SPECIFICATION_P7633770_HSCGG117RPRV006_FIRST_DISTRICT_BOILER_AND_PRESSURE_VESSEL_INSPECTIONS.pdf

DEPARTMENT OF HOMELAND SECURITY

UNITED STATES COAST GUARD

SHORE INFRASTRUCTURE LOGISTICS CENTER

SPECIFICATION

FOR

BOILER AND PRESSURE VESSEL INSPECTION AND TESTING SERVICES

AT

UNITED STATES COAST GUARD FIRST DISTRICT UNITS

PSN: 7633770

LT Joshua Smolowitz Gerry Gosselin Design Project Manager Design Branch Chief

A. A. JACOBS

TECHNICAL DIRECTOR

BY DIRECTION

COMMANDING OFFICER

CIVIL ENGINEERING UNIT PROVIDENCE

475 KILVERT ST. SUITE 100

WARWICK, RHODE ISLAND 02886

TABLE OF CONTENTS

Page

1.0 GENERAL REQUIREMENTS

1.1 Scope of Work

1.2 Pressure Vessels for Inspection

1.2.1 Inspection Exclusions

1.2.2 Addition or Deletion of Pressure Vessels

1.2.3 Pressure Vessel Locations

1.3 Inspection and Test Frequencies

1.4 Inspection and Test Reports

1.4.1 Reports

1.4.2 Invoicing

1.5 Operating Certificates

1.6 Scheduling Inspections and Tests

1.6.1 Completion of Work

1.6.2 Scheduling

1.6.3 Re-Scheduling

1.7 Tool and Equipment Requirements

1.8 Contractor’s Staff Requirements

1.9 Travel and Lodging

1.10 Applicable Publications

1.11 Definitions

2.0 INSPECTOR'S QUALIFICATIONS

2.1 Qualifications

3.0 INSPECTIONS AND TESTS

3.1 General

3.1.1 Record Review

3.1.2 Recommendations

3.2 Pressure Vessel Inspections and Tests

3.2.1 External Inspection (Type A)

3.2.2 Operational Test (Type B)

3.2.3 Internal Inspection (Type C)

3.2.4 Pressure Test (Type D)

3.2.5 Thickness Test (Type E)

3.3 Re-Inspections and Re-Tests

3.4 Closing Conference

4.0 SPECIFIC ITEMS ASSOCIATED WITH INSPECTIONS

4.1 Lagging or Insulation

4.2 Casing or Shell

4.3 Boiler Tubes

4.4 Waterside Surfaces in Boilers

4.5 Boiler Doors

4.6 Breechings

4.7 Foundation and Supports

4.8 Stays and Braces

4.9 Blow-Off Tanks

4.10 Manholes and Handholes

4.11 Ligaments

4.12 Soot Blowers

4.13 Surfaces Exposed to Fire and Hot Flue Gas

4.14 Furnace and Baffles

4.15 Heads

4.16 Nozzles

LIST OF ATTACHMENTS

Attachment (1) PRESSURE VESSEL INVENTORY Attachment (2) SERVICE SCHEDULE Attachment (3) CG FORM 5519 (Boiler and Pressure Vessel Inspection Report) Attachment (4) CEUPROV FORM 11300-1 (Operating Certificate).. 49 Attachment (5) NOTIFICATION LETTER Attachment (6) STATION AND SECTOR POINTS OF CONTACT Attachment (7) WORK REQUIREMENTS BID SCHEDULE

1.0 GENERAL REQUIREMENTS:

1.1 Scope of Work: The Contractor’s Inspector(s) shall provide all labor, services, materials, tools, equipment, travel and subsistence required to inspect and test pressure vessels in accordance with the requirements specified herein and the referenced Codes. Upon completion of the work submit a report of the results to the Customer for certifying work completion and file purposes. The Inspector shall issue an operating certificate to each pressure vessel that passes all inspections and tests and will operate safely thereafter for the greater time period of one year or the next scheduled inspection. For each pressure vessel that fails any inspection or test the Inspector shall identify in the report to the Customer all deficiencies and appropriate recommendations for corrective action that must be performed to the pressure vessel before it can be re-inspected and an operating certificate issued. The Contractor shall be responsible for reproduction of any Attachment herein for his use during the contract term.

1.2 Pressure Vessels for Inspection: Pressure vessels for

inspection and testing include fired vessels, as heating boilers and water heaters, and unfired vessels, as air receivers. All vessels in service and under contract are identified in Attachment (1). Fired vessels are used primarily for space and water heating. Unfired vessels are used primarily for compressed air service.

1.2.1 Inspection Exclusions: The following pressure vessels are exempted from the inspection requirements specified herein:

a. Cylinders for shipment or storage of compressed or liquefied gas.

b. Air tanks for vehicle brakes.

c. Unfired pressure vessels that have a volume of 5 cubic feet or less.

d. Unfired pressure vessels whose working pressure does not exceed 15 psig.

e. Unfired pressure vessels that contain only water for domestic supply purposes (including those which contain compressed air cushions)

f. Unfired pressure vessels that are used as refrigerant receivers in refrigerating and air-conditioning equipment.

g. Unit heaters (gas, electric or steam).

h. Domestic water heaters operating at temperatures less than 212oF except those listed in Attachment 1.

i. Boilers with less than 350,000 BTU/HR net heat output.

1.2.2 Addition or Deletion of Pressure Vessels: Pressure vessels may be added to or deleted from the original Attachment (1) by amendment issued to the Contractor by the Contracting Officer CO) following the award of this contract contingent upon availability of funds. A new replacement of an original pressure vessel is not considered as an addition or deletion to the contract. Coast Guard Station or Sector personnel shall notify the Pressure Vessel Inspection Program Coordinator at CEU Providence, telephone number (401) 736-1752 or by internal e-mail with a request to add or delete pressure vessels at least seven (7) days in advance of scheduled inspections. The contractor shall also notify the Program Coordinator if the actual pressure vessel inventory at a site differs from that listed in attachment (1).

The Contractor’s Inspectors are not obligated to perform inspections and tests on any pressure vessel that is not under the contract as amended. Consequently, the Contractor shall bear the costs of performing inspections or tests on any pressure vessel not under contract as amended at the time or determined to be excluded under Paragraph 1.2.1. Compensation for any vessel added shall be in accordance with the bid schedule submitted at the time of award for similar pressure vessels.

1.2.3 Pressure Vessel Locations: All pressure vessels are located at various Coast Guard Stations or Sectors in the states of Connecticut, Maine, Massachusetts, New Hampshire, New Jersey, New York, Vermont, and Rhode Island.

1.3 Inspection and Test Frequencies: All pressure vessels shall be inspected and tested during the basic (first) year of the contract. The frequency of inspections and tests during the three option years shall be in accordance with the Schedule established in Attachment (2).

1.4 Inspection and Test Reports: An appropriate report for each of the pressure vessels inspected and tested under this contract shall be submitted on CG Form 5519, "Inspection of Boiler or Pressure Vessel," Attachment (3).

1.4.1 Reports: The Inspector shall complete each report carefully and legibly, electronically or hand written, providing all information required by the report. Provide recommendations for repairs to a pressure vessel when the Inspector deems the repairs necessary to issue an operating certificate or keep the vessel in good condition for subsequent inspections. Upon completion of the inspections and tests electronic or hard copies of the completed reports shall be submitted to the Coast Guard Engineering Officer (EO) or representative who observed the inspection to affix his/her electronic or hand written signature at the appropriate place in the report certifying that inspections and tests were performed. Thereafter, the Contractor shall forward all signed, completed reports to CEU Providence during invoicing.

1.4.2 Invoicing: Only invoice for services performed. Invoicing shall be submitted to the CO periodically at the Contractor’s discretion in accordance with all contract requirements for invoicing utilizing applicable contract line item prices in the Bidding Schedules. Each invoice shall list the pressure vessels serviced by contract line item, including the inspections or tests performed and the applicable prices in subtotals. Organize the list of contract line items inspected by each Coast Guard Sector location. All invoicing shall be submitted to the CO by the close of the applicable contract term. See other invoicing requirements elsewhere in the contract for further details.

1.5 Operating Certificates: For each pressure vessel inspected under this contract and found safe for operation, the Inspector shall prepare and sign an operating certificate on Form CEU-PROV 11300-1, Attachment (4); otherwise, the Inspector shall cite deficiencies preventing the issuance of an operating certificate and make written recommendations that should 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. Use the Inspection Report, Attachment (3), to report issuance of this certificate, deficiencies, and corrective recommendations. The Inspector shall post the operating certificate on each pressure vessel found safe for operation. This operating certificate shall be enclosed in a clear plastic sleeve provided by the Contractor’s Inspectors prior to posting.

1.6 Scheduling Inspections and Tests:

1.6.1 Completion of Work: Inspections and tests of all pressure vessels in Attachment (1) as amended shall be completed by September 30, 2017 during the basic (first) year of the contract regardless of their past inspection history. Inspections shall be performed during normal working hours, Monday through Friday between 7:30 AM and 4:00 PM unless specifically agreed to by both the Contractor and the Coast Guard. During the option years all work shall be completed by September 30 of each calendar year in accordance with the Service Schedule in Attachment (2) and based upon the inspection dates established from the basic year of the contract. The Contractor shall schedule annual inspections and tests of all seasonally operated fired vessels during the heating season between October 15 and April 15. Deviation from this schedule must be approved by the CO.

1.6.2 Scheduling: Scheduling inspections and tests shall be the responsibility of the Contractor’s Inspectors and shall be coordinated with the EO at the Coast Guard Station or Sector by telephone or letter to schedule at least ten (10) working days in advance of all inspections and testing. The Contractor’s Inspectors bear the risk of refusal to access Coast Guard property with any unscheduled visit. Only the letter, Attachment (5), shall be used when the Contractor’s Inspector has any specific tasks for Coast Guard Station or Sector personnel to prepare pressure vessels in advance of the inspections and tests.

The Inspector shall check in with the EO upon arrival and/or the designated representative each day thereafter while performing inspections and tests. The Inspector shall perform all required inspections and tests in accordance with paragraph 1.6.1 above for each pressure vessel during one scheduled visit whenever possible. Some pressure vessels, like boilers, must remain operating continuously during the heating season. If the boiler must be shut down to perform an internal inspection or test during the heating season then the Contractor’s Inspector may perform them during a second scheduled, off-season visit.

Contingent on approval by the EO, the Contractor’s Inspector may schedule multiple pressure vessels for inspections and tests on a single visit to the Station or Sector. Within thirty (30) calendar days after receipt of award the Contractor shall provide the Pressure Vessel Inspection Program Coordinator at CEU Providence with a proposed list of facilities and dates during which applicable equipment will be inspected. The Contractor’s point of contact for this and other matters under this contract is the Pressure Vessel Inspection Program Coordinator at CEU Providence, telephone number (401) 736-1752.

1.6.3 Re-Scheduling: The Inspector shall attend all scheduled inspections within four (4) hours of the time scheduled, except for emergencies when the Engineering Officer at the Coast Guard Station or Sector must be notified by telephone to re-schedule an alternative date and time within the timeframe indicated above.

Otherwise, this shall constitute failure on the part of the

Contractor to attend said inspection. In the event that an Inspector arrives for a scheduled inspection and the pressure vessel is not prepared for inspection and other inspection work is not available at the station or at another station within a one hour commute, the Contractor may submit an invoice for charges equal to the contract line item price submitted in accordance with the particular inspection or test that was to be performed. Documentation of the circumstances that caused the equipment to be unavailable for inspection shall be attested to on the report over the signature of the Commanding Officer or Officer in Charge of the facility in question.

1.7 Tool and Equipment Requirements: The Contractor shall provide all necessary tools and equipment. The Contractor’s Inspectors shall provide, attach and monitor all testing equipment required to perform the inspections and tests specified herein. All tool and equipment costs associated with this contract shall be incorporated by the Contractor as part of the contract line item price for each pressure vessel inspected and tested.

1.8 Contractor's Staff Requirements: The Contractor shall have an adequate full time inspection staff of either regular or contract Inspectors sufficient to perform all the requirements under this contract. The Contractor shall additionally provide to the Coast Guard a telephone number at which the Contractor can be reached 24 hours per day, seven days per week.

1.9 Travel and Lodging: Claims for travel or lodging will not be authorized or accepted. All travel and lodging costs associated with this contract shall be incorporated by the Contractor as part of the contract line item price for each pressure vessel inspected and tested.

1.10 Applicable Publications: The publications listed below form a part of this specification to the extent referenced. The publications are referred to in the text by the basic designation only.

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) PUBLICATIONS:

ASME Boiler and Pressure Vessel Code: Section VI, Rules for Care and Operation of Heating Boilers

ASME Boiler and Pressure Vessel Code: Section VIII, Rules for Construction of Pressure Vessels

ASME Safety Control Devices: CSD-1, Controls and Safety Devices for Automatically Fired Boilers

(Editions current at time of contract award)

NATIONAL BOARD OF BOILER AND PRESSURE VESSEL INSPECTORS

PUBLICATION:

National Board Inspection Code (NBIC) (Edition current at time of contract award)

NATIONAL FIRE PROTECTION ASSOCIATION PUBLICATIONS:

National Fire Codes (NFC)

(Edition current at time of contract award)

1.11 Definitions:

Heating Boiler: A boiler which operates at a vapor pressure which does not exceed 15 psig or a water pressure which does not exceed 160 psig and a temperature which does not exceed 250 degrees F.

Unfired Pressure Vessel: A vessel which contains vapor or liquid under pressure, but which is not exposed to the products of combustion (e.g. compressed air receiver).

Safety Appliance: Any device provided for protection of a boiler or unfired pressure vessel against excess pressure of steam, vapor, air, water or other liquid. This includes pressure reducing valves, fusible plugs, air, water or other liquid pressure or combination pressure-temperature safety relief valves, and rupture discs.

Firing Equipment: Any equipment provided to inject, move or support fuel in the boiler furnace. This includes oil burners, gas burners, fuel injectors and fuel igniters.

Flame Monitoring Equipment: All flame sensing and monitoring equipment, including flame detectors, appurtenant transformers, transducers and interlocked safety devices that shut down the flow of fuel to a boiler upon detection of loss of flame.

Hydrostatic Test: The application of internal pressure by means of water to the various parts of a boiler or unfired pressure vessel required by the NBIC.

Pneumatic Test: The application of internal pressure by means of air to the various parts of a boiler or unfired pressure vessel required by the NBIC.

Design Pressure: The maximum pressure that the boiler or unfired pressure vessel was built to withstand from bursting.

Working Pressure: The pressure on the gauge that the boiler or unfired pressure vessel is normally operated. The working pressure shall not exceed the maximum allowable working pressure.

Working pressure is synonymous with the term "Operating Pressure".

Maximum Allowable Working Pressure: The pressure indicated on the nameplate of a boiler that is determined by employing factors of safety, stresses, and dimensions designated in the Code, whichever is lower. The maximum allowable working pressure is basis for the upper pressure limit of the safety relieve valves on any pressure vessel.

Boiler Auxiliaries: Any equipment of the feedwater, combustion air or fuel systems. This shall include feedwater pumps and heaters, deaerators, evaporators, economizers, condensate receivers, fans, combustion air and fuel oil pre-heaters and pumps.

Major Repair: A repair upon which the strength of a boiler or pressure vessel depends.

2.0 INSPECTOR'S QUALIFICATIONS:

2.1 Qualifications: The Contractor shall be qualified by the

National Board of Boiler and Pressure Vessel Inspectors as a current Authorized Inspection agency (AIA) in accordance with Qualifications and Duties for AIA Performing In service Inspection Activities and Qualifications for Inspectors of Boilers and Pressure Vessels (NB-369). The Contractor shall submit evidence of its AIA status as a pre-qualification of an offeror's proposal before contract award. The Contractor's Inspectors performing the work shall hold a current commission from the National Board of Boiler and Pressure Vessel Inspectors.

Include a copy of each Inspector's current National Board Commission.

3.0 INSPECTIONS AND TESTS:

3.1 General: Perform all inspections and tests as specified

herein to determine the condition of the pressure vessels, and associated auxiliary equipment currently in operation in accordance with the applicable publications under paragraph 1.10.

Consider all preparations for inspections and tests at the site in accordance with the applicable publications herein and subject to the approval of the Officer in Charge at each site. 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 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.

Also, the Coast Guard will provide all labor required for the preparation and/or dismantling of each pressure vessel for inspection, in accordance with the requirements set forth by the Contractor’s Inspector by request. A copy of the last inspection report and a list of deficiencies found since the last inspection should be made available to the Inspector by request before or at the time of his arrival.

3.1.1 Record Review: The Inspector shall review pressure vessel logs, records of maintenance, corrosion rate records or any other test or examination results. The Inspector shall consult with Coast Guard personnel regarding repairs, if any, made since the last internal inspection. The Inspector shall review the records of such repairs for compliance with applicable requirements.

3.1.2 Recommendations: The Inspector shall discuss with the Coast Guard representative any defects or deficiencies in condition, maintenance practices, or misuse of the pressure vessel and, if necessary, recommend corrective action.

3.2 Pressure Vessel Inspections and Tests: The following tests and inspections that shall be performed on each pressure vessel under contract as required in accordance with all applicable publications under paragraph 1.10 and are further described within this specification:

a. External Inspection – Type A for invoicing purposes.

b. Operational Test – Type B for invoicing purposes.

c. Internal Inspection – Type C for invoicing purposes.

d. Pressure Test – Type D for invoicing purposes.

e. Thickness Test – Type E for invoicing purposes.

When performing these inspections and tests consider all unique details of specific boiler and unfired pressure vessel types in accordance with the NBIC. The EO of the Station or Sector, or a designated representative, shall observe all inspections and tests. In accordance with paragraph 1.3 all types of inspections and tests may not be performed on a pressure vessel during a scheduled service. Reimbursement of the bid price for each type of inspection or test performed on a pressure vessel shall be in accordance with the contract line item prices submitted by the Contractor that includes the cost of subsistence and travel. See paragraph 1.4.2 for further details on invoicing.

3.2.1 External Inspection (Type A): Upon entering the area, the general cleanliness and accessibility of the pressure vessel and its auxiliary apparatus will be noted. An inspection of the external parts of a pressure vessel, including the safety appliances, piping connections, gages, controls, and other items specified herein and required by the NBIC. 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.

3.2.2 Operational Test (Type B): Typically the operational test shall be performed as part of the external inspection of the pressure vessel and after the internal inspection and remedial measures, unless the pressure vessel must remain operating continuously during the scheduled inspection. The purpose of this test shall be 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. 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.

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. The installation of these controls shall comply with the applicable publications herein. 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. All results of the testing shall be recorded on the test report in accordance with paragraph 1.4.

(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 so repairs can be made.

(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 in accordance with the applicable references under paragraph 1.10. 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) provide 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 gage fluctuations to determine possible defects in the pressure reducing valve or the pressure gage.

(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 immediately. Fusible plugs must conform to the requirements of applicable references under paragraph 1.10.

(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: The operation of all controls 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 Gage Glasses: The Inspector shall inspect water columns and gage glasses for excessive corrosion, evidence of leakage, cracked glasses or dirty glasses. For heating boilers, blow down the water columns and gage 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 Gages: Inspect pressure and temperature gages 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 gages to keep them free of restrictions. The Inspector shall check that provisions are made for blowing out the pipe leading to a steam gage, and shall note the absence thereof in his report. The location of a gage 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 gage to compare the accuracy with each gage on the pressure vessel. Evidence or suspicion of inaccurate gages 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 gages were removed, tested and their readings compared. Coast Guard personnel shall be responsible for the removal, calibration, and replacement of gages. When several pressure vessels are connected together, compare the readings of the separate and common gages.

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.

3.2.3 Internal Inspection (Type C): An inspection of the interior parts of a pressure vessel, including the safety appliances, piping connections, gages, controls, and other items specified herein and required by the NBIC. 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 Coast Guard Personnel: 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 by the Coast Guard personnel. 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 by Coast Guard personnel 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 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.

3.2.4 Pressure Test (Type D): The pressure test of a pressure vessel shall be performed in accordance with applicable provisions of the NBIC. Coast Guard personnel shall assist under the observation and direction of the Contractor's Inspector as required during the test. Contingent on the pressure vessel and preventing damage, hydrostatic or pneumatic test pressures shall be applied slowly in increments that prevent over-pressurization of the pressure vessel. Air or gas is hazardous when used as a testing medium. Pneumatic test pressure should be applied for vessels that are so designed or cannot safely be filled with water at the discretion of the Inspector considering all hazards.

The Inspector shall select or calculate an appropriate test pressure considering the in-service conditions of the pressure vessel in accordance with the NBIC. The test pressure shall not exceed the maximum allowable working pressure.

a. Preparation: After the Inspector completes internal inspection of the pressure vessel Coast Guard personnel shall perform the following necessary preparatory work prior to the pressure test:

(1) All safety valves shall be gagged to hold the disk on its seat when the test pressure is applied.

(2) Arrangements shall be made to guard against valves being subjected to pressure on both sides at the same time.

(3) New gaskets shall be installed to ensure all manholes and handholes are closed tightly.

(4) A calibrated test gage provided by the Inspector with the proper pressure range for the test pressure shall be installed at the appropriate location on the pressure vessel.

(5) Gages and controls without the proper pressure range for the test pressure shall be replaced. Remove or blank off all low pressure filling lines and other appurtenant devices that should not be subjected to the test pressure described herein.

(6) Make arrangements to ensure that main and auxiliary stop valves will not be subjected simultaneously to hydrostatic pressure on one side and steam pressure on the opposite side.

(7) Close all connections on the pressure vessel, except the vents, water gages, pressure gages, and valves through which the test pressure shall be applied. Vents shall be at high points of the pressure vessel to purge possible air pockets while filling it for a hydrostatic test. For boilers completely fill them with fresh water at a temperature between 70oF and 120oF.

(8) As required a power driven or hand pump provided by the Inspector shall be used for application of the test pressure.

The test pump shall be operated and inspected to insure that it is in proper working condition prior to connecting it to the pressure vessel.

(9) Air receiver and oil separator tanks on portable air compressors shall be hydrostatically tested with the same hydraulic/turbine oil utilized in regular service.

b. Strength Test: The strength test shall be based upon the maximum allowable working pressure of the pressure vessel on the nameplate or calculated by the Inspector contingent on the in-service conditions in accordance with the NBIC. The test pressure shall be held for a minimum of 1/2 hour.

c. Leakage Tests: The pressure gage 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 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.

d. 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 vessels 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.

3.2.5 Thickness Test (Type E): 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 by all applicable publications under paragraph 1.10. 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.

3.3 Re-Inspections and Re-Tests: If repairs of pressure

components or deficiencies preventing certification are required, then upon completion of repairs the EO at the Coast Guard Station or Sector shall notify the Contractor’s Inspector to re-inspect and re-test the pressure vessel in accordance with applicable requirements of paragraph 3.2. Complete all work within thirty

(30) calendar days after notification by the Coast Guard.

Reimbursement for each type of inspection and test performed on a pressure vessel shall be in accordance with the contract line item price submitted by the Contractor. See paragraph 1.4.2 for further details on invoicing.

3.4 Closing Conference: The Inspector shall conduct a closing conference with each EO at each Station or Sector upon completion of inspection to inform about any deficiencies and recommendations relative to correction, maintenance procedures, operations, and any other considerations for continued safe operation of the pressure vessels.

4.0 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 of pressure vessels under contract as applicable and specified herein and required by the NBIC at no additional costs.

4.1 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, Coast Guard personnel 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.

4.2 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.

4.3 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 particular 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.

4.4 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.

4.5 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.

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

4.7 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.

4.8 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.

4.9 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.

4.10 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.

4.11 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.

4.12 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.

4.13 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,…