Whiteman_AFB_0227_July_2016_Inspection_Reports_for_solicitation.pdf

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AIR FORCE CONUS BOILER & UPV INSPECTION PROGRAM

BPA Call Letter

Base: Whiteman Required Date(s) of Inspection: I 1-15 July 2016

Inspection Damarc Quality Inspection Funding

F4ATA46028AW02

Contractor:

BPA Number:

Base Contacts

Services Document:

FA8051-13-A-0002 Call Number:

MAJCOM Contact Name: DSN: Commercial: Email:

AFIMSC.DETAFGSC. WORK FLOW us.af.mil

On-site Govern ment Representative

Name Olmeda

(Sign upon completion) John

Signature: _ _ _

Date: _,,,-7---19-2016

Inspector Name: Kevin Hindal

Signature: :2'2:-. --==- Date: 7-19-2016

Primary:

Mr. John Olmeda

DSN:

975-2533

Comm . Ph. # (Include area code):

660-687-2533

Email Address:

iohn.olmeda@us.af.mil

Al ternate:

Mr. Roger Wil liams

DSN:

975-2530

Comm. Ph. # (Include area code):

660-687-2530

Email Address:

roger.williams. l5@us.af.mil

Objects to be Inspected: ( 0 Additional inspections attached) Objects Inspected:

Type of Vessel

Type of Inspection

National Board #

Bldg #

Contract Cost

Inspection Completed

(YIN)

Delay Costs?

(YIN)

Explain in

Comments

#I Boiler BC 316 140 Y N #2 Boiler BA 317 140 Y N #3 Boiler BA 318 140 Y N #4 Boiler BA 2090 140 Y N #5 Boiler BC 2443 140 Y N

Total Contract Cost Total Cost

BCE/ Installation

POC Authorization

Name: Si)) Date:

John Olmeda 7-19-2016 c.11Initials (a -+ tr mailto:iohn.olmeda@us.af.mil mailto:5@us.af.mil

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COSt Summarv

AIR FORCE CONUS BOILER & UPV INSPECTION PROGRAM

BPA Call Letter (Con't)

Totals

Special Instructions to Inspections Contractors:

U pon receipt of Call Letter, contact Installations to schedule inspections.

Provide a minimum of 48 hours notification before mobilizing to perfonn scheduled inspections.

Notify Contracting of all schedule changes/ inspection change ( 1 for 1 change with no delay is allowed ). Additional i nspection change is not allowed.

Leave one ( I ) copy of each completed and signed inspection report at the base following inspections.

Emai l final reports, approved complete call letter, and invoices to: AFCEC Contracting, M AJCOM and Base POCs.

Send hard copies of final inspection reports to A FCEC Operations.

Contractor shall obtain BCE/Installation POC authorization for payment prior to submittal in WAWF.

Contractor Comments/Explanations:

Additional Instructions to Contractor:

lns-Fection 'vne

Contract

Quantity Ordered

Estimated Cost

(Contract Cost Otv Ordered)

Quantity

Comoleted

Cost of Inspections Completed

(Contract Cost x

Otv Comolctcd)

Del Costs

( IN?)

( Explain in Contractor's Comments. belo\\-)

BA 3 3 N

BC 2 2 N

AF FORM 1222-AF EQUIVALENT (7-12-13)

BOILER OR

PRESSURE VESSEL

INSPECTION

REPORT

1. TYPE OF INSPECTION (B – Boiler ; V – Pressure Vessel ) 2. DATE OF INSPECTION

7-19-2016 INTERNAL AND EXTERNAL BA VA

INTERNAL EXTERNAL UNDER HYDROSTATIC TEST BB VB 3. INSPECTION/DELIVERY ORDER NO.

EXTERNAL UNDER OPERATION ✔ BC VC

EXTERNAL UNDER HYDROSTATIC TEST BD VD 4. CONTRACT NUMBER

FA8051-13-A-002 EXPANSION/RECEIVER TANK BE VE

5. INSTALLATION

Whiteman AFB

6. STATE

MO

7. ZIP CODE

65305

8. LOCATION (Bldg. No.)

BLDG - 140

9. PLANT

☐MANNED ☐UNMANNED

10. OBJECT INSPECTED:

BOILER: ☐FIRE TUBE ☐CAST IRON ☐WATER TUBE ☐OTHER (SPECIFY)

UPV: ☐EXPANSION TANK ☐AIR RECEIVER ☐LP ☐OTHER (SPECIFY)

11. USE: ☐POWER ☐PROCESS ☐HTHW ☐HWH ☐STEAM HEATING ☐STORAGE ☐HEAT EXCHANGE

☐OTHER (SPECIFY)

12. MANUFACTURER

english Boiler

13. MFR. RATING (MBTU or KLBS/HR): 35,000,000 Btu/Hr

14(a). NATIONAL BOARD NO.

14(b). USAF NO.

Boiler-1

15. YEAR BUILT

16. YEAR INSTALLED

17. PRIMARY FUEL (BOILER)

Nat.Gas

18. SECONDARY FUEL

No. 2 Diesel

19. PRESSURE ALLOWED MAWP 250 Psi PSIG at TEMP 650 F_ Previous Inspection MAWP 250 Psi PSIG at TEMP 650 F _

20. ACTUAL OPERATING PRESSURE (PSIG)

100 Psi Operating Pressure

21. SAFETY &/or RELIEF VALVE SETTING

(PSIG &/or ° F) 145 Psi

22. PRESSURE &/or TEMP PRIOR INSPECTION

(PSIG &/or ° F) 145 Psi

23. PRESSURE &/or TEMP THIS INSPECTION

(PSIG &/or ° F) 145 Psi

24. EXPLAIN IF PRESSURE CHANGED

No Change

25. METHOD OF FIRING (BOILERS): Automatic 26. PRESSURE GAGE CALIBRATED? ☐YES ☐NO

27. DATE/TYPE OF LAST INSPECTION

TYPE: BA DATE: 6-2016

28. HYDROSTATIC TEST ☐NEW ☐RETEST ☐REPAIR

DATE: Unknown PSIG: Unknown

29. LAST HYDROSTATIC TEST

DATE: Unknown PSIG: Unknown

30. REPAIRS/ALTERATIONS MADE SINCE LAST INSPECTION? ☐NONE ☐YES (SPECIFY)

No repairs Made

31. INTERNAL INSPECTION (DESCRIBE INSPECTION FULLY):

Internal inspection is not performed on type C inspection

Performed external inspection under operation.

Following devices were tested

-Low Water Fuel Cut-off (Primary)

-Low Water Fuel Cut-off (Secondary)

-Flame Scanner

-Low fuel cut-off switch - Adjust the setting on the low gas switch

All tests were performed satisfactory

No signs of overheating , No signs of leakage

32. EXTERNAL INSPECTION (DESCRIBE INSPECTION FULLY): Chart is N/A for BC inspection without emmissions

FUEL TYPE NG/FO: ENERGY CONTENT (BTU/ft3; BTU/gal)

BOILER EFFICIENCY TEST RESULTS:

TEST

POSITION

O2 %

CO

(ppm)

EFF %

CO2 %

STACK

TEMP

(°F)

AIR

TEMP

(°F)

EXCESS

AIR %

HYDRO-

CARBONS

¾” DIA

½” DIA

¼” DIA

BLDG - 140 316 Boiler-1

33. INSPECTION OF SAFETY DEVICES RELIEVING (lbs/hr)

MANUFACTURER SET PRESSURE-PSIG SIZE CAPACITY TESTED (Y/N?) CONDITION & HOW TESTED Kunkle 145 Psi 2 1/2 Inch 23255 Lbs/Hr Y Hand Tested under Pressure

Kunkle 155 Psi 2 Inch 24715 Lbs/Hr Y Hand Tested under Pressure

TOTAL RELIEVING CAPACITY (lbs/hr)

34. INSPECTION OF PRESSURE GAGES

20,647 Lbs/Hr

GAGE CONDITION CORRECTIONS MADE TESTED (Y/N?) REASONS WHY NOT TESTED

0-300 Satisfactory None N Not tested type BC inspection

35. OTHER APPLIANCES (e.g., WATER COLUMNS, GAGE GLASSES, GAGE COCKS, BLOWOFF PIPE & VALVE OR COCKS, FEED PIPE)

ITEM CONDITION

Pipe Connections No evidence of leakage

Water Column No evidence of leakage

Sight Glass Free and clear from debris

Isolation valve (STOP) No evidence of leakage

36. CSD-1/NFPA 85 COMPLIANT? (FOR BC ONLY)

☐YES ☐NO (EXPLAIN IN BLOCK 37) ☐N/A

37. STATE CONDITION OF OBJECT

□ SATISFACTORY ☐ UNSATISFACTORY (LIST DEFICIENCIES TO BE CORRECTED AND REPAIRS TO BE MADE.

USE A SUPPLEMENTAL SHEET, IF NECESSARY.)

No deficiencies to be corrected

38. CAN THE OBJECT CONTINUE IN OPERATION?

☐YES ☐YES, WITH RESTRICTIONS (EXPLAIN ON SUPPLEMENTAL SHEET) ☐NO (EXPLAIN ON SUPPLEMENTAL SHEET)

39. NAME AND TITLE OF INSPECTOR: 40. SIGNATURE OF INSPECTOR:

Kevin Hindal

41. NATIONAL BOARD COMMISSION NUMBER: 42. DATE:

13540 7-19-2016

43. NAME AND TITLE OF AIR FORCE REPRESENTATIVE ACCOMPANYING INSPECTOR:

John Olmeda Boiler plant supervisor 660-687-2533

44. SIGNATURE: 45. DATE:

7-19-2016

46. ACTIONS TAKEN BY AIR FORCE AT A LATER DATE TO RESOLVE DEFICIENCIES CITED ABOVE:

47. DATE OF ACTIONS TAKEN:

48. NAME AND TITLE OF AUTHORIZING OFFICIAL:

49. SIGNATURE OF AUTHORIZING OFFICIAL: 50. DATE:

AF FORM 1222-AF EQUIVALENT (7-12-13) Supplement Sheet

Supplemental Sheet

Bldg NB USAF #

BLDG - 140 316 Boiler-1

High Limit Pressure Switch Manufacturer (HoneyWell) 0-150 Set at 136 Psi, Tested by jumping(bypass) the operating limit control

High/High Limit Pressure Switch Manufacturer (Honeywell ) 0-140 Set At 140 Tested by closing the steam header causing the steam pressure to reach 140 Psi

Low water Fuel Cutoff Primary (McDonnel Miller) 150 Psi Tested by manually blowing down the water column, Simulating low water within the boiler (probe)

Low Water Fuel Cutoff Secondary (McDonnel Miller ) 150 Psi Tested by manually blowing down the water column, simulating low water (Float type)

Flame scanner manufacture( Fire Eye) – Tested by removing and covering the sensor eliminating light (simulating loss of flame)

Burner - Nat gas 35,000,00 Btu/Hr Max Fire Rate Nat.Gas – After each alarm proceeded to post purge to eliminate unused combustion gasses after each alarm when triggered during the testing process –

Gas valve Electronic (Maxxon) Tested satisfactory during each test of the control switches (Valves closed within 3 seconds of each alarm during tests)

Low Gas Pressure Switch ( Ashcroft ) 0-10 Psi – Tested by slowly closing the fuel vale upstream from sensor- Simulating low fuel pressure

All tests were performed under steam pressure and were satisfactory

INSPECTION

REPORT

1. TYPE OF INSPECTION (B – Boiler ; V – Pressure Vessel ) 2. DATE OF INSPECTION

7-19-2016 INTERNAL AND EXTERNAL ✔ BA VA

INTERNAL EXTERNAL UNDER HYDROSTATIC TEST BB VB 3. INSPECTION/DELIVERY ORDER NO.

EXTERNAL UNDER OPERATION BC VC

EXTERNAL UNDER HYDROSTATIC TEST BD VD 4. CONTRACT NUMBER

FA8051-13-A-002 EXPANSION/RECEIVER TANK BE VE

5. INSTALLATION

Whiteman AFB

6. STATE

MO

7. ZIP CODE

65305

8. LOCATION (Bldg. No.)

BLDG - 140

9. PLANT

☐MANNED ☐UNMANNED

10. OBJECT INSPECTED:

BOILER: ☐FIRE TUBE ☐CAST IRON ☐WATER TUBE ☐OTHER (SPECIFY)

UPV: ☐EXPANSION TANK ☐AIR RECEIVER ☐LP ☐OTHER (SPECIFY)

11. USE: ☐POWER ☐PROCESS ☐HTHW ☐HWH ☐STEAM HEATING ☐STORAGE ☐HEAT EXCHANGE

☐OTHER (SPECIFY)

12. MANUFACTURER

Engligh Boiler

13. MFR. RATING (MBTU or KLBS/HR): 35,000,000 Btu/Hr

14(a). NATIONAL BOARD NO.

14(b). USAF NO.

Boiler-2

15. YEAR BUILT

16. YEAR INSTALLED

17. PRIMARY FUEL (BOILER)

Nat.Gas

18. SECONDARY FUEL

No. 2 Diesel

19. PRESSURE ALLOWED MAWP 250 Psi PSIG at TEMP 650 F_ Previous Inspection MAWP 250 Psi PSIG at TEMP 650 F _

20. ACTUAL OPERATING PRESSURE (PSIG)

100 Psi Operating Pressure

21. SAFETY &/or RELIEF VALVE SETTING

(PSIG &/or ° F) 145 Psi

22. PRESSURE &/or TEMP PRIOR INSPECTION

(PSIG &/or ° F) 145 Psi

23. PRESSURE &/or TEMP THIS INSPECTION

(PSIG &/or ° F) 155 Psi

24. EXPLAIN IF PRESSURE CHANGED

No Change

25. METHOD OF FIRING (BOILERS): Automatic 26. PRESSURE GAGE CALIBRATED? ☐YES ☐NO

27. DATE/TYPE OF LAST INSPECTION

TYPE: BC DATE: 6-2016

28. HYDROSTATIC TEST ☐NEW ☐RETEST ☐REPAIR

DATE: Unknown PSIG: Unknown

29. LAST HYDROSTATIC TEST

DATE: Unknown PSIG: Unknown

30. REPAIRS/ALTERATIONS MADE SINCE LAST INSPECTION? ☐NONE ☐YES (SPECIFY)

No repairs Made

31. INTERNAL INSPECTION (DESCRIBE INSPECTION FULLY):

Internal inspection performed on this boiler in accordance with

NBIC Part 2, section 2

Inspection — detailed requirements for inservice inspection of pressure-retaining items

2.2 Boilers / 2.2.6 INTERNAL INSPECTION

Inspected the water side of steam and mud drum - Small amount of scale was found within the mud drum, Facility manager has conducted the necessary adjustments over an extended time period to significantly reduce the amount of scale.

32. EXTERNAL INSPECTION (DESCRIBE INSPECTION FULLY): Chart is N/A for BC inspection without emmissions

TEMP

(°F)

AIR

HYDRO-

CARBONS

BLDG - 140 317 Boiler-2

Kunkle 145 Psi 2 1/2 Inch 23255 Lbs/Hr Y Not Tested type BA Inspection

Kunkle 155 Psi 2 1/2 Inch 24715 Lbs/Hr Y Not Tested type BA Inspection

47,970 Lbs/Hr

35. OTHER APPLIANCES (e.g., WATER COLUMNS, GAGE GLASSES, GAGE COCKS, BLOWOFF PIPE & VALVE OR COCKS, FEED PIPE)

Pipe Connections No evidence of leakage

Water Column No evidence of leakage

Sight Glass Free and clear from debris

Isolation valve (STOP) No evidence of leakage

Continue to perform preventative maintenance to ensure safe operations

39. NAME AND TITLE OF INSPECTOR: 40. SIGNATURE OF INSPECTOR:

Kevin Hindal

41. NATIONAL BOARD COMMISSION NUMBER: 42. DATE:

13540 7-19-2016

43. NAME AND TITLE OF AIR FORCE REPRESENTATIVE ACCOMPANYING INSPECTOR:

John Olmeda Boiler plant supervisor 660-687-2533

BLDG - 140 317 Boiler-2

Supplemental Sheet is N/A for type BA inspection

INSPECTION

REPORT

1. TYPE OF INSPECTION (B – Boiler ; V – Pressure Vessel ) 2. DATE OF INSPECTION

7-19-2016 INTERNAL AND EXTERNAL ✔ BA VA

INTERNAL EXTERNAL UNDER HYDROSTATIC TEST BB VB 3. INSPECTION/DELIVERY ORDER NO.

EXTERNAL UNDER OPERATION BC VC

EXTERNAL UNDER HYDROSTATIC TEST BD VD 4. CONTRACT NUMBER

FA8051-13-A-002 EXPANSION/RECEIVER TANK BE VE

5. INSTALLATION

Whiteman AFB

6. STATE

MO

7. ZIP CODE

65305

8. LOCATION (Bldg. No.)

BLDG - 140

9. PLANT

☐MANNED ☐UNMANNED

10. OBJECT INSPECTED:

BOILER: ☐FIRE TUBE ☐CAST IRON ☐WATER TUBE ☐OTHER (SPECIFY)

UPV: ☐EXPANSION TANK ☐AIR RECEIVER ☐LP ☐OTHER (SPECIFY)

11. USE: ☐POWER ☐PROCESS ☐HTHW ☐HWH ☐STEAM HEATING ☐STORAGE ☐HEAT EXCHANGE

☐OTHER (SPECIFY)

12. MANUFACTURER

Engligh Boiler

13. MFR. RATING (MBTU or KLBS/HR): 35,000,000 Btu/Hr

14(a). NATIONAL BOARD NO.

14(b). USAF NO.

Boiler-3

15. YEAR BUILT

16. YEAR INSTALLED

17. PRIMARY FUEL (BOILER)

Nat.Gas

18. SECONDARY FUEL

No. 2 Diesel

19. PRESSURE ALLOWED MAWP 250 Psi PSIG at TEMP 650 F_ Previous Inspection MAWP 250 Psi PSIG at TEMP 650 F _

20. ACTUAL OPERATING PRESSURE (PSIG)

100 Psi Operating Pressure

21. SAFETY &/or RELIEF VALVE SETTING

(PSIG &/or ° F) 145 Psi

22. PRESSURE &/or TEMP PRIOR INSPECTION

(PSIG &/or ° F) 145 Psi

23. PRESSURE &/or TEMP THIS INSPECTION

(PSIG &/or ° F) 155 Psi

24. EXPLAIN IF PRESSURE CHANGED

No Change

25. METHOD OF FIRING (BOILERS): Automatic 26. PRESSURE GAGE CALIBRATED? ☐YES ☐NO

27. DATE/TYPE OF LAST INSPECTION

TYPE: BA DATE: 6-2016

28. HYDROSTATIC TEST ☐NEW ☐RETEST ☐REPAIR

DATE: Unknown PSIG: Unknown

29. LAST HYDROSTATIC TEST

DATE: Unknown PSIG: Unknown

30. REPAIRS/ALTERATIONS MADE SINCE LAST INSPECTION? ☐NONE ☐YES (SPECIFY)

No repairs Made

31. INTERNAL INSPECTION (DESCRIBE INSPECTION FULLY):

Internal inspection performed on this boiler in accordance with

NBIC Part 2, section 2

Inspection — detailed requirements for

Inspected the water side of steam and mud drum - Small amount of scale was found within the mud drum, Facility manager has conducted the necessary adjustments over an extended time period to significantly reduce

32. EXTERNAL INSPECTION (DESCRIBE INSPECTION FULLY): Chart is N/A for BC inspection without emmissions

TEMP

(°F)

AIR

HYDRO-

CARBONS

BLDG - 140 318 Boiler-3

Kunkle 155 Psi 2 1/2 Inch 24715 Lbs/Hr Y Hand Tested under Pressure

35. OTHER APPLIANCES (e.g., WATER COLUMNS, GAGE GLASSES, GAGE COCKS, BLOWOFF PIPE & VALVE OR COCKS, FEED PIPE)

Pipe Connections No evidence of leakage

Water Column No evidence of leakage

Sight Glass Free and clear from debris

Isolation valve (STOP) No evidence of leakage

39. NAME AND TITLE OF INSPECTOR: 40. SIGNATURE OF INSPECTOR:

Kevin Hindal

41. NATIONAL BOARD COMMISSION NUMBER: 42. DATE:

13540 7-19-2016

43. NAME AND TITLE OF AIR FORCE REPRESENTATIVE ACCOMPANYING INSPECTOR:

John Olmeda Boiler plant supervisor 660-687-2533

BLDG - 140 318 Boiler-3

INSPECTION

REPORT

1. TYPE OF INSPECTION (B – Boiler ; V – Pressure Vessel ) 2. DATE OF INSPECTION

7-19-2016 INTERNAL AND EXTERNAL ✔ BA VA

INTERNAL EXTERNAL UNDER HYDROSTATIC TEST BB VB 3. INSPECTION/DELIVERY ORDER NO.

EXTERNAL UNDER OPERATION BC VC

EXTERNAL UNDER HYDROSTATIC TEST BD VD 4. CONTRACT NUMBER

FA8051-13-A-002 EXPANSION/RECEIVER TANK BE VE

5. INSTALLATION

Whiteman AFB

6. STATE

MO

7. ZIP CODE

65305

8. LOCATION (Bldg. No.)

BLDG - 140

9. PLANT

☐MANNED ☐UNMANNED

10. OBJECT INSPECTED:

BOILER: ☐FIRE TUBE ☐CAST IRON ☐WATER TUBE ☐OTHER (SPECIFY)

UPV: ☐EXPANSION TANK ☐AIR RECEIVER ☐LP ☐OTHER (SPECIFY)

11. USE: ☐POWER ☐PROCESS ☐HTHW ☐HWH ☐STEAM HEATING ☐STORAGE ☐HEAT EXCHANGE

☐OTHER (SPECIFY)

12. MANUFACTURER

Nebraska Boiler

13. MFR. RATING (MBTU or KLBS/HR): 35,000,000 Btu/Hr

14(a). NATIONAL BOARD NO.

14(b). USAF NO.

Boiler-4

15. YEAR BUILT

16. YEAR INSTALLED

17. PRIMARY FUEL (BOILER)

Nat.Gas

18. SECONDARY FUEL

No. 2 Diesel

19. PRESSURE ALLOWED MAWP 250 Psi PSIG at TEMP 650 F_ Previous Inspection MAWP 250 Psi PSIG at TEMP 650 F _

20. ACTUAL OPERATING PRESSURE (PSIG)

100 Psi Operating Pressure

21. SAFETY &/or RELIEF VALVE SETTING

(PSIG &/or ° F) 145 Psi

22. PRESSURE &/or TEMP PRIOR INSPECTION

(PSIG &/or ° F) 145 Psi

23. PRESSURE &/or TEMP THIS INSPECTION

(PSIG &/or ° F) 155 Psi

24. EXPLAIN IF PRESSURE CHANGED

No Change

25. METHOD OF FIRING (BOILERS): Automatic 26. PRESSURE GAGE CALIBRATED? ☐YES ☐NO

27. DATE/TYPE OF LAST INSPECTION

TYPE: BA DATE: 6-2016

28. HYDROSTATIC TEST ☐NEW ☐RETEST ☐REPAIR

DATE: Unknown PSIG: Unknown

29. LAST HYDROSTATIC TEST

DATE: Unknown PSIG: Unknown

30. REPAIRS/ALTERATIONS MADE SINCE LAST INSPECTION? ☐NONE ☐YES (SPECIFY)

No repairs Made

31. INTERNAL INSPECTION (DESCRIBE INSPECTION FULLY):

Internal inspection performed on this boiler in accordance with

NBIC Part 2, section 2

Inspection — detailed requirements for

Inspected the water side of steam and mud drum - Small amount of scale was found within the mud drum, Facility manager has conducted the necessary adjustments over an extended time period to significantly reduce

32. EXTERNAL INSPECTION (DESCRIBE INSPECTION FULLY): Chart is N/A for BC inspection without emmissions

TEMP

(°F)

AIR

HYDRO-

CARBONS

BLDG - 140 2090 Boiler-4

Kunkle 155 Psi 2 1/2 Inch 24715 Lbs/Hr Y Hand Tested under Pressure

35. OTHER APPLIANCES (e.g., WATER COLUMNS, GAGE GLASSES, GAGE COCKS, BLOWOFF PIPE & VALVE OR COCKS, FEED PIPE)

Pipe Connections No evidence of leakage

Water Column No evidence of leakage

Sight Glass Free and clear from debris

Isolation valve (STOP) No evidence of leakage

39. NAME AND TITLE OF INSPECTOR: 40. SIGNATURE OF INSPECTOR:

Kevin Hindal

41. NATIONAL BOARD COMMISSION NUMBER: 42. DATE:

13540 7-19-2016

43. NAME AND TITLE OF AIR FORCE REPRESENTATIVE ACCOMPANYING INSPECTOR:

John Olmeda Boiler plant supervisor 660-687-2533

BLDG - 140 2090 Boiler-4

INSPECTION

REPORT

1. TYPE OF INSPECTION (B – Boiler ; V – Pressure Vessel ) 2. DATE OF INSPECTION

7-19-2016 INTERNAL AND EXTERNAL BA VA

INTERNAL EXTERNAL UNDER HYDROSTATIC TEST BB VB 3. INSPECTION/DELIVERY ORDER NO.

EXTERNAL UNDER OPERATION ✔ BC VC

EXTERNAL UNDER HYDROSTATIC TEST BD VD 4. CONTRACT NUMBER

FA8051-13-A-002 EXPANSION/RECEIVER TANK BE VE

5. INSTALLATION

Whiteman AFB

6. STATE

MO

7. ZIP CODE

65305

8. LOCATION (Bldg. No.)

BLDG - 140

9. PLANT

☐MANNED ☐UNMANNED

10. OBJECT INSPECTED:

BOILER: ☐FIRE TUBE ☐CAST IRON ☐WATER TUBE ☐OTHER (SPECIFY)

UPV: ☐EXPANSION TANK ☐AIR RECEIVER ☐LP ☐OTHER (SPECIFY)

11. USE: ☐POWER ☐PROCESS ☐HTHW ☐HWH ☐STEAM HEATING ☐STORAGE ☐HEAT EXCHANGE

☐OTHER (SPECIFY)

12. MANUFACTURER

Nebraska Boiler

13. MFR. RATING (MBTU or KLBS/HR): 60,000,000 Btu/Hr

14(a). NATIONAL BOARD NO.

14(b). USAF NO.

Boiler-5

15. YEAR BUILT

16. YEAR INSTALLED

17. PRIMARY FUEL (BOILER)

Nat.Gas

18. SECONDARY FUEL

No. 2 Diesel

19. PRESSURE ALLOWED MAWP 250 Psi PSIG at TEMP 650 F_ Previous Inspection MAWP 250 Psi PSIG at TEMP 650 F _

20. ACTUAL OPERATING PRESSURE (PSIG)

100 Psi Operating Pressure

21. SAFETY &/or RELIEF VALVE SETTING

(PSIG &/or ° F) 155 Psi

22. PRESSURE &/or TEMP PRIOR INSPECTION

(PSIG &/or ° F) 155 Psi

23. PRESSURE &/or TEMP THIS INSPECTION

(PSIG &/or ° F) 155 Psi

24. EXPLAIN IF PRESSURE CHANGED

No Change

25. METHOD OF FIRING (BOILERS): Automatic 26. PRESSURE GAGE CALIBRATED? ☐YES ☐NO

27. DATE/TYPE OF LAST INSPECTION

TYPE: BA DATE: 6-2016

28. HYDROSTATIC TEST ☐NEW ☐RETEST ☐REPAIR

DATE: Unknown PSIG: Unknown

29. LAST HYDROSTATIC TEST

DATE: Unknown PSIG: Unknown

30. REPAIRS/ALTERATIONS MADE SINCE LAST INSPECTION? ☐NONE ☐YES (SPECIFY)

No repairs Made

31. INTERNAL INSPECTION (DESCRIBE INSPECTION FULLY):

Internal inspection is not performed on type C inspection

Performed external inspection under operation.

Following devices were tested

-Low Water Fuel Cut-off (Primary)

-Low Water Fuel Cut-off (Secondary)

-Flame Scanner

-Low fuel cut-off switch - Adjust the setting on the low gas switch

All tests were performed satisfactory

No signs of overheating , No signs of leakage

32. EXTERNAL INSPECTION (DESCRIBE INSPECTION FULLY): Chart is N/A for BC inspection without emmissions

TEMP

(°F)

AIR

HYDRO-

CARBONS

BLDG - 140 2443 Boiler-5

Kunkle 155 Psi 2 1/2 Inch 31189 Lbs/Hr Y Hand Tested under Pressure

Kunkle 160 Psi 4 Inch 39821 Lbs/Hr Y Hand Tested under Pressure

71,010 Lbs/Hr

35. OTHER APPLIANCES (e.g., WATER COLUMNS, GAGE GLASSES, GAGE COCKS, BLOWOFF PIPE & VALVE OR COCKS, FEED PIPE)

Pipe Connections No evidence of leakage

Water Column No evidence of leakage

Sight Glass Free and clear from debris

Isolation valve (STOP) No evidence of leakage

USE A SUPPLEMENTAL SHEET, IF NECESSARY.)

High limit and Operating limit switches have a Ball Valve installed between the boiler and the devices. This valve shall be removed.

If valve is closed the high limit and operating limit switches will not work.

39. NAME AND TITLE OF INSPECTOR: 40. SIGNATURE OF INSPECTOR:

Kevin Hindal

41. NATIONAL BOARD COMMISSION NUMBER: 42. DATE:

13540 7-19-2016

43. NAME AND TITLE OF AIR FORCE REPRESENTATIVE ACCOMPANYING INSPECTOR:

John Olmeda Boiler plant supervisor 660-687-2533

BLDG - 140 2443 Boiler-5

High Limit Pressure Switch Manufacturer (HoneyWell) 0-150 Set at 136 Psi, Tested by jumping(bypass) the operating limit control

High/High Limit Pressure Switch Manufacturer (Honeywell ) 0-140 Set At 140 Tested by closing the steam header causing the steam pressure to reach 140 Psi

Low water Fuel Cutoff Primary (McDonnel Miller) 150 Psi Tested by manually blowing down the water column, Simulating low water within the boiler (probe)

Low Water Fuel Cutoff Secondary (McDonnel Miller ) 150 Psi Tested by manually blowing down the water column, simulating low water (Float type)

Flame scanner manufacture( Fire Eye) – Tested by removing and covering the sensor eliminating light (simulating loss of flame)

Burner - Nat gas 35,000,00 Btu/Hr Max Fire Rate Nat.Gas – After each alarm proceeded to post purge to eliminate unused combustion gasses after each alarm when triggered during the testing process –

Gas valve Electronic (Maxxon) Tested satisfactory during each test of the control switches (Valves closed within 3 seconds of each alarm during tests)

Low Gas Pressure Switch ( Ashcroft ) 0-10 Psi – Tested by slowly closing the fuel vale upstream from sensor- Simulating low fuel pressure

All tests were performed under steam pressure and were satisfactory

High limit and Operating limit switches have a Ball Valve installed between the boiler and the devices. This valve shall be removed.

If valve is closed the high limit and operating limit switches will not work.

REMOVE THE VALVE. NO VALVES SHALL EXIST BETWEEN THE BOILER AND HIGH LIMIT

SWITCHES.