel Qualifications: An NBIC commissioned inspector is an individual who has met the education, experience, employment, and examination requirements as outlined in NB-263, RCI-

1, Rules for Commissioned Inspectors, 2017 Edition. Fifteen (15) calendar days after the contract award the Contractor shall submit the names of proposed Inspectors and a copy of each National

Board Commission certificate to the Contracting Officer.

1.3 Type, Location, and Task List of Vessel Inspections: The following pressure vessels listed below in Table 1 and 2 are to be inspected. The type of NBIC inspection to be performed and periodicity is noted for each item. Upon completion of the inspection and/or testing, Contractor shall submit a report of the results and a Certificate of Operation to the Coast Guard. The task list below Table 1 and 2 provides further detail of Base and option year inspections http://www.nationalboard.org/SiteDocuments/Commissioned%20Inspectors/NB-263_RCI-1_2017.pdf http://www.nationalboard.org/SiteDocuments/Commissioned%20Inspectors/NB-263_RCI-1_2017.pdf

Boilers / Hot Water Tank(s)

Table 1

Air Compressor(s)

Table

Building Location Equipment Description Internal Inspection External

Inspection

Operational

Test

Industrial

Bldg.

Heat boiler #1

Make: Lochinver

Model: CHN0752

Serial: F14H00264840

Base Year & Option

Year 3 Only

Annually Annually

Barracks Bldg.

Heat boiler #2

Make: AO Smith

Model: GWH075ON-P

Serial: 1604102536757

Barracks Hot Water

Holding Tank

Make: AO Smith

Model: LW-1000 300

Serial: F-03 74388

Building Location Equipment Description Internal Inspection External

Inspection

Operational

Test

Industrial Bldg

Compressor

(196 Tradd St.)

Make: Quincy

Model: QSI100A

Serial: UTY306254

Base Year &

Option Year 3 Only

Option Year 3

Only

Industrial Bldg

Compressor Holding

Tank

(196 Tradd St.)

Make: National BD

Model: Unknown

Serial: Unknown

Building 681

(FLETC)

Make: Ingersoll Rand

Model: CBV994486

Serial: M1370961

Boat Facility

Make: Ingersoll Rand

Model:

Serial: CBV687818

Pier Papa

Make: Ingersoll Rand

Model: Unknown

Serial: Unknown

TASK LIST

• Base Year – Contractor shall perform internal inspection, external inspection, and operational testing of boilers and hot water tanks listed in the tables 1 & 2 as per sections

2.2 – 2.5. Contractor shall also perform internal inspection, external inspection, and operational test of air compressors listed in the tables 1 & 2 as per sections 2.2 – 2.5.

• Option Year 1 – Perform external inspection and operational test of the boilers and hot water tanks listed in the table 1 as per section 2.2.

• Option Year 2 – Perform external inspection and operational test of the boilers and hot

• Option Year 3 - Contractor shall perform internal inspection, external inspection, and operational testing of boilers and hot water tanks listed in the table 1 & 2 as per sections

2.2-2. Contractor shall also perform internal inspection, external inspection, and operational test of air compressors listed in the table 1 & 2 as per sections 2.2 – 2.5.

• Option Year 4 - Perform external inspection and operational test of the boilers and hot

1.4 Scheduling Work and Site Access: All work shall be performed during normal working hours, Monday through Friday between 7:00 AM and 3:30 PM unless specifically agreed to by both the Contractor and the Coast Guard facility. Scheduling Inspections, Surveys and Tests shall be the responsibility of the Contractor and shall be coordinated with the Facility Engineering

Representative at the Coast Guard facility. The Points of Contact are as follows:

• Facility Eng Rep - Mr. Scott Wright, (843) 425-1746, email Eric.S.Wright@uscg.mil

• Facility Engineer, (843) 323-5553

The Contractor shall check in with the Facility Engineering Representative upon arrival and each day thereafter while performing Inspections and Tests. The Contractor shall perform all required

Inspections and Tests for each pressure vessel during one scheduled visit whenever possible.

Contingent on approval of the facility Engineering Representative, the Contractor may schedule multiple pressure vessels for Inspections and Tests during a single visit to the facility. Within thirty

(30) calendar days after receipt of award, the Contractor shall provide the Contracting Officer with proposed dates during which applicable systems will be inspected.

The Contractor, their employees, and subcontractors shall become familiar with and obey all station regulations. All personnel employed on the project shall keep within the limits of the work and avenues of ingress and egress and shall not enter any other areas outside of the site of the work unless required to do so in the performance of their duties. The Contractor's equipment shall be conspicuously marked for identification. There shall be NO SMOKING in any Coast Guard building. Storage Areas: The facility Engineering Representative or the Contracting Officer’s

Technical Representative will determine exact location and boundaries of staging areas. Under no circumstances shall materials be stored in areas that will interfere with unit operations.

mailto:Eric.S.Wright@uscg.mil

All vehicles, owned by the Contractor or employees of the Contractor, and operators of these vehicles, shall meet all state regulations for safety, noise, loading and minimum liability insurance.

The Contractor shall not bring leaking vehicles or equipment on the site and if they begin leaking, they should be removed immediately and repaired. There shall be no parking on unpaved surfaces unless necessary to perform work. All vehicle operators demonstrating reckless or careless operations in the opinion of the Government shall not be allowed to operate vehicles on government property for the duration of the contract.

2.0 EXECUTION OF WORK

2.1.1 General Provisions: The following provisions shall be followed as part of this contract.

Perform all work in accordance with the NBIC standards published at the time of the contract award. The Contractor shall provide all labor, equipment, and material necessary for the performance of the inspections and tests, including set up and calibration of such equipment prior to the work.

The Inspector shall discuss with the Facility Engineering Representative any defects or discrepancies in condition, maintenance practices, or misuse of the pressure vessel and, if necessary, recommend corrective action to execute repairs in accordance with (2.7 Conditions

Found Report). The Facility Engineering Representative shall be given the opportunity to observe all inspections and tests.

2.1.2 Utilities: The Coast Guard will furnish water, air pressure, and 110V single phase electric power as available for the performance of all Tests and Inspections but makes no guarantee or representation as to the quality or continuity of such services. The Coast Guard will provide all labor required for the operation of systems to be tested.

2.1.3 Safety: The Contractor is wholly responsible for work site safety. The Contractor shall implement a safety program that protects the lives and health of personnel in the construction area, prevents damage to property, and avoids work interruptions. The Contractor shall provide appropriate safety barricades, signs, signal lights, etc. to comply with the requirements of all applicable Federal, State and Local safety laws, rules and regulations.

2.1.4 Lockout/Tagout: The Contractor shall comply with OSHA 29 CFR 1910.147, “The Control of Hazardous Energy “(Lockout/Tagout). The Contractor shall be responsible for locking out and tagging out of service, all equipment/utility systems involved in the work under this contract. After the Contracting Officer’s Technical Representative has approved an outage, Government personnel and the Contractor shall independently secure the equipment/utility system and tag the respective system out of service. The Contractor shall provide their own locks and chains that are required to secure the equipment/utility systems, e.g., steam, water, air, and/or electricity.

2.1.5 Safety Data Sheets: Submit a Safety Data Sheet (SDS) for all materials containing hazardous substances required for contract execution. The information provided in SDS’s shall meet the requirements of 29 CFR 1910.1200. SDS’s require Contracting Officer review and acceptance prior to bringing these materials on site. Limit the quantity of these materials stored on site to the amount needed for execution of work. Storage of excess materials will not be permitted. Assure that the storage of these materials complies with all applicable federal, state, and local laws and regulations and provide additional storage facilities (paint lockers, etc.) as required for the storage of such materials. Coordinate the physical location of storage areas with the On-site Representative prior to bringing these materials on site. The contractor shall take all protective measures outlined on the SDS’s and as required by federal, state and local regulations to protect all personnel in the vicinity of the work area from exposure to these materials. The Contractor shall dispose of all excess hazardous materials as required by the SDS and all applicable federal, state, and local laws and regulations. The Contractor shall comply with OSHA 29 CFR 1910.146, Permit-Required

Confined Space. The Contractor shall provide a Confined Space Entry Plan to the Facility Engineer representative prior to entering, or starting any work, in a confined space. The Contractor shall provide all equipment and materials as required to comply with OSHA and complete the work under this contract.

2.1.6 Fire Protection: The Contractor shall install and maintain temporary fire-protection to protect against predictable and controllable fire loss. Comply with NFPA 10 "Standard for Portable

Fire Extinguishers" and NFPA 241 "Standard for Safeguarding Construction, Alterations and

Demolition Operations". Maintain unobstructed access to fire extinguishers, fire hydrants, temporary fire-protection facilities, stairways and other access routes for fighting fires. Provide independent supervision of welding, flame cutting and other open flame work. Provide each fire supervisor with an appropriate fire extinguisher. Provide all personnel with the proper notification procedure to summon the local fire department or emergency medical service. There shall be NO

SMOKING or unsupervised open flame inside any structure, temporary or permanent; nor within

25 feet of combustible material or within 50 feet of flammable liquids or compressed gases. Any operation defined as “Hot Work” as per OSHA/NFPA requires a permit to be issued by Base

Charleston’s Safety Officer, John Difrancesco reachable at (843) 740-3160 X3865. This includes welding, cutting, brazing, grinding or any work that could produce sparks or heat and may initiate a fire.

2.1.7 Hazardous Wastes/Environmental: The Contractor shall comply with all federal, state, and local environmental regulations dealing with the generation, management, storage, and disposal of solid, toxic, and hazardous wastes. The Contractor shall ensure that all wastes are properly containerized, labeled and placarded, managed, tested, stored, transported and disposed of in accordance with all applicable regulations. All hazardous waste profiles will be signed by Base

Charleston Environmental Section. All hazardous waste will be manifested using the Base

Charleston EPA ID number SCR000005389. Hazardous waste manifests will be approved and signed by Base Charleston Environmental Section. Any waste as a result of the project shall either be recycled IAW CIM 16455.10 and the BASECHARINST 11000.1 Safety and Environmental

Compliance Guide. Base Pollution Prevention Plan or be disposed of IAW the Resource

Conservation and Recovery Act. Any Hazardous Waste shall be manifested off site with Base listed as the Generator and signatory. Any hazardous waste shall be analyzed, characterized, stored and disposed of IAW the Resource Conservation and Recovery Act (RCRA) and all applicable federal, state (i.e. DOT) and local laws and ordinances. All work will be performed IAW the Base

Spill Prevention Control and Countermeasures Plan, Clean Water Act (CWA) 40 CFR 112 and the

BASECHARINST 11000.1 Safety and Environmental Compliance Guide. All chemicals required for this project shall be preapproved by the Base Charleston Environmental Section. Safety Data

Sheets (SDS) shall be provided to both the Base Environmental and Safety offices and proper storage shall be provided IAW 29 CFR 1910.1200. All installation related solid waste shall be removed from the base after each working day. All activation flushes of the system shall be captured and disposed of in accordance with BASECHARINST 11000.1 Safety and Environmental

Compliance Guide. All extra chemicals and products shall be removed from the site upon work completion, as the Emergency Planning and Community Right-To-Know Act requires the Coast

Guard to maintain an inventory of all Hazardous Materials located at the site. Nothing shall be discharged to a storm drain at any time during the project. All storm drains within range of a potential discharge shall be covered/sealed during installation and kept covered until the work has been completed and the system has been deemed fully operational and compliant with all applicable CG policies/plans/permits/laws/ordinances.

2.1.8 Trash Removal: The Contractor shall remove and properly dispose of all trash and debris incidental to the contract work from the limits of government property, as well as all adjacent affected areas. If dumpsters are used for trash collection, they shall be covered to prevent FOD concerns or wind-blown pollution from occurring. Dumpsters shall be in good repair with no holes or damage to structures, which could allow liquids of any kind to reach the soil. The Facility

Engineering Representative shall determine the extent and interval of these cleanups. At the end of each day the entire work area and all adjacent affected areas shall be thoroughly cleaned by removing all trash, debris, dust, etc. caused by the contract work. Any floor, wall or ceiling surfaces that may have been stained or soiled by the contract work shall be restored to pre-construction condition.

2.2 External Inspection/Operational Test: This work includes an inspection of the external parts of a pressure vessel, including the safety appliances, piping connections, gauges, controls, and other items specified herein and required by the current version of the NBIC at time of award. The inspection does not necessarily require that the pressure vessel be drained. Perform operational tests and observations as part of this inspection, including testing safety appliances.

The purpose of this test is to discover any deficient or dangerous operating conditions of the pressure vessel and report its actual operating efficiency. Upon request by the Contractor’s

Inspector, Coast Guard personnel shall operate the pressure vessel to its normal working pressure and temperature. Then, the Inspector shall inspect all firing equipment, controls, indicating devices provided for pressure, temperature, combustion, and water level under both automatic and manual normal operating conditions. Soot from boilers can be hot for metals, volatiles and semi-volatile organic compounds, so if any cleaning of boilers is to take place, then all rags and waste from cleaning shall be collected and tested for proper disposal IAW the Resource Conservation and

Recovery Act and all state and local waste management regulations, policies, laws, ordinances and requirements. All fuel leaks shall be contained and reported if they discharge from the interior spaces of the building where the leaking equipment is housed. All materials used to contain and clean up leaks shall also be considered waste and disposed of properly offsite with all associated paperwork and manifests properly handled and reported to Base Environmental Compliance office.

Bills of lading and manifests shall be signed by the Environmental Compliance Office and copies left with qualified individuals from Base Charleston Environmental Section. for proper filing. No person shall remove or attempt to remove any safety appliance while a boiler is in operation. All valves, piping connections, metering and recording devices, and boiler auxiliaries shall be included. During the test the main steam or hot water distribution valves may be closed or open, as necessary, to operate boiler; otherwise, these valves shall be closed if testing interferes with distribution. In accordance with the NBIC standards, inspect the following equipment elements:

a. Firing Equipment: For heating boilers or water heaters test operation of all firing equipment including burners, fuel injectors, fuel igniters, dampers, fans, and other such equipment provided to introduce fuel into the boiler furnace, ignite the fuel, and support combustion and exhaust of flue gases shall be inspected for any deficiency that may be evidenced under operating conditions. The inspector shall withhold the operating certificate until each leak or deficiency is corrected.

b. Controls: Test operation of all controls directly associated with the operation of the pressure vessels shall be inspected. Among these controls are safety appliances such as high/low pressure and temperature limit devices, low-water fuel cutoff and feedwater devices, safety and safety relief devices, pressure reducing valves, pressure control switches, fusible plugs, rupture discs, and burner combustion and fuel cut-off safety devices. Make sure that the ability of these controls to maintain proper air-fuel ratio, pressure, and temperature is demonstrated throughout the capacity range of the pressure vessel, including load swings encountered. Check fully automatic boiler controls for proper programming sequence and timing with respect to pre-purge, ignition, pilot proving, flame proving and flame monitoring equipment, and post-purge periods. Check the operation of flame failure and combustion air failure devices to assure that they properly shut off the supply of fuel; this should be done by simulating a flame failure (by manually shutting off the fuel or by other means) and observing the operation of the controls, solenoid valves, diaphragm operated valves, etc., which are to operate during a flame failure.

(1) High/Low Pressure or Temperature Limit Devices: All devices shall be observed for indications of excessive pressure or temperature during the test of the pressure vessel. Evidence that any device is not functioning properly shall be reported to appropriate Coast Guard personnel.

(2) Low-Water Fuel Cut-off and/or Feedwater Devices: For float-operated devices, the Inspector shall inspect the float linkage and connections for wear. The float chamber will be inspected to ensure that it is free of sludge or other accumulation. Test these devices for proper operation. For float-operated devices, test by opening the drain to the float bowl and draining the bowl to the low-water level of the boiler. At the low-water level observe that the cut-off of fuel supply and/or feedwater supply occurs until proper water level is re-established. If there is a low-water fuel cut-off device controlled by a temperature element test by blowing down to a point at or before the low-water level. The point that fuel cut-off takes place should be noted and required adjustments made to restore these devices to a proper operating position. The Inspector shall verify that the operating instructions for the devices being inspected are readily available.

(3) Safety and Safety Relief Valves: The Contractor’s Inspector shall test the settings and capacities of safety and safety relief valves. It is important that the differential between the pressure setting of the valve and working pressure of the pressure vessel is sufficient to prevent the valve from weeping or simmering. The Inspector shall verify that safety valves are connected as closely as possible to the pressure vessel independent of any other connections in accordance with the NBIC.

Every safety valve shall be connected so as to stand in an upright position with spindle vertical.

When the discharge is led through a pipe, the drain opening shall be checked for obstructions. The

Inspector shall check for any hazardous conditions that may be created by the discharge. When a try lever is provided, it shall be operated to assure that it is free. Test the blow-off setting of each safety valve and relief valve by raising the pressure slowly to the test pressure. Test each valve in turn, gagging all other valves except the one being tested. Observe and report the operation of each valve at test pressure. If disassembly, adjustment in settings, or other repairs are required to restore any valve to certifiable operating condition, then the valve shall be repaired by an organization that meets NBIC requirements (holds a current “VR” Stamp) provided it is less costly than replacing the valve new. The responsible organization shall reseal any adjustments in settings or repairs to prevent tampering. A metal tag shall identify the organization and date of adjustment and/or repairs.

(4) Pressure Reducing Valves: While system is pressurized and safety conditions permit, open and then close the by-pass valve to observe pressure gauge fluctuations to determine possible defects in the pressure reducing valve or the pressure gauge.

(5) Pressure Control Switches: The Contractor’s Inspector shall inspect contacts, linkages, pressure sensing devices and connections for corrosion, rust, or other foreign substances and for loose, broken, or missing parts that may prevent proper operation.

(6) Fusible Plugs: The Inspector shall inspect all fire-actuated fusible plugs in use. Coast Guard personnel shall be informed of the existence of the fusible plugs and shall replace them as part of the inspection process.

(7) Rupture Discs: The Inspector shall inspect for any evidence of rupture discs leaking or bursting.

This may be determined by examining the try cock or free vent. The Inspector shall determine if the vent is plugged or not.

(8) Operating Efficiencies: For each heating boiler and fired water heater check for proper air-fuel ratio and exhaust stack emissions with CO, CO2 and/or O2 measuring devices, including exhaust stack temperature. Calculate and report the boiler and water heater efficiencies based on the results.

c. Valves: Test operation of all valves directly associated with the operation of the pressure vessels shall be inspected.

(1) Stop and Check Valves: Inspect the operating condition of each stop and check valve. Serious defects of externally controlled stop valves may be detected by listening to the operation of the valve or by observing any excessive vibration of the valve as it operates under pressure. The location of the various stop valves should be such that water will not be pocketed when the valves are closed and thereby establish cause for water-hammer action.

(2) Blow-Off Valves: Test the freedom of each blow-off valve and its connections by opening the valve and blowing down the pressure vessel for a few seconds. Determine whether the valve is excessively worn or otherwise defective and whether there is evidence of restriction in the valve or connected piping preventing proper blow-off.

d. Metering and Recording Devices: All devices shall be observed for proper operation during the test of the pressure vessel. Evidence that any device is not functioning properly shall be reported to appropriate Coast Guard personnel so repairs can be made.

e. Piping and Connections: All piping and connections associated with each pressure vessel shall be inspected for corrosion and leaks resulting from excessive strains, expansion and contraction, lack of proper supports, or other causes. Look for vibration in piping connections to the pressure vessel. Where excessive vibration is found inspect for any signs of damage.

f. Water Columns and Gauge Glasses: The Inspector shall inspect water columns and gauge glasses for excessive corrosion, evidence of leakage, cracked glasses or dirty glasses. For heating boilers, blow down the water columns and gauge glasses and observe the action of the water in the glass to determine whether the connection to the boilers or the blow-off piping is restricted. This will assist in determining the true condition of high and low water alarms and the automatic combustion equipment. The piping to the water column shall be inspected to assure that there is no chance of water accumulating in the pipe forming the steam connection to the water column. The steam pipe should preferably drain toward the water column. Assure that the water pipe connection to the water column drains toward the boiler. The position of the water column must be checked to determine that the column is placed in accordance with ASME Code requirements.

g. Pressure and Temperature Gauges: Inspect pressure and temperature gauges for cracked or dirty glass, illegible markings, bent or sticking pointers, leaking connections, restriction of movement or other defects. Coast Guard personnel shall blow down the pipe leading to gauges to keep them free of restrictions. The Inspector shall check that provisions are made for blowing out the pipe leading to a steam gauge, and shall note the absence thereof in his report. The location of a gauge will be noted by the Inspector to determine whether it is exposed to high temperature from an external source or to internal heat due to lack of protection by a proper siphon or trap. The Inspector shall attach a calibrated test gauge to compare the accuracy with each gauge on the pressure vessel.

Evidence or suspicion of inaccurate gauges and excessive indications shall be noted in the inspection report. The Inspector shall inspect the records of past inspections and note the most recent date that the gauges were removed, tested and their readings compared. Coast Guard personnel shall be responsible for the removal, calibration, and replacement of gauges. When several pressure vessels are connected together, compare the readings of the separate and common gauges.

h. Boiler Auxiliaries: For boilers and fired water heaters observe the operation of all auxiliaries for any defects that indicate improper operation or a lack of proper maintenance. Particular attention should be given to leaks, venting and intermittent operation of equipment creating a vacuum. The inspector shall provide recommendations of corrective actions for any defects to Coast Guard personnel in the inspection report.

i. Feedwater Treatment: The Inspector shall use internal inspection conditions of the pressure vessels as a determining factor in regard to the adequacy of materials used in feedwater treatment.

2.3 Internal Inspection: Work consists of an inspection of the interior parts of a pressure vessel, including the safety appliances, piping connections, gauges, controls, and other items specified herein and required by the current version of the NBIC at time of award. The inspection is made when a pressure vessel is shut down with the handholes, manholes, or other openings normally closed during operation are opened for inspection access to the interior. The facility personnel shall assist the Contractor's Inspector to gain access during the inspection.

a. Safety Preparations by Contractor: The Contractor’s Inspector shall not enter any pressure vessel or work site until he/she is satisfied that all following safety preparations have been taken.

The Inspector will personally verify that the preparations are in accordance with the NBIC and have been performed as applicable to the pressure vessel:

(1) Potential entry hazards have been identified and brought to the Inspector’s attention along with the methods to deal with the hazards. Vessels normally operating at high temperatures should be allowed to cool down gradually to avoid damage.

(2) Coordination of entry between the Inspector and Contractor and/or Coast Guard personnel working in or near the pressure vessel.

(3) Personnel protective equipment required for entry is available to the Inspector along with proper training for its use.

(4) The manhole and handhole covers have been removed, and circulation of air throughout the pressure vessel has occurred for a sufficient time to remove any dangerous fumes or gases.

The inspector shall be satisfied that a safe atmosphere exists in the pressure vessel before entry.

(5) The pressure vessel walls, baffles, tubes, and shell have been swept down and the soot removed. The inside of the shell, drums, and tubes have been washed down to remove mud, loose scale, or similar deposits. The vessel should be sufficiently cleaned to allow visual inspection of all internal and external exposed base material surfaces.

(6) An effective energy isolation program of lock-out and tag-out is in place that shall prevent the unexpected energizing, start-up, and release of energy.

(7) Pressure gauges have been removed for calibration if the Inspector has no other information to assess its accuracy.

2.4 Leak Tightness Testing: The leak tightness testing is not normally required except in cases where the inspection discloses unusual, hard to evaluate forms of deterioration that may affect the pressure-retaining capability. In these cases, a hydrostatic pressure test may be recommended based upon the judgment and experience of the inspector. The Inspector is cautioned that a pressure test will not provide any indication of the remaining service life or the future reliability of a pressure-retaining item (2017 NBIC Part 2 Section 4.3.1). Pressure tests occur on less than 10% of Coast

Guard equipment inspections. Coast Guard personnel will assist under the observation and direction of the Contractor's Inspector as required during the testing.

Leakage Tests: The pressure gauge shall be observed by the Inspector to determine if any leakage is occurring. If the Inspector finds leakage while pressure is being built up, the test shall cease until the necessary repairs have been completed by Coast Guard personnel to eliminate the leaks.

Maintain constant pressure for a sufficient length of time to permit any possible leakage to develop.

The pressure shall then be reduced to two thirds of the test pressure and then carefully inspected for leakage.

Inspections: With test pressure applied to the pressure vessels, the Inspector shall enter the fireside

(when accessible) and inspect all tubes, drums, headers, welded and riveted connections and other accessible pressure parts. Faults shall be indicated with chalk or other marking device, and a notation shall be made on the Inspector's written report. Note the row and number of tubes requiring replacement or rolling to facilitate their location by repair and maintenance personnel.

External inspection while the pressure vessel is under test pressure shall include all connections to boiler drums and valves and other fittings directly connected to the drums. All joints and connections shall be inspected for leaks or other defects while the vessel is under pressure. After the pressure has been released, the vessel shall be observed to see if any permanent deformation has occurred. Where permanent deformation of the vessel shell or heads has occurred the Inspector shall advise Coast Guard personnel as to the feasibility of repairs.

2.5 Wall Thickness Test: Where active corrosion is found, the Inspector will advise Coast Guard personnel regarding remedial action. For the purpose of estimating the effect of severe corrosion over large areas on the safe working pressure, the Inspector will recommend that the thickness of the remaining sound metal be determined by the use of ultrasonic examination equipment. When the Inspector has reason to believe that a pressure vessel is unduly worn or corroded, then a thickness test shall be performed to determine the maximum allowable safe working pressure for that pressure vessel. This shall be done by non-destructive testing procedures as described in the

NBIC. Coast Guard personnel shall prepare the pressure vessel for thickness testing under the

Inspector’s direction. If the actual thickness measurement is less than the original design, the maximum allowable working pressure for the pressure vessel shall be calculated and based on the minimum thickness measured, unless the vessel cannot be certified for safe operation. Calculations with the relevant references shall be submitted with the inspection report. Thickness measurements shall be made at the proper tangency points, circumferential and line intervals, and angles. Low point where water collects and corrosion may form shall be measured. The Inspector shall determine the measurement points for pressure vessel configurations other than spherical or cylindrical.

2.6 Specific Items Associated With Inspections: The Contractor’s Inspector shall inspect the condition of these specific items among other items associated with the External and Internal

Inspections under contract as applicable and specified herein and required by the NBIC.

2.6.1 Lagging or Insulation: The Inspector shall inspect the condition of all lagging or insulation on boilers, breeching, and piping connections for damage. Observe the cause of water leaks through insulating material that may require removal of insulation or fixed parts of the pressure vessel. By the Inspector’s request, Contractor shall remove lagging covering any nameplate and cleaning surfaces so that data can be read easily. Also, enough insulation that covers seams of a pressure vessel shall be removed if the Inspector cannot determine pressure vessel safety using other means. Outside insulation that appears to be sound need not be removed to inspect the joints, unless unsafe conditions are suspected. Caution: Some insulation materials may be composed of asbestos. The Inspector shall be satisfied that the pressure vessel or work site is safe to enter by communicating and reviewing asbestos records with Coast Guard personnel at the work site knowledgeable about this potential hazard; otherwise, the Inspector can refuse to enter and perform the services making note in the inspection report. The Inspector shall not enter a pressure vessel or work site containing asbestos without the appropriate personal protective equipment and the proper training to select and safely use such equipment to avoid personal health risks. Asbestos insulation shall be left intact and its presence noted in the Inspection

Report. No disposal of Lead Based Paint or Asbestos is allowed on site. If the substances are observed and need to be disturbed to complete stated work, they must be tested, handled and disposed of by certified abatement professionals whose certifications are on file with the Base

Safety Officer. All Waste disposals shall be performed in the same manner as described in

2.1.7 of this document.

2.6.2 Casing or Shell: The Inspector shall inspect pressure vessel casing or shell for evidence of bulging, corrosion cracks, distortion, leakage, loose panels, and other defects. Look particularly for cracks in plates and welded seams. A corrosion resistant lining that appears to be sound need not be removed to inspect the plates, unless unsafe conditions are suspected. Inspect riveted joints for loose or cracked rivets. Observe distortion by checking the overall dimensions of the pressure vessel.

2.6.3 Boiler Tubes: The Inspector shall inspect all boiler tubes for deterioration, including tube surfaces for bulges, cracks, or any evidence of defective welds. They should be inspected as far as possible either through handholes or at the ends. Inspect short tubes or nipples are used in joining drums or headers, for combustion deposits that are likely to cause corrosion if moisture is present.

All such places shall be thoroughly cleaned with a wire brush and inspected. Inspect the condition of the tube ends and tube sheets. Note any corrosion of the sheets and signs of leaking or excessive thinning of the tubes or tube ends. Inspect tube interiors adjacent to any drum for scaling or deterioration. Look for deterioration and signs of leakage at ends of flared sections of tubes. If scaling is serious, remove scale samples and advise the Coast Guard personnel to arrange for chemical analysis to adjust feedwater treatment. Similar inspection should be made of any headers in the evaporating section, with handhole plates removed. Inspect the space between the tubes of a return-tubular boiler to assure that there is no restriction of the circulation. This may be done using a small light between the tubes.

2.6.4 Waterside Surfaces in Boilers: The Inspector shall inspect all waterside surfaces of boilers to observe the condition caused by accumulated oil, scale, solvents, or other substances. Report the exact location and the estimated amount, hardness, and age of any scale or corrosion present. The

Inspector shall determine and report the extent and seriousness of the scale or corrosion for use in subsequent inspections. When possible, include photographs of reported conditions.

2.6.5 Boiler Doors: The Inspector shall inspect each boiler door for sagging, warping, cracking, chipped or broken edges, worn hinges and seals, defective locks or latches, and any other conditions that prevent or hinder proper opening, closing, latching and sealing of the door. Inspect blast deflectors as provided for deterioration or damage that prevents proper diversion of an explosive blast.

2.6.6 Breechings: The Inspector shall inspect breechings, stacks, and draft hoods for excessive corrosion, cracked welds, loose or broken connections, and separation of sections.

2.6.7 Foundation and Supports: The Inspector shall inspect the foundation for improper level or settlement, noting if there has been any tendency to settlement. Inspect for inadequate provision for expansion and contraction of the pressure vessel and setting. Inspect all structural supports for deterioration such as cracks and loose or dislodged material, excessive corrosion, cracked or broken welds, loose or missing bolts or rivets, warped or bent structural members, and insufficient strength or rigidity to support the vessel and its contents.

2.6.8 Stays and Braces: The Inspector shall inspect all stays and braces, including riveted or bolted ends, for defects including cracking, looseness, serious corrosion and erosion, bending, looseness, excessive tension or strain, and other conditions of weakness. Check the tension of stay bolts and through stays by tapping one end with a hammer while holding a heavy tool on the opposite end. An unbroken bolt should give a ringing sound while a broken bolt will give a hollow sound. Broken bolts will be identified for replacement. Inspect for cracks in welded connections.

2.6.9 Blow-Off Tanks: The Inspector shall inspect all external surfaces of the tank shell, manholes, handholes, connecting piping, and supports for excessive corrosion, cracks, distortion, leaks, or other evidence of weakness. Inspect safety valves required for un-vented tanks for proper placement and operation. When vent piping is provided, inspect for water pockets or obstructions between the tank and vent pipe discharge.

2.6.10 Manholes and Handholes: The Inspector shall inspect for corrosion from leakage of manholes or handholes. The Inspector shall inspect all holding clamps for an appreciable amount of corrosion, distortion, or elongation. The Inspector shall inspect reinforcing plates and openings for piping and fittings for cracks, deformations, or other evidence of weakness.

2.6.11 Ligaments: The Inspector shall inspect the ligaments between tube holes in the heads of all types of fire-tube boilers and between rivets and between tube holes in the shells of water-tube boilers, to see if any cracks have started.

2.6.12 Soot Blowers: The Inspector shall give particular attention to the position and condition of the soot blowers. Note excessive scouring of refractory baffles caused by incorrect blowing range of the soot blowers. The operation of the soot blowers shall be checked to see if:

a. Bearings are loose or in an improper condition.

b. Nozzles have incorrect alignment with boiler tubes.

c. Incorrect part sizes are being used.

d. The elements are not straight or in poor condition.

e. Blowing ranges are incorrect and inadequately trapped to prevent water from entering piping.

2.6.13 Surfaces Exposed to Fire and Hot Flue Gas: The Inspector shall inspect hot flue gas passages and plate or tube surfaces exposed to fire for bulging, blistering, corrosion, distortion, leakage, or excessive burning action. If tubes are found with a sufficient degree of distortion indicating potential failures their condition shall be brought to the attention of the COR or Facility

Engineering Representative and immediate removal recommended. Inspect for flame leakage on dry sheets, particularly at the back arch of return-tubular boilers (should be entirely clear of the rear tube sheet with sheet metal or asbestos rope covering the gap). Inspect the rods and back stays for deterioration and possible shifting.

2.6.14 Furnace and Baffles: The furnace lining and burner cones shall be inspected for spalling, cracking, and settlement. It must be found to be tight and free from distortion, abnormal cracks and seams, excessive burning and corrosion. All expansion joints must be clean. Inspect the bridge walls in vertical water-tube boilers to see if the mud-drum is not properly protected. Inspect baffle and check walls particularly for holes that may permit flaming through. Inspect that the proper baffling is in place in water-tube boilers. Report any deterioration, improper location, and improper or missing baffling required.

2.6.15 Heads: The Inspector shall inspect the inner surface of heads for cracks and other signs of distress. If the head has corrosion-resistant lining and shows evidence of distortion, Coast Guard personnel shall remove the lining to permit an inspection of the inner surface of the knuckle and the head shape. The Inspector shall inspect the flanges of circular heads that are not stayed.

2.6.16 Nozzles: The Inspector shall inspect all nozzles, including attachments for distortion, excessive corrosion and other defects. Particular attention shall be given to welded nozzles for cracks in the welds. Inspect riveted or bolted connections for loose, cracked, or seriously corroded rivets or bolts. Inspect the condition of threaded connections, and if defective, the threaded fittings shall be removed to determine the number of threads that are effective. If careful inspection shows no unsafe condition, sound corrosion-resistant linings need not be removed

2.7 Conditions Found Report: The Inspector shall provide a detailed (Conditions Found

Report) for what repairs are necessary after completion of internal, external and operational testing. The report shall include all repairs to boilers, pressure vessels, gaskets, manholes, handholes, doors, relief valves, controls, baffles, heads, nozzles and any other items not listed, and/or associated with the boilers/pressure vessels inspected. The detailed report shall itemize each repair accordingly, indicate anticipated timeline to receive required parts, execute repairs, and cost associated with repairs. All repairs will be a modification to the contract and at the discretion of the Contracting Officer. The Coast Guard reserves the right to complete any or all repairs outlined in the Conditions Found Report using in-house

(Facilities Engineering Department) personnel.

2.8 Closing Conference: The Inspector shall conduct a closing conference with the Facilities

Engineering Representative upon completion of inspection to inform the personnel of any discrepancies and recommendations relative to correction, maintenance procedures, operations, repair and any other considerations for continued safe operation of the pressure vessels.

2.9 Reporting and Equipment Certification: The following paragraphs describe report types and the content that is required as part of this Contract.

2.9.1 Inspection and Test Reports: Inspection and test reports shall use the templates found within the current version of the NBIC at the time of contract award (Pressure Vessel Report of

Inspection Form NB-6 and NB-7), augmented by detailed equipment inspection checklists with the approximate level of detail as shown in Attachment 3.2. Following Operational Certification, the

Contractor shall complete the written report in accordance with standards published in the NBIC, legibly providing all information as required by the Report. One (1) copy of the completed report shall be submitted to the Facility Engineering Representative upon completion of the inspection.

The Representative will affix his/her signature to the form to attest to the fact that Inspections and/or Tests were performed as required. In the event that an Operating Certificate is unable to be issued to a unit, Contractor shall indicate in detail reasons why and repairs required in accordance with 2.9.3. The Contractor shall sign and date the Report and forward one (1) copy of the completed Report with all signatures to the Contracting Officer during invoicing. This operating certificate shall be enclosed in a clear plastic sleeve provided by the Contractor’s Inspector and be posted onto the pressure vessel.

2.9.2 Certified Pressure Vessels: For each pressure vessel inspected under this contract and found or made safe for operation, the Contractor shall prepare and sign an Operating Certificate. The

Inspector shall post the completed Operating Certificate on each pressure vessel found safe for operation in a clear plastic sleeve. Contractor shall forward one (1) copy of the completed

Operating Certificate with all signatures to the Contracting Officer during invoicing.

2.9.3 Non-Certified Pressure Vessels: In cases of pressure vessels not found safe for operation during initial inspection, Contractor shall immediately Tag-Out the system and shall cite deficiencies preventing the issuance of an Operating Certificate onto the appropriate NBIC form, and submit with signature to the Contracting Officer by e-mail or fax within 1 working day. On the form, Contractor shall make written recommendations in their best estimation that describes the action that will correct those deficiencies and the requirements to be met in order for a pressure vessel which has failed to pass inspection to be certified in good repair and in safe operating condition upon subsequent inspection. All necessary repairs shall also be documented in accordance with (2.7 Conditions Found Report). Following determination of safe operation repairs and re-inspection or re-testing, the Contractor shall post the completed Operating Certificate with all signatures in a clear plastic sleeve and submit a copy of the Operational Certificate to the

Contracting Officer during invoicing.

2.10 Determination of Payment and Invoicing: Only invoice for services performed. Invoicing shall be submitted to the Contracting Officer periodically at the Contractor’s discretion in accordance with all contract requirements for invoicing utilizing applicable contract line item prices in the Pricing Schedule. Each invoice shall list the pressure vessels serviced by contract line item, including the inspections and tests performed and the applicable prices in subtotals. All invoicing shall be submitted to the Contracting Officer by the close of the applicable contract term.

3.0 ATTACHMENTS

3.1 Certificate to Operate: BASE CHARLESTON PRESSURE VESSEL OPERATION

CERTIFICATE

3.2 NBIC forms NB-6 and NB-7: NBIC template…