UNIFIED FACILITIES CRITERIA (UFC)
UNIFIED FACILITIES CRITERIA (UFC)
OPERATIONS AND MAINTENANCE:
OPERATIONS AND MAINTENANCE:
INSPECTION AND CERTIFICATION OF
INSPECTION AND CERTIFICATION OF
BOILERS AND UNFIRED PRESSURE
BOILERS AND UNFIRED PRESSURE
VESSELS
VESSELS
APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED
UNIFIED FACILITIES CRITERIA (UFC) UNIFIED FACILITIES CRITERIA (UFC) O&M: INSPECTION AND CERTIFICATION OF BOILERS AND
O&M: INSPECTION AND CERTIFICATION OF BOILERS AND UNFIRED PRESSUREUNFIRED PRESSURE VESSELS
VESSELS
Any copyrighted material included in this UFC is identified at its point of use. 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 Use of the copyrighted material apart from this UFC must have the permission of the copyright holder.
copyright holder.
U.S. ARMY CORPS OF ENGINEERS U.S. ARMY CORPS OF ENGINEERS
NAVAL FACILITIES ENGINEERING COMMAND (Preparing Activity) NAVAL FACILITIES ENGINEERING COMMAND (Preparing Activity) AIR FORCE CIVIL ENGINEER SUPPORT AGENCY
AIR FORCE CIVIL ENGINEER SUPPORT AGENCY
Record of Changes (changes are indicated by \
Record of Changes (changes are indicated by \ 11 \ ... / \ ... / 11 /) /) Change
Change No. No. Date Date LocationLocation 1
1 January January 2004 2004 App App C, C, Page Page 36.36. 2
2 March March 2005 2005 Pages Pages 2, 2, 9-15, 9-15, 17, 17, 27, 27, 28, 28, 3434 3
3 May May 2007 2007 Addition Addition of of paragraphs paragraphs 8-2.1 8-2.1 and and 8-2.2; 8-2.2; subsequentsubsequent adjustments throughout as marked.
adjustments throughout as marked.
This UFC supersedes MIL-HDBK-1152 dated 30 September 1996. This UFC supersedes MIL-HDBK-1152 dated 30 September 1996.
FOREWORD FOREWORD
The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides The Unified Facilities Criteria (UFC) system is prescribed by MIL-STD 3007 and provides
planning, design, construction, sustainment, restoration, and modernization criteria, and applies planning, design, construction, sustainment, restoration, and modernization criteria, and applies to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance to the Military Departments, the Defense Agencies, and the DoD Field Activities in accordance with
with USD(AT&L) MemorandumUSD(AT&L) Memorandumdated 29 May 2002. UFC will be used for all dated 29 May 2002. UFC will be used for all DoD projects andDoD projects and work for other customers where appropriate.
work for other customers where appropriate. All construction outside of All construction outside of the United States isthe United States is also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction also governed by Status of Forces Agreements (SOFA), Host Nation Funded Construction Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.) Agreements (HNFA), and in some instances, Bilateral Infrastructure Agreements (BIA.)
Therefore, the acquisition team must ensure compliance with the more stringent of the UFC, the Therefore, the acquisition team must ensure compliance with the more stringent of the UFC, the SOFA, the HNFA, and the BIA, as applicable.
SOFA, the HNFA, and the BIA, as applicable.
UFC are living documents and will be periodically reviewed, updated, and made available to 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
users as part of the Services’ responsibility for providing technical criteria for military construction.
construction. Headquarters, U.S. Army Headquarters, U.S. Army Corps of Engineers (Corps of Engineers (HQUSACE), Naval FacilitiesHQUSACE), Naval Facilities
Engineering Command (NAVFAC), and Air Force Civil Engineer Support Agency (AFCESA) are Engineering Command (NAVFAC), and Air Force Civil Engineer Support Agency (AFCESA) are responsible for administration of
responsible for administration of the UFC system. the UFC system. Defense agencies should contact Defense agencies should contact thethe preparing service for
preparing service for document interpretation and document interpretation and improvements. improvements. Technical content of Technical content of UFC isUFC is the responsibility of
the responsibility of the cognizant DoD the cognizant DoD working group. working group. Recommended changes with supportingRecommended changes with supporting rationale should be sent to the respective service proponent office by the following electronic rationale should be sent to the respective service proponent office by the following electronic form:
form: Criteria Change Request (CCR)Criteria Change Request (CCR). . The form is The form is also accessible from the also accessible from the Internet sites listedInternet sites listed below.
below.
UFC are effective upon issuance and are distributed only in electronic media from the following UFC are effective upon issuance and are distributed only in electronic media from the following source:
source:
•
• Whole Building Design Guide web siteWhole Building Design Guide web site http://dod.wbdg.org/ http://dod.wbdg.org/ ..
Hard copies of UFC printed from electronic media should be checked against the current Hard copies of UFC printed from electronic media should be checked against the current electronic version prior to use to ensure that they are current.
electronic version prior to use to ensure that they are current.
AUTHORIZED BY: AUTHORIZED BY:
______________________________________ ______________________________________
DONALD L. BASHAM, P.E. DONALD L. BASHAM, P.E.
Chief, Engineering and Construction Division Chief, Engineering and Construction Division U.S. Army Corps of Engineers
U.S. Army Corps of Engineers
______________________________________ ______________________________________
DR. JAMES W WRIGHT, P.E. DR. JAMES W WRIGHT, P.E. Chief Engineer
Chief Engineer
Naval Facilities Engineering Command Naval Facilities Engineering Command
______________________________________ ______________________________________
KATHLEEN I. FERGUSON, P.E. KATHLEEN I. FERGUSON, P.E. The Deputy Civil Engineer
The Deputy Civil Engineer DCS/Installations & Logistics DCS/Installations & Logistics Department of the Air Force Department of the Air Force
______________________________________ ______________________________________
Dr. GET W. MOY, P.E. Dr. GET W. MOY, P.E.
Director, Installations Requirements and Director, Installations Requirements and
Management Management
Office of the Deputy Under Secretary of Defense Office of the Deputy Under Secretary of Defense
(Installations and Environment) (Installations and Environment)
CONTENTS CONTENTS
Page Page CHAPTER
CHAPTER 1 1 INTRODUCTIONINTRODUCTION
Paragraph 1-1
Paragraph 1-1 SCOPESCOPE ... ... 11 1-1.1
1-1.1 Army Army CriteriaCriteria... ... 11 1-1.2
1-1.2 Air Air Force Force Criteria...Criteria... ... 11 1-2 1-2 PURPOSEPURPOSE ... ... 11 1-3 1-3 RESPONSIBILITYRESPONSIBILITY ... ... 11 1-4 1-4 APPLICABILITY...APPLICABILITY... ... 22 1-5
1-5 LEASED LEASED AND/OR AND/OR CONTRACTOR-OWNED CONTRACTOR-OWNED AND AND OPERATEDOPERATED BOILERS
BOILERS LOCATED LOCATED ON ON NAVY NAVY OWNED OWNED PROPERTYPROPERTY ... ... 33 1-6
1-6 APPLICABLE APPLICABLE CODESCODES ... ... 33
CHAPTER 2
CHAPTER 2 INSPECTOR QUALIFICATIONS, INSPECTOR QUALIFICATIONS, CERTIFICATIONS AND CERTIFICATIONS AND LICENSESLICENSES
Paragraph
Paragraph 2-1 2-1 NAVY NAVY EMPLOYEESEMPLOYEES ... ... 55 2-1.1
2-1.1 Qualifications Qualifications for for CertificationCertification ... ... 55 2-1.2
2-1.2 Certification Certification ProceduresProcedures ... 5... 5 2-1.3
2-1.3 Inspector Inspector Certification Certification TestTest ... ... 66 2-1.4
2-1.4 Qualifications Qualifications for for NAVFAC NAVFAC LicensingLicensing ... ... 66 2-1.5
2-1.5 Conflict Conflict of of Interest...Interest... ... 66 2-1.6
2-1.6 Inspector Inspector SupportSupport ... ... 77 2-2
2-2 CONTRACT CONTRACT EMPLOYEES...EMPLOYEES... ... 77 2-3
2-3 CREDENTIAL CREDENTIAL REQUIREMENTSREQUIREMENTS ... ... 77 2-4
2-4 QUALITY QUALITY ASSURANCE ASSURANCE FOR FOR INSPECTIONSINSPECTIONS ... ... 88 2-5
2-5 GUIDELINES GUIDELINES FOR FOR INSPECTION INSPECTION CONTRACTSCONTRACTS ... ... 88 2-5.1
2-5.1 Contractor Contractor Abilities...Abilities... .... 88 2-5.2
2-5.2 Companies Companies Other Other than than Authorized Authorized Inspection Inspection AgenciesAgencies ... ... 99 2-5.3
2-5.3 AssistanceAssistance ... ... 99 2-5.4
2-5.4 Activity Activity Administered Administered ContactsContacts ... .. 99
CHAPTER 3
CHAPTER 3 INSPECTION AND INSPECTION AND TEST FREQUENCIESTEST FREQUENCIES
Paragraph
Paragraph 3-1 3-1 BOILERSBOILERS ... ... 1010 3-2
3-2 UNFIRED UNFIRED PRESSURE PRESSURE VESSELS...VESSELS... .... 1111
CHAPTER
CHAPTER 4 4 BOILER BOILER INSPECTIONSINSPECTIONS
Paragraph
Paragraph 4-1 4-1 GUIDANCEGUIDANCE ... ... 1616 4-2
4-2 EXTERNAL EXTERNAL INSPECTION INSPECTION OF OF BOILERSBOILERS ... ... 1616 4-3
4-3 INTERNAL INTERNAL INSPECTION INSPECTION OF OF BOILERSBOILERS ... .. 1616 4-4
4-4 BOILERS BOILERS IN IN WET WET OR OR DRY DRY LAY-UP...LAY-UP... ... 1616
CHAPTER 5
CHAPTER 5 UNFIRED PRESSURE UNFIRED PRESSURE VESSEL VESSEL INSPECTIONSINSPECTIONS
Paragraph
Paragraph 5-1 5-1 GUIDANCEGUIDANCE ... ... 1717 5-2
5-2 EXTERNAEXTERNAL L INSPECTINSPECTIONS IONS OF OF UNFIRED UNFIRED PRESSURE PRESSURE VESSELVESSELSS . . 1717 5-3
5-3 INTERNAINTERNAL L INSPECTINSPECTIONS IONS OF OF UNFIRED UNFIRED PRESSURE PRESSURE VESSELVESSELSS .. .. 1717 5-4
5-4.1
5-4.1 Internal Internal and and External External InspectionsInspections ... ... 1717 5-4.2
5-4.2 Ultrasonic Ultrasonic ExaminationExamination ... . 1717 5-4.3
5-4.3 VariationsVariations... ... 1818 5-5
5-5 DEAERATORSDEAERATORS ... ... 1818 5-6
5-6 LIQUIFIED LIQUIFIED PETROLEUM PETROLEUM GAS GAS (LPG) (LPG) TANKS...TANKS... ... 1818 5-6.1
5-6.1 External External InspectionInspection ... ... 1818 5-6.2
5-6.2 Internal Internal InspectionInspection ... ... 1818 5-6.3
5-6.3 Hydrostatic Hydrostatic TestTest... ... 1919 5-6.4
5-6.4 Safety Safety Relief Relief Valves...Valves... ... 1919
CHAPTER
CHAPTER 6 6 PRESSURE PRESSURE TESTSTESTS
Paragraph
Paragraph 6-1 6-1 HYDROSTATIC HYDROSTATIC TESTSTESTS ... .. 2020 6-1.1
6-1.1 Strength Strength Test Test PressurePressure... .. 2020 6-1.2
6-1.2 Tightness Tightness Test Test PressurePressure... ... 2121 6-1.3
6-1.3 PrecautionsPrecautions... ... 2121 6-1.4
6-1.4 Possible Possible Deformation...Deformation... ... 2121 6-1.5
6-1.5 Hold Hold PressurePressure ... .. 2121 6-1.6
6-1.6 Inspection Inspection Under Under PressurePressure ... ... 2121 6-1.7
6-1.7 Permanent Permanent Deformation...Deformation... ... 2121 6-1.8
6-1.8 Gaskets...Gaskets... ... 2222 6-2
6-2 PNEUMATIC PNEUMATIC TESTSTESTS ... ... 2222 6-3
6-3 PRESSURE PRESSURE TEST TEST RESULTSRESULTS ... ... 2222 6-3.1
6-3.1 Yielding Yielding During During TestTest ... ... 2222 6-3.2
6-3.2 No No Yielding Yielding During During TestTest... ... 2222 6-3.3
6-3.3 Inspection Inspection Under Under PressurePressure ... ... 2222
CHAPTER
CHAPTER 7 7 OPERATIONAL OPERATIONAL TESTSTESTS
Paragraph
Paragraph 7-1 7-1 GUIDANCEGUIDANCE ... ... 2323 7-1.1
7-1.1 PurposePurpose ... ... 2323 7-1.2
7-1.2 Conditions Conditions to to be be ReportedReported ... ... 2323 7-2
7-2 FIRING FIRING EQUIPMENTEQUIPMENT ... ... 2323 7-3
7-3 CONTROLSCONTROLS ... ... 2323 7-4
7-4 PIPING PIPING AND AND PIPING PIPING CONNECTIONSCONNECTIONS ... ... 2424 7-5
7-5 DEVICESDEVICES ... ... 2424 7-5.1
7-5.1 Temperature Temperature Indicating Indicating DevicesDevices ... ... 2424 7-5.2
7-5.2 Metering Metering and and Recording Recording Devices...Devices... 24... 24 7-6
7-6 VALVESVALVES... ... 2424 7-6.1
7-6.1 Blow-Down Blow-Down ValvesValves... ... 2424 7-6.2
7-6.2 Stop Stop and and Check Check ValvesValves ... ... 2424 7-6.3
7-6.3 Pressure Pressure Reducing Reducing ValvesValves ... ... 2525 7-6.4
7-6.4 Safety Safety and and Safety Safety Relief Relief ValvesValves ... 25.. 25 7-7
7-7 BOILER BOILER AUXILIARIESAUXILIARIES ... . 2525 7-8
7-8 BOILER BOILER AND AND FEEDWATER FEEDWATER TREATMENTTREATMENT ... ... 2525 7-9
7-9 FUEL FUEL HANDLING HANDLING PRACTICESPRACTICES ... .. 2525
CHPATER 8
8-2.1
8-2.1 NAVY NAVY Welder Welder QualificationsQualifications ... ... 2727 8-2.2
8-2.2 Repairs Repairs by by a a Navy Navy WelderWelder ... 27... 27 8-3
8-3 SETTING SETTING SAFETY SAFETY AND AND RELIEF RELIEF VALVESVALVES ... ... 2828 8-4
8-4 RECORDSRECORDS ... ... 2828
CHAPTER 9
CHAPTER 9 INSPECTION CERTIFICATES INSPECTION CERTIFICATES AND REPORTSAND REPORTS
Paragraph
Paragraph 9-1 9-1 PROCEDURES PROCEDURES FOR FOR SUBMITTING SUBMITTING REPORTS REPORTS AND AND FORMS... FORMS... 2929 9-1.1
9-1.1 Inspection Inspection Reports Reports – – Boilers Boilers and and Unfired Unfired Pressure Pressure Vessels ... 29Vessels ... 29 9-1.2
9-1.2 Inspection Inspection Certificate Certificate for for Boilers Boilers – – Unfired Unfired Pressure Pressure VesselsVessels ... 29... 29
CHAPTER 10
CHAPTER 10 MAXIMUM ALLOWABLE MAXIMUM ALLOWABLE WORKING PRESSUREWORKING PRESSURE
Paragraph
Paragraph 10-1 10-1 GUIDANCEGUIDANCE ... ... 3030 10-2
10-2 STANDARD STANDARD BOILERSBOILERS ... .. 3030 10-2.1
10-2.1 Standard Standard Watertube Watertube Boilers...Boilers... 30... 30 10-2.2
10-2.2 Standard Standard Cast-Iron Cast-Iron Steam Steam BoilersBoilers ... 30... 30 10-3
10-3 NONSTANDARD NONSTANDARD BOILERSBOILERS ... ... 3030 10-3.1
10-3.1 Nonstandard Nonstandard Riveted Riveted BoilersBoilers ... 30... 30 10-3.2
10-3.2 Nonstandard Nonstandard Welded Welded BoilersBoilers ... 30.... 30 10-3.3
10-3.3 Nonstandard Nonstandard Cast-Iron Cast-Iron BoilersBoilers ... 30... 30 10-4
10-4 CALCULATIONS CALCULATIONS OF OF MAXIMUM MAXIMUM ALLOWABLE ALLOWABLE WORKINGWORKING PRESSURE
PRESSURE ... .... 3131 10-5
10-5 FACTOR FACTOR OF OF SAFETYSAFETY ... ... 3131
CHAPTER 11
CHAPTER 11 MISHAP OR MISHAP OR PROPERTY DAMAGE PROPERTY DAMAGE REPORTINGREPORTING
Paragraph
Paragraph 11-1 11-1 REPORTING REPORTING REQUIREMENTSREQUIREMENTS ... ... 3232 11-2
11-2 INFORMATION INFORMATION COPIESCOPIES ... ... 3232
APPENDIX
APPENDIX A A REFERENCESREFERENCES ... ... 3333
APPENDIX
APPENDIX B B THE THE NAVFACENGCOM NAVFACENGCOM BOILER BOILER AND AND PRESSURE PRESSURE VESSEL VESSEL INSPECTIONINSPECTION PROGRAM: QUALITY
PROGRAM: QUALITY ASSURANCE ORGANIZATIONASSURANCE ORGANIZATION ... ... 3535
APPENDIX
APPENDIX C C DUTIES DUTIES AND AND QUALIFICATIONS QUALIFICATIONS OF OF THE THE SENIOR SENIOR INSPECTORS... 36INSPECTORS... 36
APPENDIX
APPENDIX D D PROCEDURES PROCEDURES FOR FOR LAY-UP LAY-UP OF OF BOILERSBOILERS ... ... 3737
APPENDIX
APPENDIX E E REPORTS REPORTS AND AND FORMSFORMS... ... 3939
APPENDIX
APPENDIX F F PMI PMI CHECKLIST CHECKLIST FOR FOR SMALL SMALL BOILERSBOILERS ... ... 4747
APPENDIX
APPENDIX G G WHAT WHAT TO TO EXPECT EXPECT WHEN WHEN THE THE BOILER BOILER INSPECTOR INSPECTOR CALLSCALLS ... ... 5151
INDEX
FIGURES FIGURES
Figure Title Figure Title
B-1
B-1 Quality Quality Assurance Assurance OrganizationOrganization... 3535 E-1
E-1 Inspection Inspection Report Report – – BoilerBoiler ... 3939 E-2
E-2 Unfired Unfired Pressure Pressure Vessel Vessel ReportReport... 4242 E-3
E-3 Inspection Inspection Certificate Certificate for for Boiler-Unfired Boiler-Unfired Pressure Pressure Vessel Vessel Form, Form, NAVFAC NAVFAC 9- 9-11014/32(3/67) 11014/32(3/67) ... 4545 TABLES TABLES Table Title Table Title 2-1
2-1 Credentials Credentials Required...Required... ... 88 3-1
3-1 Inspection Inspection and and Test Test Frequencies Frequencies – – BoilersBoilers ...10....10 3-2
3-2 Inspection Inspection and and Test Test Frequencies Frequencies – – Unfired Unfired Pressure Pressure Vessels Vessels (UPV)(UPV) ...11...11 3-3
3-3 Inspection Inspection and and Test Test Frequencies Frequencies – – UPVs UPVs (Special (Special Cases)...Cases)...13...13 3-4
3-4 Inspection Inspection and and Test Test Frequencies Frequencies – – DeaeratorsDeaerators ...15...15 F-1
F-1 Steam Steam Boiler Boiler PMI PMI ChecklistChecklist ...47.47 F-2
CHAPTER 1 CHAPTER 1 INTRODUCTION INTRODUCTION 1-1
1-1 SCOPESCOPE. . The Department of the The Department of the Navy (DON), including Navy (DON), including the Naval Shorethe Naval Shore Establishment and the Marine
Establishment and the Marine Corps, will use Corps, will use this UFC. this UFC. It presents basic operation It presents basic operation andand maintenance guidance on inspection and certification of boilers and unfired pressure maintenance guidance on inspection and certification of boilers and unfired pressure vessels.
vessels. 1-1.1
1-1.1 Army CriteriaArmy Criteria. . Operation and Operation and Maintenance requirements Maintenance requirements for boilers for boilers andand unfired pressure vessels on Army installations are contained in Army
unfired pressure vessels on Army installations are contained in Army Technical ManualTechnical Manual
(TM) 5-650,
(TM) 5-650, Central Heating Plants Central Heating Plants andand TM 5-642,TM 5-642, Small Heating Systems Small Heating Systems . These. These documents can be found at
documents can be found at http://www.hnd.usace.army.mil/techinfo/ http://www.hnd.usace.army.mil/techinfo/ .. 1-1.2
1-1.2 Air Force CriteriaAir Force Criteria. . Requirements for Requirements for boilers and unfirboilers and unfired pressure vesselsed pressure vessels on Air Force installations are contained in Air Force Instruction (AFI) 32-1068,
on Air Force installations are contained in Air Force Instruction (AFI) 32-1068, Heating Heating Systems and Unfired Pressure Vessels
Systems and Unfired Pressure Vessels , 1 Oct 1998, found at http://www.e-, 1 Oct 1998, found at
http://www.e-publishing.af.mil/pubfiles/af/32/afi32-1068/afi32-1068.pdf
publishing.af.mil/pubfiles/af/32/afi32-1068/afi32-1068.pdf.. 1-2
1-2 PURPOSEPURPOSE.. This UFC covers the procedures necessary to determine theThis UFC covers the procedures necessary to determine the material condition of boilers and unfired pressure vessels to ensure their continued safe, material condition of boilers and unfired pressure vessels to ensure their continued safe, reliable, and efficient
reliable, and efficient operation. operation. The procedures also require The procedures also require determination ofdetermination of
combustion efficiency and proper operation of boilers, boiler auxiliaries, and controls. 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 For the DON, exceptions to these requirements will not be made without the formal concurrence of the Naval Facilities Engineering Command's (NAVFACENGCOM or concurrence of the Naval Facilities Engineering Command's (NAVFACENGCOM or NAVFAC) Boiler Inspection
NAVFAC) Boiler Inspection Certification Board. Certification Board. The authority for The authority for these requirements isthese requirements is a Chief of Naval Operations letter dated 22 October 1970,
a Chief of Naval Operations letter dated 22 October 1970, Inspections of Boilers,Inspections of Boilers, Unfired Pressure Vessels, Elevators, Dumbwaiters and Escalators
Unfired Pressure Vessels, Elevators, Dumbwaiters and Escalators . . The The frequency frequency ofof inspection and testing, the various items or components to be inspected or tested, and inspection and testing, the various items or components to be inspected or tested, and the forms to be used are specified in this UFC.
the forms to be used are specified in this UFC. 1-3
1-3 RESPONSIBILITYRESPONSIBILITY.. The Commanding Officers of the cognizant activitiesThe Commanding Officers of the cognizant activities ensure that the boilers and unfired pressure vessels installed at their facilities and
ensure that the boilers and unfired pressure vessels installed at their facilities and covered by this UFC
covered by this UFC are certified as specifiare certified as specified. ed. Inspection and testing of boilerInspection and testing of boilers ands and unfired pressure vessels must be made by a boiler inspector certified by one of the unfired pressure vessels must be made by a boiler inspector certified by one of the NAVFAC Senior Boiler Inspectors.
NAVFAC Senior Boiler Inspectors. This boiler inspector This boiler inspector will be on the will be on the cognizantcognizant activity's rolls, except where:
activity's rolls, except where:
•
• Inspection responsibility has been assigned to the Commanding Officer ofInspection responsibility has been assigned to the Commanding Officer of
\3\ the Region or respective /3/ Public Works. \3\ the Region or respective /3/ Public Works.
•
• Commanding Officers of major or lead activities are responsible forCommanding Officers of major or lead activities are responsible for
performing the maintenance of public works and public utilities at adjacent performing the maintenance of public works and public utilities at adjacent activities.
•
• It may be impractical to employ qualified personnel for such inspectionsIt may be impractical to employ qualified personnel for such inspections
because of the limited
because of the limited workload. workload. In such situations, rIn such situations, request assistance inequest assistance in obtaining inspection services from the appropriate Senior Boiler Inspector. obtaining inspection services from the appropriate Senior Boiler Inspector. The Senior Boiler Inspector will arrange for the performance of those
The Senior Boiler Inspector will arrange for the performance of those inspection services by a Navy or contract inspector located near the inspection services by a Navy or contract inspector located near the requesting activity.
requesting activity. When assistance is When assistance is required, such assistance required, such assistance will bewill be rendered on a
rendered on a reimbursable basis. reimbursable basis. The requesting activitThe requesting activity is responsibley is responsible for providing the funds to accomplish the inspections.
for providing the funds to accomplish the inspections.
1-4 \3\
1-4 \3\ APPLICABILITYAPPLICABILITY.. This UFC is applicable to all heating and powerThis UFC is applicable to all heating and power boilers and unfired pressure vessels owned or leased by the DON, including portable boilers and unfired pressure vessels owned or leased by the DON, including portable boilers and portable unfired pressure vessels, liquefied petroleum gas (LPG) storage boilers and portable unfired pressure vessels, liquefied petroleum gas (LPG) storage tanks, and Mobile Util
tanks, and Mobile Utilities Support Equipment (Mities Support Equipment (MUSE) boilers. USE) boilers. The following equipmentThe following equipment is not covered by this UFC: /3/
is not covered by this UFC: /3/
•
• Cylinders, including Department of Transportation (DOT) flasks, Cylinders, including Department of Transportation (DOT) flasks, forfor
shipment of
shipment of compressed or liquefied compressed or liquefied gases. gases. Defense Logistics AgencyDefense Logistics Agency (DLA) Instruction 4145.25,
(DLA) Instruction 4145.25, Storage and Handling of Liquefied and Storage and Handling of Liquefied and Gaseous Compressed Gasses and their Full and Empty Containers
Gaseous Compressed Gasses and their Full and Empty Containers of 16of 16 June 2000 governs.
June 2000 governs.
•
• \3\ Shore-based hyperbaric facility support pressure vessels, including, but\3\ Shore-based hyperbaric facility support pressure vessels, including, but
not limited to, vessels used for manned operations or for testing animals not limited to, vessels used for manned operations or for testing animals or equipment, gas storage flasks, volume tanks, fire water tanks, and or equipment, gas storage flasks, volume tanks, fire water tanks, and filters. (these are under the
filters. (these are under the authority of NAVFAC System Certificationauthority of NAVFAC System Certification Authority.) /3/
Authority.) /3/
•
• Air tanks for air brakes on vehicles.Air tanks for air brakes on vehicles. •
• Unfired pressure vessels operating at an internal or external gageUnfired pressure vessels operating at an internal or external gage
pressure not exceeding 103.42 kiloPascals (kPa) (15 pounds per square pressure not exceeding 103.42 kiloPascals (kPa) (15 pounds per square inch gage (psig)) with no limitation on size \2\, except deareators. /2/ inch gage (psig)) with no limitation on size \2\, except deareators. /2/
•
• Unfired pressure vessels that do not exceed the following volume,Unfired pressure vessels that do not exceed the following volume,
pressure, and dimension limits: pressure, and dimension limits:
0.14 cu. meters (5 cu ft) in volume and 1723.69 kPa (250 psi) 0.14 cu. meters (5 cu ft) in volume and 1723.69 kPa (250 psi) design pressure; or
design pressure; or
0.08 cu. meters (3 cu ft) in volume and 2413.17 kPa (350 psi) 0.08 cu. meters (3 cu ft) in volume and 2413.17 kPa (350 psi) design pressure;
design pressure;
0.042 cu. meters (1-1/2 cu ft) in volume and 4136.85 kPa (600 psi) 0.042 cu. meters (1-1/2 cu ft) in volume and 4136.85 kPa (600 psi) design pressure.
•
• Vessels having an inside diameter, width, height, or cross section diagonalVessels having an inside diameter, width, height, or cross section diagonal
not exceeding 152.4 mm (6 inches), with no limitation on length of vessel not exceeding 152.4 mm (6 inches), with no limitation on length of vessel or pressure.
or pressure.
•
• Unfired pressure vessels containing only water under pressure at ambientUnfired pressure vessels containing only water under pressure at ambient
temperature for
temperature for domestic or industrdomestic or industrial process supply ial process supply purposes. purposes. ThoseThose containing air, the compression of which serves only as a cushion, must containing air, the compression of which serves only as a cushion, must be inspected if pressures and volumes exceed those specified above. be inspected if pressures and volumes exceed those specified above.
•
• Unfired pressure vessels used as refrigerant receivers for refrigerating andUnfired pressure vessels used as refrigerant receivers for refrigerating and
air conditioning equipment. air conditioning equipment.
•
• Coil type steam vapor cleaners unless requested by the activity.Coil type steam vapor cleaners unless requested by the activity. •
• Unit heaters (gas, electric, or steam).Unit heaters (gas, electric, or steam). •
• Boilers and direct fired and domestic water heaters under 117124.2 WBoilers and direct fired and domestic water heaters under 117124.2 W
(400,000 BTUs/hour) input capacity unless requested by the activity. (400,000 BTUs/hour) input capacity unless requested by the activity.
•
• Residential and commercial warm air furnaces.Residential and commercial warm air furnaces. •
• Fire extinguishers.Fire extinguishers. •
• \3\ (deletion) /3/ \3\ (deletion) /3/
1-5 \3\
1-5 \3\ LEASED AND/OR CONTRACTOR-OWNED AND LEASED AND/OR CONTRACTOR-OWNED AND OPERATEDOPERATED BOILERS AND UPVs LOCATED ON NAVY OWNED PROPERTY
BOILERS AND UPVs LOCATED ON NAVY OWNED PROPERTY.. These boilers andThese boilers and UPVs must be inspected by a contractor-provided boiler inspector meeting the
UPVs must be inspected by a contractor-provided boiler inspector meeting the requirements of paragraph 2-2.
requirements of paragraph 2-2. For the DON, For the DON, the Facilities Engineering the Facilities Engineering CommandCommand (FEC)/Commanding Officer (CO) reserves the right to have these boilers inspected by a (FEC)/Commanding Officer (CO) reserves the right to have these boilers inspected by a Navy inspector. /3/
Navy inspector. /3/ 1-6
1-6 APPLICABLE CODESAPPLICABLE CODES. . The latest versions The latest versions of the follof the following codes areowing codes are applicable in the inspection and testing of boilers and pressure vessels:
applicable in the inspection and testing of boilers and pressure vessels:
•
• American Society of Mechanical Engineers (ASME),American Society of Mechanical Engineers (ASME), Boiler and Pressure Boiler and Pressure
Vessel Code (BPVC)
Vessel Code (BPVC). . Published by Published by the American the American Society of Society of MechanicalMechanical Engineers
Engineers,, New York, NY.New York, NY.
•
• American Society of Mechanical Engineers (ASME) CSD-1,American Society of Mechanical Engineers (ASME) CSD-1, Controls and Controls and
Safety Devices for Automatically Fired Boilers
Safety Devices for Automatically Fired Boilers . . Published by Published by the Amthe Americanerican Society of Mechanical Engineers, New York, NY.
Society of Mechanical Engineers, New York, NY.
•
• National Board Inspection Code (NBIC)National Board Inspection Code (NBIC) . . Published by Published by the National the National BoardBoard
of Boiler and Pressure Vessel Inspectors, Columbus, OH. of Boiler and Pressure Vessel Inspectors, Columbus, OH.
•
• National Fire Codes National Fire Codes .. Published by the National Fire ProtectionPublished by the National Fire Protection
Association, Quincy, MA. Association, Quincy, MA.
•
• \3\ UFC 3-240-13FN, /3/ \3\ UFC 3-240-13FN, /3/ Industrial Water Treatment Industrial Water Treatment ..
This UFC governs when a conflict occurs between this UFC and the codes. This UFC governs when a conflict occurs between this UFC and the codes.
CHAPTER 2 CHAPTER 2
INSPECTOR QUALIFICATIONS, CERTIFICATIONS AND LICENSES INSPECTOR QUALIFICATIONS, CERTIFICATIONS AND LICENSES 2-1
2-1 NAVY EMPLOYEESNAVY EMPLOYEES.. Navy employees who perform the inspections,Navy employees who perform the inspections, witness the tests, prepare the reports, and issue the certifications described in this UFC witness the tests, prepare the reports, and issue the certifications described in this UFC must satisfy the following two conditions:
must satisfy the following two conditions:
•
• Possess a valid NAVFACENGCOM Certificate of Competency.Possess a valid NAVFACENGCOM Certificate of Competency. •
• Possess a current license issued by the respective (East or West) SeniorPossess a current license issued by the respective (East or West) Senior
Boiler Inspector of NAVFAC. Boiler Inspector of NAVFAC. 2-1.1
2-1.1 Qualifications for CertificationQualifications for Certification. . Candidates for Candidates for the Certifithe Certificate ofcate of Competency must be qualified as follows:
Competency must be qualified as follows: 2-1.1.1
2-1.1.1 The Candidate Inspector:The Candidate Inspector:
•
• \3\ Graduation from an accredited school, a degree in mechanical\3\ Graduation from an accredited school, a degree in mechanical
engineering plus 1 year of experience in design, construction, operation, engineering plus 1 year of experience in design, construction, operation, or inspection of
or inspection of boilers and pressure boilers and pressure vessels. vessels. Accredited school isAccredited school is defined as an engineering school accredited by the Accreditation Board defined as an engineering school accredited by the Accreditation Board for Engineering Technology (ABET); /3/
for Engineering Technology (ABET); /3/ or
or
•
• /3/ Graduation from an accredited school, a degree in a branch of/3/ Graduation from an accredited school, a degree in a branch of
engineering other than mechanical engineering plus 2 years of experience engineering other than mechanical engineering plus 2 years of experience in design, construction, operation, or inspection of boilers and pressure in design, construction, operation, or inspection of boilers and pressure vessels; /3/
vessels; /3/ or
or
•
• \3\ High school diploma or GED or the equivalent plus 3 years of\3\ High school diploma or GED or the equivalent plus 3 years of
experience in one of the following categories: experience in one of the following categories:
(1)
(1) in boiler in boiler and pressure vessel and pressure vessel construction, operation,construction, operation, maintenance or repair.
maintenance or repair. (2)
(2) in the inspection in the inspection of boilers of boilers and pressure vessels. and pressure vessels. /3/ /3/ 2-1.1.2
2-1.1.2 Job RequirementJob Requirement: : The inspection and The inspection and certification of certification of at least 10 at least 10 boilersboilers and/or unfired pressure vessels per year.
and/or unfired pressure vessels per year. 2-1.2
2-1.2 Certification ProceduresCertification Procedures. . The activity The activity will rwill recommend qualifiedecommend qualified candidates for certification to the NAVFACENGCOM
candidates for certification to the NAVFACENGCOM Boiler Inspection CertificationBoiler Inspection Certification Board via the respective
Board via the respective NAVFAC Senior Boiler NAVFAC Senior Boiler Inspector. Inspector. Include in the letter Include in the letter ofof recommendation:
•
• Current position.Current position. •
• Occupational record.Occupational record. •
• Educational background.Educational background. •
• Supervisor's recommendation.Supervisor's recommendation. •
• Proposed inspection workload. Proposed inspection workload. Minimum workload Minimum workload is the inspection is the inspection of 10of 10
boilers and/or unfired pressure vessels per year as specified by paragraph boilers and/or unfired pressure vessels per year as specified by paragraph 2-1.1.2.
2-1.1.2.
•
• Evidence of successful completion of the National Board of BoilerEvidence of successful completion of the National Board of Boiler
Inspectors (NBBI) qualification examination. Inspectors (NBBI) qualification examination. 2-1.3
2-1.3 Inspector Certification TestInspector Certification Test. . The qualifiThe qualification examination cation examination tests thetests the ability of the candidate to understand the ASME Boiler and Pressure Vessel Code ability of the candidate to understand the ASME Boiler and Pressure Vessel Code (BPVC).
(BPVC). Candidates may wish to attCandidates may wish to attend one of the commend one of the commercially available boilerercially available boiler inspector preparatory schools.
inspector preparatory schools. When requested by the rWhen requested by the respective (East or West)espective (East or West) NAVFAC Senior Boiler Inspector, the board will arrange the formal testing of qualified NAVFAC Senior Boiler Inspector, the board will arrange the formal testing of qualified Navy candidates by members of
Navy candidates by members of the NBBI. the NBBI. Information must be Information must be received at the NBBIreceived at the NBBI prior to the dat
prior to the date of the examination e of the examination to ensure the candidate is to ensure the candidate is scheduled. scheduled. \3\ The\3\ The preparation for and taking of this test can take several weeks of effort, to avoid wasting 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
resources, we strongly recommend the activity discuss and review a candidate’s
qualifications with their respective NAVFAC Senior Boiler Inspector before they prepare qualifications with their respective NAVFAC Senior Boiler Inspector before they prepare and take this exam. /3/
and take this exam. /3/ 2-1.3.1 \3\
2-1.3.1 \3\ EmploymentEmployment. . Only employees Only employees of the of the Navy will Navy will be certifibe certified. ed. Gaps inGaps in employment do not affect certification. /3/
employment do not affect certification. /3/ 2-1.4
2-1.4 Qualifications for NAVFAC LicensingQualifications for NAVFAC Licensing. . The Senior The Senior Boiler Boiler InspectorInspector licenses Navy employed inspectors every 2 years, providing they satisfy the following licenses Navy employed inspectors every 2 years, providing they satisfy the following five conditions:
five conditions:
•
• Possess a valid NAVFACENGCOM Certificate of CompetencyPossess a valid NAVFACENGCOM Certificate of Competency •
• \3\ Are full or part-time employees of the Navy. /3/ \3\ Are full or part-time employees of the Navy. /3/ •
• Maintain an inspection workload of at least 10 boilers and/or unfiredMaintain an inspection workload of at least 10 boilers and/or unfired
pressure vessels per year. pressure vessels per year.
•
• Conduct inspections in accordance with this UFC.Conduct inspections in accordance with this UFC. •
• Are not employed in a capacity that constitutes a conflict of interest, asAre not employed in a capacity that constitutes a conflict of interest, as
defined in paragraph 2-1.5. defined in paragraph 2-1.5.
•
• Operate or maintain any of the boilers to be inspected.Operate or maintain any of the boilers to be inspected. •
• Supervise the operation or maintenance of such boilers.Supervise the operation or maintenance of such boilers. •
• Report directly to the boiler operations or maintenance supervisor in anyReport directly to the boiler operations or maintenance supervisor in any
capacity of their employment. capacity of their employment. 2-1.6
2-1.6 Inspector SupportInspector Support. . Before licensing inspectors, Before licensing inspectors, NAVFAC will NAVFAC will seek theseek the following assurances from the employing activity:
following assurances from the employing activity:
•
• Current applicable codes, equipment, and tools are maintained andCurrent applicable codes, equipment, and tools are maintained and
available to the inspector. available to the inspector.
•
• Records of inspection are maintained and available for examination byRecords of inspection are maintained and available for examination by
NAVFAC’s Senior Boiler Inspectors and the activity’s boiler inspection NAVFAC’s Senior Boiler Inspectors and the activity’s boiler inspection program manager.
program manager.
•
• The inspector will be available to other activities for inspection on aThe inspector will be available to other activities for inspection on a
reimbursable basis, depending on workload. reimbursable basis, depending on workload. 2-2
2-2 CONTRACT EMPLOYEESCONTRACT EMPLOYEES. . All persons All persons employed by employed by contractors thatcontractors that perform the inspections, witness the tests, prepare the reports, and issue the certificates perform the inspections, witness the tests, prepare the reports, and issue the certificates described in this UFC must, as a minimum, \3\ must meet the qualifications and /3/ described in this UFC must, as a minimum, \3\ must meet the qualifications and /3/ possess a Certificate of Competency or the equivalent (see note 3 of Table 2-1) issued 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 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
United States or Canada that is a member of the NBBI except for contractors performing inspections
performing inspections outside the U.S. outside the U.S. Requirements for Requirements for contract employees outsidecontract employees outside the U.S. vary depending on the country; check with your respective (East or West) the U.S. vary depending on the country; check with your respective (East or West) NAVFAC Senior Boiler Inspector.
NAVFAC Senior Boiler Inspector. 2-3
2-3 CREDENTIAL REQUIREMENTSCREDENTIAL REQUIREMENTS. . NAVFACENGCOM NAVFACENGCOM Form Form 9-11014/329-11014/32 (3-67),
(3-67), Inspection Certificates Inspection Certificates , for boilers and unfired pressure vessels may only be, for boilers and unfired pressure vessels may only be issued by inspectors who meet one of the two category requirements in Table 2-1. issued by inspectors who meet one of the two category requirements in Table 2-1.
Table
Table 2-1 2-1 Credentials Credentials RequiredRequired Category
Category Credentials RequiredCredentials Required State Certificate of State Certificate of Competency Competency NAVFACENGCOM NAVFACENGCOM Certificate of Certificate of Competency Competency NAVFAC License/ NAVFAC License/ Authorization to Authorization to Inspect Inspect 1. Contract 1. Contract Inspector Inspector X X XX 2. Civil Service 2. Civil Service Inspector Inspector X X XX Notes: Notes: 1.
1. A A NAVFACENGCOM NAVFACENGCOM Certificate Certificate of of Competency Competency issued issued after after September September 19831983 requires passing the NBBI
requires passing the NBBI examination. examination. A NAVFACENGCOM Certificate of A NAVFACENGCOM Certificate of CompetencyCompetency issued before September 1983
issued before September 1983 required passing a required passing a Navy examination. Navy examination. In addition,In addition,
authorization to issue NAVFACENGCOM Inspection Certificates requires a NAVFAC license. authorization to issue NAVFACENGCOM Inspection Certificates requires a NAVFAC license. 2.
2. \3\ \3\ A A contract contract inspector inspector may may not not be be employed employed by by a a contractor contractor utilized utilized to to operate operate oror maintain the equipment to be certified. /3/
maintain the equipment to be certified. /3/ 3.
3. In In addition addition to to the the State State Certificate Certificate of of Competency, Competency, contract contract inspectors inspectors must must \3\ \3\ meetmeet the qualifications outlined in paragraphs 2-1.1 and /3/ have written Authorization to Inspect the qualifications outlined in paragraphs 2-1.1 and /3/ have written Authorization to Inspect from the respective (East or West)
from the respective (East or West) NAVFAC Senior Boiler Inspector. NAVFAC Senior Boiler Inspector. An official letter An official letter from afrom a member jurisdiction of the NBBI stating that the individual has passed the NBBI examination member jurisdiction of the NBBI stating that the individual has passed the NBBI examination can be considered equivalent to the State Certificate of Competency.
can be considered equivalent to the State Certificate of Competency.
2-4
2-4 QUALITY ASSURANCE FOR INSPECTIONSQUALITY ASSURANCE FOR INSPECTIONS. . Appendix B Appendix B shows tshows thehe NAVFAC Boiler and Unfired Pressure Vessel Inspection Program Quality Assurance NAVFAC Boiler and Unfired Pressure Vessel Inspection Program Quality Assurance Organization.
Organization. This organization provides a This organization provides a method of monitoring tmethod of monitoring the performance ofhe performance of Navy and contract inspections.
Navy and contract inspections. The key element of the The key element of the organization is the NAVFACorganization is the NAVFAC Senior Boiler Inspector.
Senior Boiler Inspector. The duties and qualifications of The duties and qualifications of the NAVFAC Senior Boilthe NAVFAC Senior Boilerer Inspector are outlined in Appendix C.
Inspector are outlined in Appendix C. 2-5
2-5 GUIDELINES FOR INSPECTION CONTRACTSGUIDELINES FOR INSPECTION CONTRACTS. . The The inspection inspection ofof boilers and pressure vessels is highly specialized work requiring qualified personnel boilers and pressure vessels is highly specialized work requiring qualified personnel and, in many cases, specialized
and, in many cases, specialized testing equipment. testing equipment. The Contracting Officer The Contracting Officer isis
responsible for ensuring the quality of inspections performed by companies awarded responsible for ensuring the quality of inspections performed by companies awarded Navy inspection contracts.
Navy inspection contracts. 2-5.1
2-5.1 Contractor AbilitiesContractor Abilities. . Contractors’ and Contractors’ and their inspectors’ their inspectors’ ability to ability to provideprovide adequate inspections can be
adequate inspections can be highly variable. highly variable. The NBBI commissiThe NBBI commissions inspectors ofons inspectors of jurisdictions, which have adopted and administer one or more sections of the ASME jurisdictions, which have adopted and administer one or more sections of the ASME
Boiler and Pressure Vessel Code
Boiler and Pressure Vessel Code as a legal requirement and has a representativeas a legal requirement and has a representative
serving as a member of the ASME Conference Committee; or to an insurance company serving as a member of the ASME Conference Committee; or to an insurance company which is licensed by a
which is licensed by a U.S. state to U.S. state to write boiler and write boiler and pressure vessel insurance. pressure vessel insurance. AnAn Authorized Inspection Agency is not working within the NBBI charter when performing Authorized Inspection Agency is not working within the NBBI charter when performing
military reservations and
military reservations and the Government does not ithe Government does not insure its equipment. nsure its equipment. Furthermore,Furthermore, Authorized Inspection Agencies usually do not qualify as small businesses.
Authorized Inspection Agencies usually do not qualify as small businesses. 2-5.2 \3\
2-5.2 \3\ Companies Other than Authorized Inspection AgenciesCompanies Other than Authorized Inspection Agencies. Quality. Quality assurance for such companies may not be structured according to a standard
assurance for such companies may not be structured according to a standard recognized by the NBBI or
recognized by the NBBI or may even be non-existent. may even be non-existent. Contracting officers must Contracting officers must ensureensure adequate inspections by requiring qualifications of the contractor before awarding the adequate inspections by requiring qualifications of the contractor before awarding the contract.
contract. These assurances, at a minimum, These assurances, at a minimum, include requiring the include requiring the contractor to supplycontractor to supply inspectors meeting the credential requirements of paragraphs 2-1.1, 2-1.2 and 2-3. /3/ inspectors meeting the credential requirements of paragraphs 2-1.1, 2-1.2 and 2-3. /3/ 2-5.3
2-5.3 AssistanceAssistance. . When an activity When an activity elects to elects to administer its administer its own inspectionown inspection contract, NAVFAC Senior Boiler Inspectors can provide assistance to the Contracting contract, NAVFAC Senior Boiler Inspectors can provide assistance to the Contracting Officer by reviewing the contract requirements and determining the suitability of a Officer by reviewing the contract requirements and determining the suitability of a company to
company to perform perform inspections. inspections. The NAVFAC The NAVFAC Senior Boiler Senior Boiler Inspectors provide Inspectors provide thisthis service on a reimbursable
service on a reimbursable basis. basis. They also provide quality They also provide quality control by monitoring control by monitoring thethe performance of contractors
performance of contractors and their inspectors. and their inspectors. Upon satisfactory review, Upon satisfactory review, the NAVFACthe NAVFAC Senior Boiler Inspector can issue an Authorization to Inspect to the firms qualifying
Senior Boiler Inspector can issue an Authorization to Inspect to the firms qualifying inspectors for the term
inspectors for the term of the contract. of the contract. The Authorization to Inspect The Authorization to Inspect identifies the abilityidentifies the ability of the inspector to perform the work satisfactorily and authorizes the inspector to sign 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 the Inspection Report-Boiler or the Unfired Pressure Vessel Report and issue the Inspection Certificate, NAVFAC Form 9-11014/32
Inspection Certificate, NAVFAC Form 9-11014/32 (3-67).(3-67). 2-5.4
2-5.4 Activity Administered ContractsActivity Administered Contracts. . When When the activithe activity’s Contrty’s Contractingacting Officer elects to administer the contracts, the Contracting Officer should require the Officer elects to administer the contracts, the Contracting Officer should require the contractors to provide enough information to determine positively that the firm has contractors to provide enough information to determine positively that the firm has qualified inspectors and has the
qualified inspectors and has the capability to do the capability to do the required work. required work. The scope of workThe scope of work for the inspection contract should include the number, function, type (such as boiler or 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’ pressure vessel), construction (such as the American Society of Mechanical Engineers’ (ASME)
(ASME) Boiler and Pressure Vessel Code Boiler and Pressure Vessel Code or military specification), capacity, andor military specification), capacity, and pressure rating of each
pressure rating of each vessel. vessel. In addition, the In addition, the contract will rcontract will require that the contractorequire that the contractor have:
have:
•
• Inspectors with credentials complying with \3\ paragraphs 2-1.1, 2-2, andInspectors with credentials complying with \3\ paragraphs 2-1.1, 2-2, and
2-3. /3/ 2-3. /3/
•
CHAPTER 3 CHAPTER 3
INSPECTION AND TEST FREQUENCIES INSPECTION AND TEST FREQUENCIES 3-1
3-1 BOILERSBOILERS.. Inspection and test frequencies for boilers are shown in Table 3-1.Inspection and test frequencies for boilers are shown in Table 3-1. \2\ Table
\2\ Table 3-1 3-1 Inspection and Inspection and Test Frequencies Test Frequencies - Boilers- Boilers
Item Internal
Item Internal
Inspection Inspection
External Insp. & External Insp. & Operational Test Operational Test Hydrostatic Test Hydrostatic Test Boilers – Wet Boilers – Wet or dry lay-up or dry lay-up At least annually. At least annually. At resumption of At resumption of active service. active service. External at least External at least annually. annually. External and External and operational at operational at resumption of active resumption of active service. service.
Tightness test at resumption of Tightness test at resumption of active service. active service. Boilers –Heating Boilers –Heating ASME Section IV ASME Section IV Hot Water Heating Hot Water Heating or Hot Water or Hot Water Supply Boilers Supply Boilers Steam Heating Steam Heating Boilers Boilers \3\ (deletion) /3/At \3\ (deletion) /3/At least every three least every three years. After any years. After any repair or alteration of repair or alteration of pressure parts. \3\ pressure parts. \3\ Check firesides on oil Check firesides on oil fired units annually fired units annually /3/
/3/
At least annually. At least annually. After any repair or After any repair or alteration of pressure alteration of pressure parts. parts. At least annually. At least annually. After any alteration or After any alteration or modification to modification to boilers, control boilers, control equipment, or equipment, or Auxiliaries. Auxiliaries. At least annually. At least annually. After any alteration or After any alteration or modification to modification to boilers, control boilers, control equipment, or equipment, or auxiliaries. auxiliaries.
Strength test at least once Strength test at least once every \3\ 3 /3/ years. \3\ every \3\ 3 /3/ years. \3\
(deletion) /3/ Strength test after (deletion) /3/ Strength test after repair or alteration of pressure repair or alteration of pressure parts. Additional times at the parts. Additional times at the discretion of the inspector. discretion of the inspector.
Strength test at least once Strength test at least once every \3\ 3 /3/ years. Tightness every \3\ 3 /3/ years. Tightness test all other years. Strength test all other years. Strength test after repair or alteration of test after repair or alteration of pressure parts. Additional times pressure parts. Additional times at the discretion of the
at the discretion of the inspector. inspector. Boilers – Power Boilers – Power ASME Section I ASME Section I High Pressure High Pressure Steam and Water Steam and Water Boilers, Boilers, MUSE MUSE (see note 1) (see note 1) At least annually. At least annually. After any repair or After any repair or alteration of pressure alteration of pressure parts. parts. At least annually. At least annually. After any alteration or After any alteration or modification to modification to boilers, control boilers, control equipment, or equipment, or auxiliaries. auxiliaries.
Strength test at least once Strength test at least once every 3 years. Tightness test all every 3 years. Tightness test all other years. Strength test after other years. Strength test after repair or alteration of pressure repair or alteration of pressure parts. Additional times at the parts. Additional times at the discretion of the inspector. discretion of the inspector. Domestic Hot Domestic Hot Water Heaters Water Heaters (HLW) (HLW) ASME Section IV ASME Section IV If \3\ practical /3/: At If \3\ practical /3/: At least every two years least every two years
At least every two At least every two years.
years.
Discretion of inspector. Note: Discretion of inspector. Note: Glass-lined vessels not to Glass-lined vessels not to exceed Maximum Allowable exceed Maximum Allowable Working Pressure (MAWP). Working Pressure (MAWP).
Notes: Notes:
1.
1. Additionally, Additionally, MUSE MUSE boilers boilers and and other other portable portable boilers boilers are are to to be be inspected inspected externally externally andand internally and certified each time they are
internally and certified each time they are relocated from one activity to anotrelocated from one activity to another. her. MUSE steam coil typeMUSE steam coil type boilers are exempt from annual inspections while in dry or wet lay-up.
boilers are exempt from annual inspections while in dry or wet lay-up. 2.
2. All All manhole manhole and and handhole handhole gaskets gaskets must must be be replaced replaced after after application application of of the the strength strength testtest unless they are of the non-compressible steel
unless they are of the non-compressible steel type.type. /2/
/2/ 3.2
3.2 UNFIRED PRESSURE VESSELSUNFIRED PRESSURE VESSELS.. Inspection and test frequencies forInspection and test frequencies for unfired pressure vessels are as shown in Tables 3-2, 3-3, or 3-4, as applicable.
unfired pressure vessels are as shown in Tables 3-2, 3-3, or 3-4, as applicable. \2\ Table 3-2
\2\ Table 3-2 Inspection and Test Inspection and Test Frequencies - Unfired Frequencies - Unfired Pressure Vessels (UPVs)Pressure Vessels (UPVs)
Item
Item Internal Inspection Internal Inspection External External Insp. Insp. && Operational Test Operational Test Hydrostatic Test Hydrostatic Test Pressure Pressure Vessels & Vessels & Heat Heat Exchangers Exchangers (15 to 250 psig (15 to 250 psig MAWP) MAWP)
Every 3 years or more Every 3 years or more frequently as
frequently as determined by determined by
procedures in the NBBI procedures in the NBBI Code for vessels
Code for vessels subject to corrosion. subject to corrosion. After any repair or After any repair or alteration of pressure alteration of pressure parts.
parts.
For LPG see Table 3-3. For LPG see Table 3-3.
Every 3 years or more Every 3 years or more frequently as determined by frequently as determined by procedures in the NBBI procedures in the NBBI Code for vessels subject to Code for vessels subject to corrosion.
corrosion. After After any rany repairepair or alteration of pressure or alteration of pressure parts.
parts. Inspection Inspection mustmust include test and calibration include test and calibration of safety valves and
of safety valves and pressure and temperature pressure and temperature gages.
gages.
After repair or alteration of After repair or alteration of pressure
pressure parts. parts. AdditionalAdditional times at the discretion of the times at the discretion of the inspector. inspector. Pressure Pressure Vessels & Vessels & Heat Heat Exchangers Exchangers (greater than (greater than 250 psig MAWP) 250 psig MAWP)
Every 3 years or more Every 3 years or more frequently as
frequently as determined by determined by
procedures in the NBBI procedures in the NBBI Code for vessels
Code for vessels subject to corrosion. subject to corrosion. After any repair or After any repair or alteration of pressure alteration of pressure parts.
parts.
For LPG see Table 3-3. For LPG see Table 3-3.
Every 3 years or more Every 3 years or more frequently as determined by frequently as determined by procedures in the NBBI procedures in the NBBI Code for vessels subject to Code for vessels subject to corrosion.
corrosion. After After any rany repairepair or alteration of pressure or alteration of pressure parts.
parts. Inspection Inspection mustmust include test and calibration include test and calibration of safety valves and
of safety valves and pressure and temperature pressure and temperature gages.
gages.
Every 6
Every 6 years of years of service. service. IfIf inspection shows no sign of inspection shows no sign of corrosion, the test may be corrosion, the test may be deferred until the next deferred until the next inspection, but must be inspection, but must be tested at least every 12 tested at least every 12 years.
years.
After any repair or alteration After any repair or alteration of
of pressure pressure parts. parts. AdditionalAdditional times at the discretion of the times at the discretion of the inspector.
inspector. Notes:
Notes: 1.
1. Test Test frequencies frequencies and and inspections inspections may may be be increased increased at at the the discretion discretion of of the the inspector inspector or or owner owner ifif the UPV is subjected, by the nature of its service, to an accumulation of deposits or thermal or
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
mechanical stresses that could affect the integrity of the vessel.vessel. 2.
2. A A hydrostatic hydrostatic pressure pressure test test not not to to exceed exceed 1.5 1.5 times times the the MAWP MAWP for for BPVC BPVC ASME ASME Section Section VIIIVIII Division 1 vessels and 1.25 times the MAWP for BPVC ASME Section VIII Division 2 vessels may be Division 1 vessels and 1.25 times the MAWP for BPVC ASME Section VIII Division 2 vessels may be substituted for the internal inspection.
substituted for the internal inspection. 3.
3. If If the the tube tube bundle bundle of of the the heat heat exchangers exchangers is is a a higher higher pressure pressure than than the the shell, shell, both both sides sides of of thethe heat exchanger must be hydrostatically tested.
heat exchanger must be hydrostatically tested. 4.
4. Unfired Unfired pressure pressure vessels vessels are are to to be be inspected inspected externally externally and and re-certified re-certified anytime anytime they they areare relocated or moved.
relocated or moved. It is the It is the activity’s responsibility to activity’s responsibility to inform the inspector inform the inspector of the move. of the move. For UPVsFor UPVs designed and built to be portable, reinspections are not required after a move as long as the vessel does designed and built to be portable, reinspections are not required after a move as long as the vessel does not leave the base.
not leave the base. The inspector will indicate the UPV is “portable” on The inspector will indicate the UPV is “portable” on all appropriate reports. Once aall appropriate reports. Once a UPV designed to be portable is relocated outside the base, any certified NAVFAC boiler inspector or UPV designed to be portable is relocated outside the base, any certified NAVFAC boiler inspector or NAVFAC-approved contract boiler inspector may
deployment period but not exceeding the original cer
deployment period but not exceeding the original certificate's expiration date. tificate's expiration date. A copy of the originalA copy of the original inspection report and certificate must accompany the
inspection report and certificate must accompany the pressure vessel during the deployment/transferpressure vessel during the deployment/transfer period.
period. The extent of reinspection aftThe extent of reinspection after the move for pressure vessels designed er the move for pressure vessels designed to be portable consiststo be portable consists of an external inspection to check for damage incurred while in transit, a visual examination to determine of an external inspection to check for damage incurred while in transit, a visual examination to determine if the installation is conforming with applicable codes and a visual examination to verify that all code if the installation is conforming with applicable codes and a visual examination to verify that all code required safety devices are
required safety devices are installed. installed. If any of these inspection processes If any of these inspection processes indicates discrepancies withindicates discrepancies with the pressure vessel and/or installation then the full inspection requirements of this UFC apply.
the pressure vessel and/or installation then the full inspection requirements of this UFC apply. 5.
5. Use Use of of ultrasonic ultrasonic thickness thickness (UT) (UT) testing testing in in addition addition to to internal internal inspection inspection is is highly highly encouraged.encouraged. /2/
\2\ Table 3-3
\2\ Table 3-3 Inspection and Test Inspection and Test Frequencies - UPVs Frequencies - UPVs (Special Cases)(Special Cases) Item
Item Internal Internal Inspection Inspection External External Insp. Insp. && Operational Test Operational Test Hydrostatic Test Hydrostatic Test MILSPEC MILSPEC Vessels Vessels See note 1 See note 1 Every 3 years of Every 3 years of service. Inspection service. Inspection must include test and must include test and calibration of safety calibration of safety valves and pressure and valves and pressure and temperature gages. temperature gages. See Note 1. See Note 1. Every 3 years of Every 3 years of service. Inspection service. Inspection must include test and must include test and calibration of safety calibration of safety valves and pressure and valves and pressure and temperature gages. temperature gages.
See note 2 See note 2
For MILSPEC Vessels (Pressure Vessels Design, Built and Stamped to For MILSPEC Vessels (Pressure Vessels Design, Built and Stamped to MIL-F-22606) or any non-ASME vessels see Note 3.
22606) or any non-ASME vessels see Note 3. \3\
\3\ (deletion) (deletion) /3/ /3/ \3\ \3\ (deletion) (deletion) /3/ /3/ \3\ \3\ (deletion) (deletion) /3/ /3/ \3\ \3\ (deletion) (deletion) /3/ /3/ For MILSPEC Vessels (Pressure Vessels Design, Built and Stamped to For MILSPEC Vessels (Pressure Vessels Design, Built and Stamped to MIL-F-22606) or any non-ASME vessels see Note 3.
22606) or any non-ASME vessels see Note 3. Carbon Dioxide Carbon Dioxide (CO2) Storage (CO2) Storage Tanks Tanks See note 4 See note 4
Only if the vessel has Only if the vessel has been depressurized or been depressurized or has been opened to the has been opened to the atmosphere other than atmosphere other than for immediate repair or for immediate repair or maintenance; or when maintenance; or when directed by an directed by an authorized boiler authorized boiler inspector. inspector.
Every 3 years; or after Every 3 years; or after any repair or alteration any repair or alteration of pressure parts; or of pressure parts; or when directed by an when directed by an authorized boiler authorized boiler inspector. inspector. See note 5 See note 5
After any repair or alteration After any repair or alteration of pressure parts; or when of pressure parts; or when directed by an authorized directed by an authorized boiler
boiler inspector. inspector. CautionCaution should be taken in performing should be taken in performing hydrostatic
hydrostatic testing. testing. It It isis essential that all water be essential that all water be removed from the vessel removed from the vessel before returning it to service. before returning it to service. Water will freeze and create Water will freeze and create blockages. blockages. Liquid Petroleum Liquid Petroleum Gas (LPG) Gas (LPG) Storage Tanks Storage Tanks
Every 3 years or more Every 3 years or more frequently as
frequently as determined by determined by
procedures in the NBBI procedures in the NBBI Code.
Code. After After any any repairrepair or alteration of pressure or alteration of pressure parts.
parts. Use Use ultrasonicultrasonic testing instead of visual testing instead of visual internal inspection. internal inspection.
Every 3 years or more Every 3 years or more frequently as
frequently as determined by determined by
procedures in the NBBI procedures in the NBBI Code.
Code. After After any rany repairepair or alteration of pressure or alteration of pressure parts.
parts. Bench Bench test test oror replace the UL or ASME replace the UL or ASME safety valves every 6 safety valves every 6 years.
years. See note 6 See note 6
After any repair or alteration After any repair or alteration of pressure parts, otherwise of pressure parts, otherwise at the discretion of the at the discretion of the inspector.
inspector.
Notes: Notes: 1.
1. A A visual visual internal internal inspection inspection for for MILSPEC MILSPEC vessels vessels \3\ \3\ (deletion) (deletion) /3/ /3/ is is not not required required every every 3 3 yearsyears provided the vessel (or vessel bank) successfully passes a gas analysis with oil mist plus particulate 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 matter concentration equal to or less than 5 milligrams per cubic meter and dew point equal to or colder than -40
than -40°°C (-40C (-40°°F); and an ultrasonic thickness measurement check in accordance with Paragraph 5-F); and an ultrasonic thickness measurement check in accordance with Paragraph
5-4.2.
4.2. The maximum acceptable interval The maximum acceptable interval between visual inspections is between visual inspections is 12 years.12 years. 2.
2. At At intervals intervals indicated indicated inin Naval Ship’s Technical Manual Naval Ship’s Technical Manual S9086-SY-STM-010, Chapter 551,S9086-SY-STM-010, Chapter 551, vessels will be required to be tested a
vessels will be required to be tested according to “551-1.14.1”. ccording to “551-1.14.1”. The flask(s) requiring re-ceThe flask(s) requiring re-certification isrtification is to be tested by Ultrasonic
to be tested by Ultrasonic (UT) testing or Acoustic Emission (AE) t(UT) testing or Acoustic Emission (AE) testing. esting. Hydrostatic testing is beingHydrostatic testing is being eliminated because it does not provide data on flask wall cracking which has been determined to be the eliminated because it does not provide data on flask wall cracking which has been determined to be the primary failure mode.”
primary failure mode.” 3.
3. Activities Activities may may elect elect to to prepare prepare and and inspect inspect MILSPEC MILSPEC vessels vessels using using NAVSEASYSCOM NAVSEASYSCOM boilerboiler inspectors according to
