PWS Attachment 4 UFC-3-430-07 Testing and Certification of Boilers.pdf

UFC 3-430-07

24 July 2003 including Change 5, 07 May 2019

UNIFIED FACILITIES CRITERIA (UFC)

OPERATIONS AND MAINTENANCE:

INSPECTION AND CERTIFICATION OF

BOILERS AND UNFIRED PRESSURE

VESSELS

APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

O&M: INSPECTION AND CERTIFICATION OF BOILERS AND UNFIRED PRESSURE

VESSELS

Any copyrighted material included in this UFC is identified at its point of use.

Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.

U.S. ARMY CORPS OF ENGINEERS

NAVAL FACILITIES ENGINEERING COMMAND (Preparing Activity)

AIR FORCE CIVIL ENGINEER SUPPORT AGENCY

Record of Changes (changes are indicated by \1\ ... /1/)

Change No. Date Location 1 January 2004 Appendix C, Page 36.

2 March 2005 Pages 2, 9-15, 17, 27, 28, 34 3 May 2007 Addition of paragraphs 8-2.1 and 8-2.2; subsequent adjustments throughout as marked.

4 March 2014 General editorial formatting throughout; Additional clarifications and updates where required are marked.

5 May 2019 General editorial formatting throughout: New Appendix

I, New Appendix F (Figure F-1, Boiler Report and Figure F-4 Boiler Certificate), additional clarifications and update where required are marked.

This UFC supersedes MIL-HDBK-1152 dated 30 September 1996.

FOREWORD

The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with USD (AT&L) Memorandum dated 29 May 2002. UFC will be used for all DoD projects and work for other customers where appropriate. All construction outside of the United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)

Therefore, the acquisition team must ensure compliance with the most stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.

UFC are living documents and will be periodically reviewed, updated, and made available to users as part of the Services’ responsibility for providing technical criteria for military construction. Headquarters, U.S. Army Corps of Engineers (HQUSACE), Naval Facilities Engineering Command (NAVFAC), and Air Force Civil Engineer Center (AFCEC) are responsible for administration of the UFC system. Defense agencies should contact the preparing service for document interpretation and improvements. Technical content of UFC is the responsibility of the cognizant DoD working group. Recommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic form: Criteria Change Request. The form is also accessible from the Internet sites listed below.

UFC are effective upon issuance and are distributed only in electronic media from the following source:

• Whole Building Design Guide web site http://dod.wbdg.org/.

Refer to UFC 1-200-01, General Building Requirements, for implementation of new issuances on projects.

AUTHORIZED BY:

DONALD L. BASHAM, P.E.

Chief, Engineering and Construction U.S. Army Corps of Engineers

DR. JAMES W WRIGHT, P.E.

Chief Engineer Naval Facilities Engineering Command

KATHLEEN I. FERGUSON, P.E.

The Deputy Civil Engineer DCS/Installations & Logistics Department of the Air Force

Dr. GET W. MOY, P.E.

Director, Installations Requirements and Management Office of the Deputy Under Secretary of Defense (Installations and Environment) http://www.wbdg.org/pdfs/ufc_implementation.pdf http://www.wbdg.org/ccb/browse_cat.php?o=29&c=4 http://dod.wbdg.org/

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REVISION SUMMARY SHEET

Document: UFC 3-430-07, O&M: INSPECTION AND CERTIFICATION OF BOILERS

AND UNFIRED PRESSURE VESSELS

Superseding: MIL-HDBK-1152, Inspection and Certification of Boilers and Unfired Pressure Vessels dated 30 September 1996

Description: This UFC covers the procedures necessary to determine material conditions of boiler and unfired pressure vessels to ensure their continued safe, reliable, and efficient operation. It presents operation and maintenance requirements as well as inspection and certification procedures of these items, and is applicable to all heating and power boilers and unfired pressure vessels owned or leased by the Department of the Navy (DON), including portable boilers, portable unfired pressure vessels and liquefied petroleum gas (LPG) storage tanks. This UFC also provides updated policy and guidance for the essential services that are required by Naval Facilities Engineering Command (NAVFAC) to support its mission for shore activities while utilizing its resources in an efficient and cost effective manner.

Reasons for Document:

• This update to UFC 3-430-07 incorporate changes to Department of the Navy inspection and certification requirements of boilers and unfired pressure vessels.

These changes are based on lessons learned from the previous requirements, new technologies, updated requirements for inspection and certification of boilers and unfired pressure vessels, and new regulations and other reference documents.

These changes include, but not limited to updating the references, and requirements for the following:

• Inspector qualifications and licensing, inspection and test frequencies, procedures for submitting reports and forms, vessel repair and alteration guidance and mishap or property damage reporting.

• Responsibility, Applicability, Leased and/or Contractor Owned Boilers and Unfired Pressure Vessels, Applicable Codes, and Environmental Compliance in Chapter 1.

• Inspector Qualifications, Certifications and Licenses in Chapter 2.

• Inspection and Test Frequencies in Tables 3-1 and 3-2, and Chapters 4 and 5.

• Hydrostatic Tests in paragraph 6-1.

• Pneumatic Tests in paragraph 6-2.

• Operational Tests in paragraphs 7-2 through 7-4.

• Contractor Repairs and Records in Chapter 8.

• Inspection Reports and Certificates in paragraphs 9-1.1 and 9-1.2.

• Mishap or Property Damage Reporting in Chapter 11.

• NAVFAC Boiler and Pressure Vessel Inspection Program in Appendix B.

Impact:

The Boiler Safety Program has a high degree of technical complexity (e.g. power boilers, heating boilers, unfired pressure vessels (UPV's) etc.) requiring certification personnel to be licensed and certified by the regulatory agencies and professional institutions who produce the regulations and Standards they enforce. The Navy's Inspection program has been standardized, Navy Wide, by the Naval Facilities Engineering and Expeditionary Warfare Center (NAVFAC EXWC). Program requirements remain essentially the same regardless of location of the equipment throughout the world. These certification processes are extremely important to Naval Commanding Officers and other government officials, as in many states, these leaders have personal pecuniary responsibility for assuring the health and safety of shore based facilities within their purview. For Foreign Regions that use Base Operation and Support (BOS) Contracts, the certification personnel shall be licensed by the host nation government agency and approved by the Region Facilities Engineering Command (FEC) Boiler & UPV Lead Certifying Official (LCO) and NAVFAC EXWC Boiler & UPV Inspection Program Manager.

Unification Issues This UFC references Service-Specific documents, which the Tri-Service boiler and unfired pressure vessel inspection and certification community does not oversee. Army and Air Force documents are currently referenced as an initial step to unify the requirements. Further unification efforts are planned for the next revision.

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TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION

1-1 SCOPE

1-1.1 Army Criteria

1-1.2 Air Force Criteria

1-2 PURPOSE

1-3 GENERAL BUILDING REQUIREMENTS

1-4 RESPONSIBILITY

1-5 APPLICABILITY

1-6 LEASED AND/OR CONTRACTOR-OWNED AND OPERATED

1-7 APPLICABLE CODES

1-8 ENVIRONMENTAL COMPLIANCE

CHAPTER 2 INSPECTOR QUALIFICATIONS, CERTIFICATIONS AND LICENSES ... 6

2-1 NAVY EMPLOYEES

2-1.1 Qualifications for Certification

2-1.2 Certification Procedures

2-1.3 Qualifications for NAVFAC License to Inspect

2-1.4 Reasons for Not Issuing, Renewing or Revoking a NAVFAC License. .. 8

2-1.5 Inspector Support

2-2 CONTRACT EMPLOYEES

2-3 CREDENTIAL REQUIREMENTS

2-4 QUALITY ASSURANCE FOR INSPECTIONS

2-5 GUIDELINES FOR INSPECTION CONTRACTS

2-5.1 Contractor Abilities

2-5.2 Companies Other than Authorized Inspection Agencies

2-5.3 Assistance

2-5.4 Activity Administered Contracts

2-5.5 Certification Extensions

CHAPTER 3 INSPECTION AND TEST FREQUENCIES

3-1 BOILERS

3-2 UNFIRED PRESSURE VESSELS

CHAPTER 4 BOILER INSPECTIONS

ii

4-1 GUIDANCE

4-2 NEWLY INSTALLED BOILERS

4-2.1 Design Requirements

4-2.2 Design, Submittal Reviews & Acceptance & Certification Inspection. .. 20

4-3 EXTERNAL INSPECTION OF BOILERS

4-4 INTERNAL INSPECTIONS OF BOILERS

4-5 BOILERS IN WET OR DRY LAY-UP

CHAPTER 5 UNFIRED PRESSURE VESSEL INSPECTIONS

5-1 GUIDANCE

5-2 EXTERNAL INSPECTIONS OF UNFIRED PRESSURE VESSELS

5-3 INTERNAL INSPECTIONS OF UNFIRED PRESSURE VESSELS

5-4 MILITARY SPECIFICATION (MILSPEC) PRESSURE VESSELS

5-4.1 Internal and External Inspections

5-4.2 Ultrasonic Examination Military Specification

5-4.3 Variations

5-5 DEAERATORS

5-6 LIQUIFIED PETROLEUM GAS (LPG) TANKS

5-6.1 External Inspection

5-6.2 Internal Inspection

5-6.3 Hydrostatic Test

5-6.4 Safety Relief Valves

CHAPTER 6 PRESSURE TESTS

6-1 HYDROSTATIC TESTS

6-1.1 Strength Test Pressure

6-1.2 Tightness Test Pressure

6-1.3 Precautions

6-1.4 Possible Deformation

6-1.5 Hold Pressure

6-1.6 Inspection Under Pressure

6-1.7 Permanent Deformation

6-1.8 Gaskets

6-2 PNEUMATIC TESTS

iii

6-3 PRESSURE TEST RESULTS

6-3.1 Yielding During Test

6-3.2 No Yielding During Test

6-3.3 Inspection Under Pressure

CHAPTER 7 OPERATIONAL TESTS

7-1 GUIDANCE

7-1.1 Purpose

7-1.2 Conditions to be Reported

7-2 FIRING EQUIPMENT

7-3 CONTROLS

7-4 PIPING AND PIPING CONNECTIONS

7-5 DEVICES

7-5.1 Temperature Indicating Devices

7-5.2 Metering and Recording Devices

7-6 VALVES

7-6.1 Blow-Down Valves

7-6.2 Stop and Check Valves

7-6.3 Pressure Reducing Valves

7-6.4 Safety and Safety Relief Valves

7-7 BOILER AUXILIARIES

7-8 BOILER AND FEEDWATER TREATMENT

7-9 FUEL HANDLING PRACTICES

CHAPTER 8 REPAIRS AND ALTERATIONS

8-1 GUIDANCE

8-2 CONTRACTOR REPAIRS

8-3 SETTING SAFETY AND RELIEF VALVES

8-4 RECORDS

CHAPTER 9 INSPECTION CERTIFICATES AND REPORTS

9-1 PROCEDURES FOR SUBMITTING REPORTS AND FORMS

9-1.1 Inspection Reports - Boilers and Unfired Pressure Vessels

9-1.2 Inspection Certificate for Boilers - Unfired Pressure Vessels; NAVFAC Form 9-11014/32(09/15)

CHAPTER 10 MAXIMUM ALLOWABLE WORKING PRESSURE

iv

10-1 GUIDANCE

10-2 STANDARD BOILERS

10-2.1 Standard Watertube Boilers

10-2.2 Standard Cast Iron Steam Boilers

10-3 NONSTANDARD BOILERS

10-3.1 Nonstandard Riveted Boilers

10-3.2 Nonstandard Welded Boilers

10-3.3 Nonstandard Cast Iron Boilers

10-4 CALCULATIONS OF MAXIMUM ALLOWABLE WORKING PRESSURE.

10-5 FACTOR OF SAFETY

CHAPTER 11 MISHAP OR PROPERTY DAMAGE REPORTING

11-1 REPORTING REQUIREMENTS

11-2 INFORMATION COPIES

APPENDIX A REFERENCES

APPENDIX B NAVFAC BOILER AND UNFIRED PRESSURE VESSEL INSPECTION

PROGRAM

APPENDIX C DUTIES OF THE NAVFAC EXWC BOILER & UPV INSPECTION

PROGRAM MANAGER

APPENDIX D DUTIES OF THE FEC BOILER & UPV LCO

APPENDIX E PROCEDURES FOR LAY-UP OF BOILERS

E-1 GUIDANCE

E-2 DRY STORAGE

E-3 WET STORAGE

E-4 ALTERNATIVE WET LAY-UP METHODS

APPENDIX F INSPECTION REPORTS, CHECKLISTS, AND FORMS

APPENDIX G PREVENTIVE MAINTENANCE INSPECTION (PMI) CHECKLISTS

FOR SMALL BOILERS

APPENDIX H WHAT TO EXPECT WHEN THE BOILER INSPECTOR CALLS

APPENDIX I CHARTER FOR THE NAVAL FACILITIES ENGINEERING AND

EXPEDITIONARY WARFARE CENTER (NAVFAC EXWC) BOILER

INSPECTION CERTIFICATION BOARD (NBICB)

v

FIGURES

FIGURE B-1 QUALITY ASSURANCE ORGANIZATION

FIGURE F-1 BOILER AND UPV REPORT FORM

FIGURE F-2 FIELD CHECKLIST FOR BOILERS

FIGURE F-3 FIELD CHECKLIST FOR UNFIRED PRESSURE VESSELS

FIGURE F-4 INSPECTION CERTIFICATE FOR BOILER-UNFIRED PRESSURE

VESSEL

TABLES

TABLE 2-1 CREDENTIALS REQUIRED

TABLE 3-1 INSPECTION AND TEST FREQUENCIES – BOILERS

TABLE 3-2 INSPECTION AND TEST FREQUENCIES - UNFIRED PRESSURE

VESSELS (UPVS)

TABLE 3-3 INSPECTION AND TEST FREQUENCIES - UPVS (SPECIAL CASES) .. 17

TABLE 3-4 INSPECTION AND TEST FREQUENCIES - DEAERATORS

TABLE G-1 STEAM BOILERS PMI CHECKLIST

TABLE G-2 HOT WATER BOILERS PMI CHECKLIST

CHAPTER 1 INTRODUCTION

1-1 SCOPE.

The Department of the Navy (DON), including the Naval Shore Establishment and the Marine Corps, will use this UFC. It presents basic operation and maintenance guidance on inspection and certification of boilers and unfired pressure vessels.

\5\ The Army will use documents that are referenced in paragraph 1-1.1 below entitled "Army Criteria." The Air Force will use documents that are referenced in paragraph 1-

1.2 below entitled "Air Force Criteria." The Army and the Air Force will not need to refer to the remainder of this UFC. /5/

1-1.1 Army Criteria.

\5\ Operation and Maintenance requirements for boilers and unfired pressure vessels on Army installations are contained in Army Facilities Management AR 420-1, Army Technical Manual (TM) 5-650, Central Heating Plants and TM 5-642, Small Heating Systems. /5/ \4\ /4/

1-1.2 Air Force Criteria.

\5\ Requirements for boilers and unfired pressure vessels on Air Force installations are contained in Air Force Manual (AFMAN) 32-1068, Heating Systems and Unfired Pressure Vessels \4\ /4/. /5/

1-2 PURPOSE.

This UFC covers the procedures necessary to determine the material condition of boilers and unfired pressure vessels to ensure their continued safe, reliable, and efficient operation. The procedures also require determination of combustion efficiency and proper operation of boilers, boiler auxiliaries, and controls. For the DON, exceptions to these requirements will not be made without the formal concurrence of the Naval Facilities Engineering Command's (\4\ NAVFAC /4/) Boiler Inspection Certification Board (NBICB). \5\ The authority for these requirements is a Chief of Naval Operations letter dated 22 October 1970, Inspections of Boilers, Unfired Pressure Vessels, Elevators, Dumbwaiters and Escalators, the Commander Naval Facilities Engineering Command letter dated 18 September 2015, Boiler and Unfired Pressure Vessel Inspection, the NAVFAC Building Management System (BMS) B-5.2.4, Boiler and Unfired Pressure Vessel (UPV) Inspection and Oversight and the Navy Shore Boiler Guide dated March 2019. /5/ The frequency of inspection and testing, the various items or components to be inspected or tested, and the forms to be used are specified in this

UFC.

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1-3 GENERAL BUILDING REQUIREMENTS.

Comply with UFC 1-200-01, General Building Requirements. UFC 1-200-01 provides applicability of model building codes and government unique criteria for typical design disciplines and building systems, as well as for accessibility, antiterrorism, security, high performance and sustainability requirements, and safety. Use this UFC in addition to UFC 1-200-01 and the UFCs and government criteria referenced therein. /4/

1-4 RESPONSIBILITY.

The Commanding Officers of the cognizant activities ensure that the boilers and unfired pressure vessels installed at their facilities and covered by this UFC are certified as specified. \5\ Inspection and testing of boilers and unfired pressure vessels must be made by a boiler inspector certified by the NAVFAC EXWC Boiler & UPV Inspection Program Manager. /5/ This boiler inspector will be on the cognizant activity's rolls, except where:

• Inspection responsibility has been assigned to the Commanding Officer of \3\ the Region or respective /3/ Public Works.

• Commanding Officers of major or lead activities are responsible for performing the maintenance of public works and public utilities at adjacent activities.

• It may be impractical to employ qualified personnel for such inspections because of the limited workload. \5\ In such situations, request assistance in obtaining inspection services from the appropriate NAVFAC Facilities Engineering Command (FEC) Boiler & Unfired Pressure Vessel (UPV) Lead Certifying Official (LCO) or the NAVFAC EXWC Boiler & UPV Inspection Program Manager. The NAVFAC FEC Boiler & UPV LCO or the NAVFAC EXWC Boiler & UPV Inspection Program Manager will arrange for the performance of those inspection services by a Navy or contract inspector located near the requesting activity. /5/ When assistance is required, such assistance will be rendered on a reimbursable basis. The requesting activity is responsible for providing the funds to accomplish the inspections.

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1-5 APPLICABILITY.

This UFC is applicable to all heating and power boilers and unfired pressure vessels owned or leased by the DON, including portable boilers and portable unfired pressure vessels, \4\ and liquefied petroleum gas (LPG) storage tanks. /4/ The following equipment is not covered by this UFC:

/3/

• Cylinders, including Department of Transportation (DOT) flasks, for shipment of compressed or liquefied gases. Defense Logistics Agency (DLA) Instruction 4145.25, Storage and Handling of Liquefied and

Gaseous Compressed Gasses and their Full and Empty Containers \4\ /4/governs.

• \3\ Shore-based hyperbaric facility support pressure vessels, including, but not limited to, vessels used for manned operations or for testing animals or equipment, gas storage flasks, volume tanks, fire water tanks, and filters. (these are under the authority of NAVFAC System Certification Authority.) /3/

• Air tanks for air brakes on vehicles.

• Unfired pressure vessels operating at an internal or external gage pressure not exceeding 15 pounds per square inch gage (psig) (103.42 kilopascals (kPa)) with no limitation on size \2\, except deaerators. /2/

• Unfired pressure vessels that do not exceed the following volume, pressure, and dimension limits:

• 5 cu ft (0.14 cu. meters) in volume and 250 psi (1723.69 kPa) design pressure; or

• 3 cu ft (0.08 cu. meters) in volume and 350 psi (2413.17 kPa) design pressure;

• 1-1/2 cu ft (0.042 cu. meters) in volume and 600 psi (4136.85 kPa) design pressure.

Note: In an assembly of vessels, the limitations apply to each vessel and not the assembly as a whole.

• Vessels having an inside diameter, width, height, or cross section diagonal not exceeding 6 inches (152.4 mm), with no limitation on length of vessel or pressure.

• \5\ \4\ Unfired pressure vessels containing only water, with or without additives, under pressure, including those containing compressed gas which serves only as a cushion, and do not exceed a design pressure of 300 psi (2.1 MPa) and/or a design temperature of 210 degrees F (99 degrees C) /4/ with external heating source. /5/

• Unfired pressure vessels used as refrigerant receivers for refrigerating and air conditioning equipment.

• Coil type steam vapor cleaners unless requested by the activity.

• \5\ Domestic Hot Water Storage Tanks with external heat source (Hot Water Storage Tanks with internal heat source shall be inspected)

• Hot water system expansion tanks

• Cryogenic Tanks - (Helium, Hydrogen, Neon, Nitrogen, Fluorine, Argon, Oxygen) /5/

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

• Boilers and direct fired and domestic water heaters under 400,000 BTUs/hour (117124.2 W) input capacity unless requested by the activity.

• Residential and commercial warm air furnaces.

• Fire extinguishers.

• \5\ Breathing Air Tanks /5/ \3\ /3/ \3\ \4\

1-6 LEASED AND/OR CONTRACTOR-OWNED AND OPERATED.

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\5\ Leased and/or Contractor-Owned and Operated boilers and UPVs must be inspected by a contractor-provided boiler inspector meeting the requirements of the paragraph in Chapter 2 entitled, “Contract Employees”. For the DON, the Facilities Engineering Command (FEC)/Commanding Officer (CO) reserves the right to have these boilers inspected by a NAVFAC inspector. Foreign Leased and/or Contractor- Owned and Operated boilers and UPV’s can be inspected by the Host Nation Government Agency Inspector that meets the Host Nation Government Agency Codes and licensing requirements that align with this UFC and approved by the NAVFAC EXWC Boiler & UPV Inspection Program Manager and FEC Boiler & UPV LCO. /5/

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1-7 APPLICABLE CODES.

The latest versions of the following codes are applicable in the inspection and testing of boilers and pressure vessels:

• American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code (BPVC).

• American Society of Mechanical Engineers (ASME) CSD-1, Controls and Safety Devices for Automatically Fired Boilers.

• \5\ National Board of Boiler and Pressure Vessel Inspectors (NBBPVI) National Board Inspection Code (NBIC), Part 1 Installation, Part 2 Inspection and Part 3 Repairs and Alterations. /5/

• National Fire Protection Association (NFPA) National Fire Codes.

• \4\ Department of Defense (DOD) /4/ \3\ UFC 3-240-13FN, /3/ Industrial Water Treatment.

• \5\ Acceptable and/or equivalent International Codes. /5/ This UFC governs when a conflict occurs between this UFC and the codes.

1-8 ENVIRONMENTAL COMPLIANCE.

Military installations must comply with an increasing number of federal, state, and local environmental regulations that affect the operation, maintenance, and testing of external combustion devices such as boilers, unfired pressure vessels, furnaces, process heaters, and incinerators. Failure to comply with these regulations can present a significant liability to installation commanding officers. While environmental compliance is not a primary responsibility of a boiler inspector, boiler inspectors are in a unique position as equipment and subject matter experts to assist installation commanding officers with environmental compliance by ensuring that equipment is operated and maintained in accordance with manufacturer specifications and facility operating procedures and by ensuring that equipment or operational deficiencies are promptly reported to the chain of command for correction. Boiler inspectors are strongly encouraged to communicate with installation environmental offices in order to gain a basic understanding of the environmental compliance requirements for the equipment they are inspecting and to communicate with the appropriate chain of command if a possible compliance deficiency is observed during the course of equipment inspection and certification.

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CHAPTER 2 INSPECTOR QUALIFICATIONS, CERTIFICATIONS AND LICENSES

2-1 NAVY EMPLOYEES.

Navy employees who perform the inspections, witness the tests, prepare the reports, and issue the certifications described in this UFC must satisfy the following two conditions:

• Possess a valid \4\ NAVFAC /4/ Certificate of Competency.

• \5\ Possess a current “License to Inspect” issued by the NAVFAC EXWC Boiler & UPV Inspection Program Manager. /5/

2-1.1 Qualifications for Certification.

Candidates for the Certificate of Competency must be qualified as follows:

2-1.1.1 The Candidate Inspector:

\5\ \3\

• Graduation from an accredited school, a degree in mechanical engineering plus 2 years of experience in design, construction, operation, or inspection of boilers and pressure vessels. Accredited school is defined as an engineering school accredited by the Accreditation Board for Engineering Technology (ABET);

or

• Graduation from an accredited school, a degree in a branch of engineering other than mechanical engineering plus 3 years of experience in design, construction, operation, or inspection of boilers and pressure vessels; /3/ or

• High school diploma or GED or the equivalent plus 5 years of experience in one of the following categories:

• in boiler and pressure vessel construction, operation, maintenance or repair.

• in the inspection of boilers and pressure vessels.

/3/ /5/

2-1.1.2 Job Requirement:

\5\ Inspect and certify a minimum of 20 boilers and/or unfired pressure vessels per year.

/5/

2-1.2 Certification Procedures.

\5\ The Navy or Marine Corps activities must recommend only qualified candidates for certification to the \4\ NAVFAC /4/ Boiler Inspection Certification Board (Appendix I) via the NAVFAC EXWC Boiler & UPV Inspection Program Manager. Prior to hiring, activities are encouraged to schedule a phone interview between prospective candidate and NAVFAC EXWC Boiler & UPV Inspection Program Manager prior to recommending certification. The candidate’s application package must include the following:

• Full Name, address, phone number(s), e-mail address.

• Current position and grade/step.

• 5-year occupational history, directly related to Stationary Engineering Principles: steam/hot water plant operation and maintenance, power generation equipment, pumps, compressors, water science and process equipment, chemical treatment systems, industrial processes, measurement and control devices.

• Educational background; include all Certifications, Licenses, Diplomas.

• Supervisor's “Letter of Recommendation.”

• Commanding Officer’s or Public Works Officer’s signed recommendation.

• Proposed inspection workload. Minimum workload is the inspection of 20 boilers and/or unfired pressure vessels per year as specified in the paragraph in this chapter entitled, “Job Requirement”.

• Copy of the National Board of Boiler Inspectors (NBBI) qualification examination.

2-1.2.2 National Board of Boiler Inspectors (NBBI) Qualification Exam.

The NBBI Qualification Examination tests the ability of the candidate to understand the ASME Boiler and Pressure Vessel Code (BPVC). Candidates may wish to attend one of the commercially available boiler inspector preparatory schools. Information must be received at the NBBI prior to the date of the examination to ensure the candidate is scheduled. \3\ The preparation for and taking of this test can take several weeks of effort, to avoid wasting resources, we strongly recommend the activity discuss and review a candidate’s qualifications with the NAVFAC EXWC Boiler & UPV Inspection Program Manager before they prepare and take this exam. /3/ The FEC Boiler & UPV LCO in each region shall establish and maintain a list of perspective candidates to insure they meet all requirements and recommend qualified candidates to the NAVFAC EXWC Boiler & UPV Inspection Program Manager when the candidate is ready for the NBBI examination.

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2-1.2.3 Employment.

Only employees of the Navy and Marine Corps will be certified. Prolonged gaps in employment may affect certification.

/3/

2-1.3 Qualifications for NAVFAC License to Inspect.

The NAVFAC EXWC Boiler & UPV Inspection Program Manager administers licenses to Navy and Marine Corps employed inspectors every 2 years, providing they satisfy the following six conditions:

• Possess a valid \4\ NAVFAC /4/ Certificate of Competency

• \3\ Are full or part-time employees of the Navy. /3/

• Maintain an inspection workload of at least 20 boilers and/or unfired pressure vessels per year.

• Conduct inspections in accordance with this UFC and all other applicable U.S. Codes: ASME Section I, ASME Section IV, ASME Section VIII, ASME CSD-1, NBIC Part 1, Part 2 and Part 3, NFPA 85 and the BMS.

• Conduct inspections in accordance with all applicable Foreign National Boiler Code and Environmental Governing Standards as mandated in the Status of Forces Agreement (SOFA) between a host country and the U.S.

military forces (Outside the Continental United States (OCONUS only).

• Are not employed in a capacity that constitutes a conflict of interest, as defined in the paragraph below entitled, “Reasons for Not Issuing, Renewing or Revoking a NAVFAC License.”

2-1.4 Reasons for Not Issuing, Renewing or Revoking a NAVFAC License.

The NAVFAC EXWC Boiler and UPV Inspection Program Manager does not license inspectors whom:

• Have a conflict of interest:

• Operate or maintain any of the boilers to be inspected.

• Supervise the operation or maintenance of such boilers.

• Report directly to the boiler operations or maintenance supervisor in any capacity of their employment.

• Fail to attend the NAVFAC Boiler Inspectors Workshop.

• Fail to provide inspection reports in accordance with this UFC.

• Has been counseled by supervisor and/or FEC Boiler & UPV LCO for sub-par job performance and have not shown improvement after additional training and probation.

• Are no longer serving in a position as a NAVFAC Boiler Inspector.

• Officially retired from Government Service.

• Deliberately violate boiler and/or UPV operational safety that resulted in personal injury/death and/or severe equipment damage resulting in costly repair and had negatively impacted mission readiness and/or capability.

• Lose their Security Clearance.

• Conduct themselves unprofessionally in the work place and/or job site.

2-1.5 Inspector Support.

Before licensing inspectors, NAVFAC will seek the following assurances from the employing activity:

\4\

• Provide inspector with all current applicable ASME codes, Navy UFC’s, NBIC Part 1, Part 2, and Part 3, NFPA 70, 85 and 87, UL 353 and 873.

• Ensure that test equipment, and tools are maintained and available to the inspector. Some of the required test equipment and tools shall include:

• Combustion Analyzer (capable of measuring oxygen from 0 to 21%, carbon monoxide in ppm, and Exhaust Gas Temperature)

• Ultrasonic Thickness Gauge

• Boroscope (Hand-held Inspection Camera)

• Digital Camera (if allowed)

• Flashlight, mirror, magnifying glass

• Personal Protective Equipment (PPE)

• Multimeter

• Records of inspection are maintained and available for examination by NAVFAC EXWC Boiler & UPV Inspection Program Manager and/or FEC Boiler & UPV LCO.

• The inspector is available to other activities for inspection, at their request, on a reimbursable basis, depending on workload and advance notice.

/4/ /5/

2-2 CONTRACT EMPLOYEES.

All persons employed by contractors that perform the inspections, witness the tests, prepare the reports, and issue the certificates described in this UFC must, as a minimum, \3\ \4\ /4/ meet the qualifications and /3/ possess a Certificate of Competency or the equivalent (see note 3 of Table 2-1) issued by any political subdivision (such as state, province, territory, county, or city) of the United States or Canada that is a member of the NBBI except for contractors performing inspections outside the U.S. \5\ Requirements for contract employees outside the U.S. vary depending on the country;

check with your respective FEC Boiler & UPV LCO and/or NAVFAC EXWC Boiler & UPV Inspection Program Manager. \4\ Contract Employees shall have access to up-to-date Code Books, test equipment and tools outlined in the paragraph above entitled “Inspector Support”. /4/

For Foreign Regions, inspectors contact the NAVFAC EXWC Boiler & UPV Inspection Program Manager for contract inspections outside the U.S. At a minimum the Foreign Inspectors must meet the qualifications from the Host Nation Government agency licensing requirements that align with this UFC and are approved by the NAVFAC EXWC Boiler & UPV Inspection Program Managers and FEC Boiler & UPV LCO for Boilers & UPV’s manufactured under the Host Nations Codes and stamping requirements. For all U.S manufactured boilers and UPV’s that are installed at U.S.

oversea bases shall be inspected by an inspector employed by NAVFAC that meets all the requirements of this UFC. /5/

2-3 CREDENTIAL REQUIREMENTS.

\5\ \4\ NAVFAC /4/ Form 9-11014/32 (09/15), Inspection Certificates, for boilers and unfired pressure vessels may only be issued by inspectors who meet one of the two category requirements in Table 2-1. /5/

Table 2-1 Credentials Required

Category Credentials Required State Certificate of

Competency

\4\ NAVFAC /4/

Certificate of Competency

NAVFAC License/ Authorization to

Inspect

1. Contract Inspector

X X

2. Civil Service Inspector

X X

Notes:

1. A \4\ NAVFAC Certificate of Competency issued after September 1983 requires passing the NBBI examination. A NAVFAC Certificate of Competency issued before September 1983 required passing a Navy examination. In addition, authorization to issue NAVFAC /4/ Inspection Certificates requires a NAVFAC license.

2. \3\ A contract inspector may not be \4\ an employee of a contractor utilized to operate or maintain the equipment to be certified. /3/ A contract inspector may not report directly to the boiler operations or maintenance supervisor in any capacity of their employment. /4/

3. \5\ In addition to the State Certificate of Competency \4\ and/or current NBBI card /4/, contract inspectors must \3\ meet the qualifications outlined in the paragraph in Chapter 2 entitled, “Qualifications of Certification” and /3/ have written Authorization to Inspect from the NAVFAC EXWC Boiler & UPV Inspection Program Manager. /5/ An official letter from a member jurisdiction of the NBBI stating that the individual has passed the NBBI examination can be considered equivalent to the State Certificate of Competency.

2-4 QUALITY ASSURANCE FOR INSPECTIONS.

Appendix B shows the NAVFAC Boiler and Unfired Pressure Vessel Inspection Program Quality Assurance Organization. This organization provides a method of monitoring the performance of Navy and contract inspections. \5\ The key elements of the organization are the NAVFAC EXWC Boiler & UPV Inspection Program Manager and the FEC Boiler & UPV LCO. The duties of the NAVFAC EXWC Boiler & UPV Inspection Program Manager are outlined in Appendix C, and the duties of the FEC Boiler & UPV LCO are outlined in Appendix D. /5/

2-5 GUIDELINES FOR INSPECTION CONTRACTS.

The inspection of boilers and pressure vessels is highly specialized work requiring qualified personnel and, in many cases, specialized testing equipment. \5\ The Contracting Officer is responsible for ensuring that boiler and UPV inspections performed by companies awarded Navy inspection contracts are inspected and certified in accordance with this UFC. Foreign National inspections on Navy leased property must meet requirements in paragraph above entitled “CONTRACT EMPLOYEES.” /5/

2-5.1 Contractor Abilities.

Contractors’ and their inspectors’ ability to provide adequate inspections can be highly variable. The NBBI commissions inspectors of jurisdictions, which have adopted and administer one or more sections of the ASME Boiler and Pressure Vessel Code as a legal requirement and has a representative serving as a member of the ASME Conference Committee; or to an insurance company which is licensed by a U.S. state to write boiler and pressure vessel insurance. An Authorized Inspection Agency (AIA) is not working within the NBBI charter when performing inspections on a Federal reservation because a state's jurisdiction does not encompass military reservations and the Government does not insure its equipment. \4\ /4/

\3\

2-5.2 Companies Other than Authorized Inspection Agencies.

Quality assurance for such companies may not be structured according to a standard recognized by the NBBI or may even be non-existent. Contracting officers must ensure adequate inspections by requiring qualifications of the contractor before awarding the contract. These assurances, at a minimum, include requiring the contractor to supply inspectors meeting the credential requirements of the paragraphs in this chapter entitled, “Qualifications for Certification”, “Certification Procedures” and “Credential Requirements”.

/3/

2-5.3 Assistance.

\5\ When an activity elects to administer its own inspection contract, NAVFAC EXWC Boiler & UPV Inspection Program Manager and/or FEC Boiler & UPV LCO can provide assistance to the Contracting Officer by reviewing the contract requirements and determining the suitability of a company to perform inspections. The NAVFAC EXWC Boiler & UPV Inspection Program Manager and FEC Boiler & UPV LCO provide this service on a reimbursable basis. They also provide quality control by monitoring the performance of contractors and their inspectors. Upon satisfactory review, the NAVFAC EXWC Boiler & UPV Inspection Program Manager can issue an Authorization to Inspect to the firms qualifying inspectors for the term of the contract. The Authorization to Inspect identifies the ability of the inspector to perform the work satisfactorily and authorizes the inspector to sign the Inspection Report-Boiler or the Unfired Pressure Vessel Report and issue the Inspection Certificate, NAVFAC Form 9-11014/32 (09/15).

/5/

2-5.4 Activity Administered Contracts.

\5\ When the activity’s Contracting Officer elects to administer the contracts, the Contracting Officer must ensure the contractor provides enough information to determine positively that the firm has qualified inspectors and has the capability to do the required work. /5/ The scope of work for the inspection contract should include the number, function, type (such as boiler or pressure vessel), construction (such as the American Society of Mechanical Engineers’ (ASME) Boiler and Pressure Vessel Code or military specification), capacity, and pressure rating of each vessel. In addition, the contract will require that the contractor have:

• Inspectors with credentials complying with \3\ the paragraphs in this chapter entitled, “Qualifications for Certification”, “Contract Employees” and “Credential Requirements” /3/

• An inspection work history similar to that required for the proposed work.

2-5.5 Certification Extensions.

Inspectors are allowed to give a onetime extension for an expiring certificate up to 60 days past the reinspection date for inspections they have performed. The activity is to post the written extension next to the certificate. \5\ This must be in writing and name all applicable boilers and or UPVs with copy to the NAVFAC EXWC Boiler & UPV Inspection Program Manager. Acceptable reasons include unforeseen disruption in inspection support. NAVFAC EXWC Boiler & UPV Inspection Program Manager may provide an activity with a blanket extension of 90 days to an activity previously inspected by themselves or by anyone within their area of responsibility. /5/ Acceptable reasons include unforeseen disruption in inspection services and/or inspection support.

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CHAPTER 3 INSPECTION AND TEST FREQUENCIES

3-1 BOILERS.

Inspection and test frequencies for boilers are shown in Table 3-1.

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Table 3-1 Inspection and Test Frequencies – Boilers

Item Internal Inspection

External Insp. & Operational Test

Hydrostatic Test

Boilers – Wet or dry lay-up

Annually or at the discretion of the inspector.

At resumption of active service.

External at least annually.

External and operational at resumption of active service.

Hydrostatic testing in accordance with NBBI, Part 2, paragraph 4.3.1. Test pressure should not exceed 90% of the lowest setting pressure relief device at the resumption of active service.

Boilers –Heating ASME Section IV

Hot Water Heating or Hot Water Supply Boilers

\3\ /3/ At least every three years or at the discretion of the inspector. After any repair or alteration of pressure parts. \3\ Check firesides on oil fired units annually /3/

At least annually.

After any alteration or modification to boilers, control equipment, or Auxiliaries.

Hydrostatic test in accordance with NBBI, Part 2, paragraph

4.3.1. Test pressure should not

exceed 90% of the lowest setting pressure relief device at least annually. Strength test in accordance with NBBI, Part 3, paragraph 4.4.1 after repair or alteration of pressure parts.

Additional times at the discretion of the inspector.

Steam Heating Boilers

At least annually.

After any repair or alteration of pressure parts.

At least annually.

After any alteration or modification to boilers, control equipment, or auxiliaries.

Hydrostatic testing in accordance with NBBI, Part 2, paragraph 4.3.1. Test pressure should not exceed 90% of the lowest setting pressure relief device at least annually.

Strength test in accordance with NBBI, Part 3, paragraph

4.4.1 after repair or alteration of pressure parts. Additional times at the discretion of the inspector.

High Efficiency and Condensing Hot Water Heating Gas Fired Boilers

At least every three years or at the discretion of the inspector. (See Note 2 Borescope)

At least annually.

After any alteration or modification to boilers, control equipment, or

Hydrostatic testing in accordance with NBBI, Part 2, paragraph 4.3.1. Test pressure should not exceed 90% of the lowest setting pressure relief auxiliaries. device at least annually.

Boilers – Power ASME Section I

High Pressure Steam and Water Boilers

At least annually.

After any repair or alteration of pressure parts.

At least annually.

After any alteration or modification to boilers, control equipment, or auxiliaries.

Hydrostatic testing in accordance with NBBI, Part 2, paragraph 4.3.1. Test pressure should not exceed 90% of the lowest setting pressure relief device at least annually.

Strength test after repair or alteration of pressure parts.

Additional times at the discretion of the inspector.

Domestic Hot Water Heaters

(HLW)

ASME Section IV

If \3\ practical /3/: At least every two years or at the discretion of the inspector. Check oil fired units annually. (See Note 2)

At least every two years. Check oil fired units annually.

Discretion of inspector. Note:

Glass-lined vessels not to exceed Maximum Allowable Working Pressure (MAWP).

Notes:

1. All manhole and handhole gaskets must be replaced after application of the strength test unless they are of the non-compressible steel type.

2. The inspector should use good judgment when inspecting the firesides and watersides of these type boilers. Borescopes should be used when possible to avoid damage to the units. If removal of the burner assemblies and watersides is warranted by the inspector the maintenance personnel shall have proper training in the safe removal of components without damaging the unit. Ensure that all required gaskets are on hand before disassembly of components.

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3-2 UNFIRED PRESSURE VESSELS.

Inspection and test frequencies for unfired pressure vessels are as shown in Tables 3-2, 3-3, or 3-4, as applicable.

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Table 3-2 Inspection and Test Frequencies - Unfired Pressure Vessels (UPVs)

Item Internal Inspection External Insp. & Operational Test

Hydrostatic Test

Pressure Vessels & Heat Exchangers (15 to 250 psig) (100 kPa to

1.7 MPa)

MAWP

Every 3 years or more frequently as determined by procedures in the NBBI Code for vessels subject to corrosion.

After any repair or alteration of pressure parts.

For LPG see Table 3-3.

(See Note 5 Borescope)

Every 3 years or more frequently as determined by procedures in the NBBI Code for vessels subject to corrosion. After any repair or alteration of pressure parts. Inspection must include test and calibration of safety valves and pressure and temperature gages.

Hydrostatic Testing at the discretion of the inspector. If required, it shall be conducted in accordance with NBBI, Part 2, paragraph 4.3.1. Test pressure should not exceed 90% of the lowest setting pressure relief valve. Strength test is required in accordance with NBBI, Part 3, paragraph

4.4.1 after repair or alteration of pressure parts. (See Note 5)

Pressure Vessels & Heat Exchangers (greater than 250 psig) (1.7 MPa)

( MAWP)

Every 3 years or more frequently as determined by procedures in the NBBI Code for vessels subject to corrosion.

After any repair or alteration of pressure parts.

For LPG see Table 3-3.

(See Note 5 Borescope)

Every 3 years or more frequently as determined by procedures in the NBBI Code for vessels subject to corrosion. After any repair or alteration of pressure parts. Inspection must include test and calibration of safety valves and pressure and temperature gages.

Hydrostatic Testing at the discretion of the inspector. If required, it must be conducted in accordance with NBBI, Part 2, paragraph 4.3.1. Test pressure should not exceed 90% of the lowest setting pressure relief device. Strength test is required in accordance with NBBI, Part 3, paragraph

4.4.1 after repair or alteration of pressure parts. (See Note 5)

Notes:

1. Test frequencies and inspections may be increased at the discretion of the inspector or owner if the UPV is subjected, by the nature of its service, to an accumulation of deposits or thermal or mechanical stresses that could affect the integrity of the vessel.

2. A hydrostatic pressure test not to exceed 1.5 times the MAWP for BPVC ASME Section VIII Division 1 vessels and 1.25 times the MAWP for BPVC ASME Section VIII Division 2 vessels may be substituted for the internal inspection.

3. If the tube bundle of the heat exchangers is a higher pressure than the shell, both sides of the heat exchanger must be hydrostatically tested.

4. Unfired pressure vessels are to be inspected externally and re-certified anytime they are relocated or moved. It is the activity’s responsibility to inform the inspector of the move. For UPVs designed and built to be portable, reinspection is not required after a move as long as the vessel does not leave the base. The inspector will indicate the UPV is “portable” on all appropriate reports. Once a UPV designed to be portable is relocated outside the base, any certified NAVFAC boiler inspector or NAVFAC-approved contract boiler inspector may issue a certificate (9-11014/32) for the length of the deployment period but not exceeding the original certificate's expiration date. A copy of the original inspection report and certificate must accompany the pressure vessel during the deployment/transfer period. The extent of reinspection after the move for pressure vessels designed to be portable consists of an external inspection to check for damage incurred while in transit, a visual examination to determine if the installation is conforming to applicable codes and a visual examination to verify that all code required safety devices are installed. If any of these inspection processes indicates discrepancies with the pressure vessel and/or installation, then the full inspection requirements of this UFC apply.

5. Use of ultrasonic thickness (UT) and borescope testing in addition to internal inspection is highly encouraged. Nondestructive Testing (NDT) in lieu of Hydrostatic Testing may be used to evaluate the properties of a material, component or system without causing damage. NDT testing such as Ultrasonic Thickness (UT), Acoustic Emissions (AE) or Shear Wave (SW) may be required by the inspector.

/4/ /2/ \2\

Table 3-3 Inspection and Test Frequencies - UPVs (Special Cases)

Item Internal Inspection External Insp. & Operational Test

Hydrostatic Test

High Pressure

(H.P.) ASME &

MILSPEC

Vessels

See note 1

Every 3 years of service. Inspection must include test and calibration of safety valves and pressure and temperature gages.

See Note 1.

Every 3 years of service. Inspection must include test and calibration of safety valves and pressure and temperature gages.

See note 2

For MILSPEC Vessels (Pressure Vessels Design, Built and Stamped to \4\ MIL- DTL-22606 /4/) or any non-ASME vessels see Note 3.

\3\ /3/ \3\ /3/ \3\ /3/ \3\ /3/ For MILSPEC Vessels (Pressure Vessels Design, Built and Stamped to \4\ MIL-

DTL-22606 /4/) or any non-ASME vessels see Note 3.

Carbon Dioxide (CO2) Storage Tanks

See note 4

Only if the vessel has been depressurized or has been opened to the atmosphere other than for immediate repair or maintenance; or when directed by an authorized boiler inspector.

Every 3 years; or after any repair or alteration of pressure parts; or when directed by an authorized boiler inspector.

See note 5

After any repair or alteration of pressure parts; or when directed by an authorized boiler inspector. Caution should be taken in performing hydrostatic testing. It is essential that all water be removed from the vessel before returning it to service.

Water will freeze and create blockages.

Liquid Petroleum Gas (LPG) Storage Tanks

Every 3 years or more frequently as determined by procedures in the NBBI Code. After any repair or alteration of pressure parts. Use ultrasonic testing instead of visual internal inspection.

Every 3 years or more frequently as determined by procedures in the NBBI Code. After any repair or alteration of pressure parts. Bench test or replace the UL or ASME safety valves every 6 years.

See note 6

After any repair or alteration of pressure parts, otherwise at the discretion of the inspector.

Notes:

1. A visual internal inspection for H.P. ASME or MILSPEC vessels \3\ /3/ is not required every 3 years provided the vessel (or vessel bank) successfully passes a gas analysis with oil mist plus particulate matter concentration equal to or less than 5 milligrams per cubic meter and dew point equal to or colder than -40 degrees F (-40 degrees C); and an ultrasonic thickness measurement check in accordance with the Paragraph in Chapter 5 entitled, “Ultrasonic Examination Military Specification”.

The maximum acceptable interval between visual inspections is 12 years.

2. At intervals indicated in Naval Ship’s Technical Manual S9086-SY-STM-010, Chapter 551, vessels will be required to be tested according to “551-1.14.1”. The flask(s) requiring re-certification is to be tested by Ultrasonic (UT), Acoustic Emission (AE) or Shear Wave (SW) testing. Hydrostatic testing is being eliminated because it does not provide data on flask wall cracking which has been determined to be the primary failure mode.”

3. Activities may elect to prepare and inspect MILSPEC vessels using NAVSEASYSCOM boiler inspectors according to Naval Ship’s Technical Manual S9086-SY-STM-010, Chapter 551, Compressed Air Plants and Systems. However, if either a NAVSEASYSCOM or NAVFAC boiler inspectors are used they will be required to perform internal and external inspections as explained above every 3 years (as opposed to the 6-20 year re-certification intervals allowed in Naval Ship’s Technical Manual S9086-SY- STM-010, Chapter 551). A pressure vessel that is neither MILSPEC nor ASME code may only be certified when design drawings and engineering calculations from the manufacturer are available to the inspector to positively determine whether the vessel is safe to operate. The inspector may ask for proof of the manufacturer’s quality control procedures and tests prior to issuing a certificate\4\ ./4/ \3\ /3/

4. We recommend inspectors familiarize themselves with current versions of Compressed Gas Association (CGA) G-6.1, Standard for Insulated Carbon Dioxide Systems at Consumer Sites, and CGA G-6.7, Safe Handing of Liquid Carbon Dioxide Containers That Have Lost Pressure.

5. Inspection must include testing of relief…