Boiler Safety Administrative Rules - Adoption Justification

JUSTIFICATION FOR ADMINISTRATIVE RULE ADOPTION
Boilers
16 TAC Chapter 65, amendments Subchapter A, §65.1 and §65.2; Subchapter C, §§65.12 - 65.15; Subchapter D §65.25 and §65.30; Subchapter G, §65.45; Subchapter J, §65.72; Subchapter N, §65.217; Subchapter O, §65.300; Subchapter R, §§65.601, 65.603, 65.606-65.609; repeal Subchapter I, §65.63; and new Subchapter I, §65.63 and §65.64

The Texas Commission of Licensing and Regulation (Commission) adopts amendments to  existing rules at 16 Texas Administrative Code (TAC), Chapter 65, Subchapter A, §65.1 and §65.2; Subchapter C, §§65.13 - 65.15; Subchapter D §65.25; Subchapter E, §65.30; Subchapter G, §65.45; Subchapter J, §65.72; Subchapter N, §65.217; Subchapter O, §65.300; Subchapter R, §§65.601, 65.603, 65.606-65.609; proposes repeal of current Subchapter I, §65.63; and proposes new Subchapter I, §65.63 and §65.64, regarding the Boilers program, without changes to the proposed text as published in the October 6, 2017, issue of the Texas Register (42 TexReg 5307). The rules will not be republished.

The Commission also adopts amendments to existing rules at 15 TAC, Chapter 65, Subchapter C, §65.12, with changes to the proposed text as published in the October 6, 2017, issue of the Texas Register (42 TexReg 5307). The rule will be republished.

The Texas Legislature enacted House Bill 3257 (H.B. 3257), 85th Legislature, Regular Session (2017), which set the periodicity of portable boiler inspections. Editorial corrections and clarifications are also being adopted. The adopted amendments, repeal and new rules are necessary to implement H.B. 3257.

The adopted amendments to §65.1 corrects the statutory authority.

The adopted amendments to §65.2 removes the definitions for “existing installations” and “new installations” since the terms are not used in this program. Editorial changes are also made to renumber the section accordingly. 

The adopted amendments to §65.12 clarifies that the current certificate of operation is to be displayed under glass in a conspicuous place on or near the boiler.

The adopted amendments to §65.13 clarifies the process to test-fire and operate a newly installed boiler and the Temporary Operating Permit.

The adopted amendments to §65.14 corrects the name of the National Board Commission and requires the applicant to demonstrate they meet eligibility requirements.

The adopted amendments to §65.15 changes the title of the section to correctly name boiler certification requirements and clarify when inspection reports and written authorization are needed.

The adopted amendments to §65.25 changes the title of the section to correctly name authorized inspector requirements. 

The adopted amendments to §65.30 clarifies the requirement for the applicant to demonstrate they meet eligibility requirements.

The adopted amendments to §65.45 removes “portable boiler” language in the title and section to be placed in a new section.

The adopted repeal of current §65.63 is to renumber it to proposed new §65.64.

The adopted new §65.63 establishes the requirements of H.B. 3257.

The adopted amendments to §65.72 further identify which stamped tag designates the boiler as condemned and clarify the decal which shall be altered/defaced.

The adopted amendments to §65.217 adds a reference and makes an editorial change.

The adopted amendments to §65.300 corrects the title to reflect all fees and specifies who is required to pay each fee.

The adopted amendments to §65.601 clarifies existing language to reflect practice and makes editorial changes.

The adopted amendments to §65.603 clarifies where the record of calibration must be placed.

The adopted amendments to §65.606 corrects the title of the section to reflect practice.

The adopted amendments to §65.607 makes editorial changes.

The adopted amendments to §65.608 makes editorial changes.

The adopted amendments to §65.609 makes editorial changes. 

The Department drafted and distributed the proposed rules to persons internal and external to the agency. The proposed rules were published in the October 6, 2017, issue of the Texas Register (42 TexReg 5307). The deadline for public comments was November 6, 2017. The Department did not receive any comments on the proposed rules during the 30-day public comment period.

The Board of Boiler Rules (Board) met on November 14, 2017, and recommended adopting the proposed rules with changes to §65.12(2) conforming that subsection to Health and Safety Code §755.029(c). At its meeting on December 15, 2017, the Commission adopted the proposed rules with changes as recommended by the Board.

The amendments are adopted under Texas Occupations Code, Chapter 51, which authorize the Commission, the Department’s governing body, to adopt rules as necessary to implement these chapters and any other law establishing a program regulated by the Department.

The statutory provisions affected by the adoption are those set forth in Texas Occupations Code, Chapter 51 and Health and Safety Code, Chapter 755. No other statutes, articles, or codes are affected by the adoption.

Subchapter A. General Provisions

65.1 Authority

This chapter is promulgated under authority of Texas Health and Safety Code, Chapter 755 and Texas Occupations Code, Chapter 51.

65.2. Definitions

The following words and terms, when used in this chapter, shall have the following meanings, unless the context clearly indicates otherwise.

(1) Alteration--A change in the item described on the original Manufacturer's Data Report which affects the pressure containing capability of the pressure retaining item. Nonphysical changes such as an increase in the maximum allowable working pressure (Internal or External), increase in design temperature, or a reduction in minimum temperature of a pressure-retaining item shall be considered an alteration.

(2) Application for Certification--The completed first inspection report.

(3) Approved--Agreed to by the executive director.

(4) ASME--The American Society of Mechanical Engineers Boiler and Pressure Vessel Code, code cases, and interpretations adopted by the council of the society.

(5) Authorized Inspection Agency (In-service)--An entity accredited by the National Board meeting NB-369, "Qualifications and Duties for Authorized Inspection Agencies Performing In-service Activities and Qualifications for Inspectors of Boilers and Pressure Vessels".

(6) Authorized Inspection Agency (New Construction--ASME Activities)--An entity accredited by the National Board meeting the qualification and duties of NB-360, "Criteria for Acceptance of Authorized Inspection Agencies for New Construction".

(7) Authorized Inspector--An inspector employed by an authorized inspection agency holding a commission issued by the executive director.

(8) AWP--The allowable working pressure at which the boiler can safely operate.

(9) Board--The Board of Boiler Rules.

(10) "Boiler" means:

(A) a heating boiler;

(B) a nuclear boiler;

(C) a power boiler;

(D) an unfired steam boiler; or

(E) a process steam generator.

(11) Boiler External Piping--The piping which begins where the ASME Section I or Section VIII, Division 1, 2, or 3 boiler proper or separately fired superheater terminates at:

(A) the first circumferential joint for welding end connections; or

(B) the face of the first flange in bolted flange connections; or

(C) the first threaded joint in that type of connection; and which extends up to and including the valve or valves required by ASME.

(12) Certificate Inspection--The required internal or external boiler inspection, the report of which is used by the chief inspector to decide whether to issue a certificate of operation.

(13) Certificate of Operation--A certificate issued by the executive director to allow the operation of a boiler.

(14) Changeover Valve--A valve, which allows two redundant pressure relief valves to be installed for the purpose of changing from one pressure relief valve to the other while the boiler is operating and designed such that there is no intermediate position where both pressure relief valves are isolated from the boiler.

(15) Chief Inspector--The inspector appointed in accordance with Texas Health and Safety Code, §755.023.

(16) Code--ASME Code.

(17) Commission--The Texas Commission of Licensing and Regulation.

(18) Competent Attendant--An individual who has been trained to properly operate, start up, shut down, respond to emergencies and maintain control of the boiler in safe operating condition.

(19) Condemned Boiler--A boiler inspected and declared unfit for further service by the chief inspector, the deputy inspector, or the executive director.

(20) Department--Texas Department of Licensing and Regulation.

(21) Deputy Inspector--An inspector appointed by the executive director.

(22) Disconnected Boiler--A boiler in which all fuel, water, steam and electricity are removed from any connection on the boiler. These connections shall provide an isolated gap and the source shall be safely isolated to prevent potential leaks or electrical hazards.

(23) Electric Boiler--A boiler in which the source of heat is electricity, such as an electrode type boiler and an immersion resistance element type boiler.

(24) Electrode Type Boiler--An electric boiler in which heat is generated by the passage of electric current using water as the conductor.

(25) Executive Director--The executive director of the department.

(26) External Inspection--An inspection of the exterior of a boiler and its appurtenances that is made, if possible, while the boiler is in operation.

(27) Heat Recovery Steam Generator (HRSG)--A boiler which produces steam where its principle source of thermal energy is a hot gas stream having high ramp rates, such as the exhaust of a gas turbine.

(28) Heating Boiler--A steam heating boiler, hot water heating boiler, hot water supply boiler, or potable water heater that is directly fired with oil, gas, solar energy, electricity, coal, or other solid or liquid fuel.

(29) High-Temperature Water Boiler--A water boiler designed for operation at pressures exceeding 160 pounds per square inch gage (1100 kilopascals) or temperatures exceeding 250 degrees Fahrenheit (121 degrees Celsius).

(30) Hot Water Heating Boiler--A boiler designed for operation at a pressure not exceeding 160 pounds per square inch gage (1100 kilopascals) or temperatures not exceeding 250 degrees Fahrenheit (121 degrees Celsius) at or near the boiler outlet.

(31) Hot Water Supply Boiler--A boiler designed for operation at pressures not exceeding 160 pounds per square inch gage (1100 kilopascals) or temperatures not exceeding 250 degrees Fahrenheit (121 degrees Celsius) at or near the boiler outlet if the boiler's heat input exceeds 200,000 British thermal units per hour (58.6 kilowatts); water temperature exceeds 210 degrees Fahrenheit (99 degrees Celsius); or nominal water-containing capacity exceeds 120 gallons (454 Liters).

(32) Immersion Resistance Element Type Boiler--An electric boiler in which heat is generated by the passage of an electric current through a resistance heating element immersed in water.

(33) Inspection Agency--An authorized inspection agency providing inspection services.

(34) Inspector--The chief inspector, a deputy inspector, or an authorized inspector.

(35) Install--To place, position or fit into position and then to connect, change or modify in such a manner as to bring the boiler into service.

(36) Installation--The act of installing a boiler or associated equipment.

(37) Internal inspection--A complete and thorough inspection of the interior waterside and fireside areas of a boiler as construction allows.

(38) Maximum Allowable Working Pressure (MAWP)--The greatest pressure at which a boiler is designed to operate.

(39) Metric (SI)--An international system of measurement.

(40) Metrication--The process of converting between US customary units and metric (SI) units.

(41) Modular Boiler--A steam or hot water heating assembly consisting of a group of individual boilers called modules, intended to be installed as a unit, with a single inlet and single outlet. Modules may be under one jacket or may be individually jacketed.

(42) Multiple Pressure Steam Generator--A boiler consisting of several sections of heat exchange surface designed for different pressure levels.

(43) National Board--The National Board of Boiler and Pressure Vessel Inspectors.

(44) National Board Inspection Code--The manual for boiler and pressure vessel inspectors published by the National Board.

(45) Nominal--The accepted ASME standard used to designate a size or capacity of an item.

(46) Non-Code Boiler--A complete boiler not constructed to the appropriate ASME Code.

(47) Nonstandard Boiler--A boiler that does not qualify as a standard boiler.

(48) Nuclear Boiler--A nuclear power plant system, including its pressure vessels, piping systems, pumps, valves, and storage tanks that produces and controls an output of thermal energy from nuclear fuel and the associated systems essential to the function of the power system.

(49) Owner or Operator--Any person, firm, or corporation owning or operating boilers within the State of Texas.

(50) Person--An individual, corporation, partnership, association or other legal entity.

(51) Pool Heater--A hot water supply boiler or a potable water heater designed to provide hot water to a pool.

(52) Portable Boiler--A boiler primarily intended for use at a temporary location.

(53) Potable Water Heater--A boiler designed for operation at pressures not exceeding 160 pounds per square inch gage (1100 kilopascals) and water temperatures not exceeding 210 degrees Fahrenheit (99 degrees Celsius) if the boiler's heat input exceeds 200,000 British thermal units per hour (58.6 kilowatts) or nominal water-containing capacity exceeds 120 gallons (454 liters).

(54) Power Boiler--A high-temperature water boiler or a boiler in which steam is generated at a pressure exceeding 15 pounds per square inch gage (103 kilopascals) for a purpose external to the boiler.

(55) Preliminary order--A written order issued by the chief inspector or any commissioned boiler inspector to require repairs or alterations to render a boiler safe for use or to require that operation of the boiler be discontinued. The Boiler Inspection report which requires repairs to be made or the boiler operation to be ceased which is signed by the chief inspector or a commissioned boiler inspector is a Preliminary Order.

(56) Process Steam Generator--An evaporator, heat exchanger, or vessel in which steam is generated by the use of heat resulting from the operation of a processing system that contains a number of pressure vessels, such as used in the manufacture of chemical and petroleum products.

(57) Reinstalled Boiler--A boiler removed from its original setting and reinstalled at the same location or at a new location without change of ownership.

(58) Repair--The work necessary to restore pressure-retaining items to a safe and satisfactory operating condition.

(59) Rules--The rules promulgated and enforced by the commission in accordance with Texas Health and Safety Code, §755.032 and Texas Occupations Code, Chapter 51.

(60) Safety Appliance--A safety device such as a safety valve or a pressure relief valve for a boiler provided to diminish the danger of accidents.

(61) Secondhand Boiler--A boiler in which the location and ownership have changed.

(62) Serious Accident--An explosion resulting in any degree of distortion to the wall of the boiler or related equipment or damage to the building where the boiler is located. Or, emergency medical services are dispatched to the location of a boiler accident in which one or more persons require on-site medical services, transport to a medical facility or the accident results in a fatality.

(63) Special Inspection--An inspection by the chief inspector or deputy inspector other than those in Texas Health and Safety Code, §§755.025 - 755.027.

(64) Stacked Boiler--A design in which one boiler is placed onto a rack above another boiler, as designed by the boiler manufacturer with a rack nameplate, and as approved by the department.

(65) Standard Boiler--A boiler that bears the stamp of a nationally recognized engineering professional society, or the stamp of any jurisdiction that has adopted a standard of construction equivalent to the standard required by the executive director.

(66) Steam Heating Boiler--A boiler designed for operation at pressures not exceeding 15 pounds per square inch gage (103 kilopascals).

(67) System Pressure--The pressure of the boiler system, which is governed by the highest safety valve or pressure relief valve set pressure as allowed by ASME Code and this chapter.

(68) Texas Commission--Authorization to inspect boilers and enforce Texas Health and Safety Code, Chapter 755, and 16 Texas Administrative Code, Chapter 65, on behalf of the department.

(A) ASME Only Commission--Only authorizes an inspector to conduct ASME new construction activities.

(B) In-Service Only Commission--Only authorizes an inspector to conduct boiler in-service activities.

(C) ASME and In-Service Commission--Authorizes an inspector to conduct both activities in subparagraphs (A) and (B).

(69) Unfired Steam Boiler--An unfired pressure vessel in which steam is generated. The term does not include: vessels known as evaporators or heat exchangers; or vessels in which steam is generated by using the heat that results from the operation of a processing system that contains a number of pressure vessels, as used in the manufacture of chemical and petroleum products.

Subchapter C. Boiler Registration and Certificate of Operation--Requirements

65.12. Boiler Registration and Certificate of Operation Required

Except as provided by this chapter, each boiler operated in this state must:

(1) be registered with the department; and

(2) have qualified for a current certificate of operation with the current certificate of operation posted under glass in a conspicuous place on or near the boiler for which it is issued.

65.13. Boiler Installation

(a) The owner or operator of a boiler in this state must submit the following to the department within thirty (30) days after completion of a boiler installation.

(1) A boiler installation report; and

(2) A manufacturer's data report for the boiler.

(b) The boiler shall not be test-fired or operated prior to the required first inspection except as allowed under subsection (c).

(c) Temporary Operating Permit.

(1) The owner or operator may request a Temporary Operating Permit on a department-approved form.

(2) The owner or operator must pay the applicable fee required under §65.300.

(3) Upon approval of the Temporary Operating Permit from the department, the boiler may be operated prior to the required initial inspection for up to thirty (30) days.

65.14. Inspector Commissions

(a) In-Service Commission. To be eligible for in-service commission, an applicant must:

(1) submit a completed application on a department-approved form demonstrating eligibility;

(2) successfully pass a criminal background check;

(3) pass a written examination approved by the department;

(4) attend a department-approved boiler orientation program; and

(5) pay the fee required under §65.300.

(b) Texas ASME Commissions. To be eligible for a Texas ASME commission, an applicant must:

(1) submit a completed application on a department-approved form;

(2) successfully pass a criminal background check;

(3) hold a valid National Board Authorized Inspector Commission; and

(4) pay the fee required under §65.300.

65.15. Boiler Certification Requirements

(a) To be eligible for a certificate of operation each boiler must meet the following:

(1) comply with §65.200;

(2) have an applicable inspection report completed;

(3) if necessary, complete required repairs; and

(4) pay the fees required under §65.300.

(b) If the boiler has not been registered with the National Board, the owner or operator may apply to the department for a variance.

(c) Non-code boilers may not be installed or operated without written authorization from the department.

(1) Non-code boilers, if installed without written authorization from the department, must be completely replaced to ensure the complete boiler meets or exceeds ASME code and this chapter.

(2) Installing code compliant parts onto a non-code boiler does not make a non-code boiler ASME code compliant.

Subchapter D. Authorized Inspector

65.25. Authorized Inspector--Eligibility Requirements

To be an authorized inspector, an applicant must have at least five years' experience in the construction, installation, inspection, operation, maintenance, or repair of boilers.

Subchapter E. Examinations and Waiver of Examination

65.30. Waiver of Examination

An applicant for a Texas Commission who is licensed or commissioned in another state that has an examination substantially equivalent to that required by this chapter, as determined by the department, may obtain a commission without examination, if the person:

(1) submits a completed application on a department-approved form demonstrating eligibility; and

(2) except for the examination requirement otherwise meets the requirements in Subchapter F.

Subchapter G. Application to Operate Nonstandard Boilers in the State

 65.45. Nonstandard Boilers

(a) Operation of a nonstandard boiler is prohibited unless the department has granted approval as a nonstandard boiler used for exhibition, instruction, education, show, display, or demonstration.

(b) The applicant must:

(1) submit a boiler installation report;

(2) include a description of the materials, methods of construction, drawings, and such other design information sufficient to establish the MAWP; and

(3) pay the fee required under §65.300.

(c) If the materials submitted under subsection(b)(2) are insufficient to establish the MAWP, the department may require a proof test of the nonstandard boiler in accordance with the edition of the code determined to be most applicable for the method of construction.

Subchapter I. Inspection of Boilers

65.63. Inspection of Portable Boilers

(a) The internal and external inspection of Portable Boilers shall occur as follows:

(1) Boilers fabricated in accordance with the ASME Section I (i.e. “S” or any other Section I Designator) shall be inspected annually;

(2) Boilers fabricated in accordance with the ASME Section IV, “H” Designator shall be inspected biennially;

(3) Boilers fabricated in accordance with the ASME Section IV, “HLW” Designator shall be inspected triennially; and

(4) Boilers designated as a Nonstandard Boiler in accordance with §65.43, shall be inspected annually.

65.64. Extension of Interval between Internal Inspections

(a) For the interval between internal inspection to be extended as provided for in Texas Health and Safety Code, §755.026, the following procedure must be followed.

(1) Not less than thirty (30) days and not more than sixty (60) days prior to the expiration date of the current certificate of operation, the owner or operator shall submit in a manner prescribed by the department a request for each boiler, stating the desired length of extension, which will be no more than one (1) year from the expiration date of the current certificate of operation, the date of the last internal inspection, and a statement certifying that records are available showing compliance with Texas Health and Safety Code, §755.026, and pay the required fees.

(2) The department shall notify the owner or operator and the inspection agency having jurisdiction of the maximum extension period that may be approved.

(3) Prior to the expiration of the current certificate of operation, the inspection agency shall review all records, make an external inspection, and submit the external inspection report to the department.

(4) Upon completion of paragraphs (1) - (3) and payment of all required fees, a new certificate of operation may be issued for the extended period of operation.

(5) Violations noted during the external inspection may be cause for denial of the extension request.

(6) If the department denies an extension request, the boiler shall be internally inspected prior to the expiration of the certificate of operation, unless authorized in writing to continue operation until an internal inspection can be conducted.

(b) An additional extension for up to one hundred twenty (120) days may be allowed as provided for in Texas Health and Safety Code, §755.026, when it is established an emergency exists.

(1) Prior to the expiration date of the current certificate the owner or operator shall submit to the department a request stating an emergency exists with an explanation of the emergency and the date of the last internal inspection. The request shall be submitted along with the inspection agency's external inspection report, confirming compliance with Texas Health and Safety Code, §755.026.

(2) The department shall notify the owner or operator and the inspection agency having jurisdiction of the maximum extension period that may be approved.

(3) Upon completion of paragraphs (1) and (2) and payment of all required fees, a new certificate of operation may be issued for the extended period of operation.

Subchapter J. Texas Boiler Numbers

 65.72. Condemned Boilers

(a) Any boiler, stamped or identified with the corrosion-resistant metal tag, having been inspected and declared unsafe by the chief inspector, deputy inspector or executive director, shall be stamped by the inspector with an "X" on the star on either side of the Texas boiler number. The “X” stamped tag identifies/designates the boiler as condemned.

(b) Any boiler, identified with the Texas boiler number decal, having been inspected and declared unsafe by the chief inspector or deputy inspector, shall have the decal altered/defaced by the inspector by removing the star on either side of the Texas boiler number on the decal. The altered/defaced decal identifies/designates the boiler as condemned.

Subchapter N. Responsibilities of the Owner and the Operator

65.217. Variance

(a) Requests to waive or modify a rule or code requirement must be submitted on a department-approved variance application form. A separate variance application form shall be submitted for each boiler for which a variance is sought.

(b) In evaluating a request for variance, the department shall consider whether the variance would be in the public interest, and may consider factors such as the effect of the proposed variance on the public, the burden that compliance imposes on the Owner or Operator, and whether the Owner or Operator has in place a maintenance plan that promotes boiler safety.

(c) Variance applications shall be submitted by the owner/operator of the boiler, and shall be accompanied by the applicable fee and any supporting documentation such as boiler design plans, photos and code references.

(d) A denial of a variance application may be appealed to the director of compliance, or designee, in writing within thirty (30) calendar days from issuance, upon payment of the applicable appeal fee. Supporting documentation such as boiler design plans, photos and code references not previously reviewed may be submitted for consideration.

(e) A denial of a variance appeal from the director of compliance may be appealed to the executive director of the department, or designee, in writing within thirty (30) calendar days of notification of the director of compliance's decision. Supporting documentation such as boiler design plans, photos and code references not previously reviewed may be submitted for consideration.

(f) When a variance or variance appeal determination has been made, the owner or operator making the submission shall be advised in writing of the determination.

(g) A denial of a variance appeal from the executive director of the department, or designee, must be submitted in writing within thirty (30) calendar days from receipt of the appeal.

(h) An approved variance must be posted next to the certificate of operation of the boiler for which it is issued, in accordance with §65.12.

Subchapter O. Fees

65.300. Fees

(a) Certificate of operation. The owner or operator shall make payment for the following fees:

(1) On or before expiration date--$70; in addition to all outstanding invoices, including any past due invoices associated with the boiler.

(2) After expiration date--Late fees for certificates are provided for under §60.83 of this title (relating to Late Renewal Fees).

(3) Duplicate--$25

(b) Inspections. The owner or operator shall make payment for the following fees:

(1) Heating boilers.

(A) With an inspection opening--$70

(B) Without an inspection opening--$40

(2) Other than heating boilers--$70

(c) Special inspections or non-standard boiler reviews. The owner or operator shall make a $1,700 fee payment, which must be received by the department before the department may schedule the requested special inspection or non-standard boiler review.

(d) Commission Fees. The Authorized Inspector seeking or holding the Commission shall make payment for the following fees:

(1) New--$50

(2) Reinstatement--$50

(3) Renewal--$50

(4) Duplicate--$25

(5) Reissuance after re-employment--$50

(6) Late renewal fees for commissions issued under this chapter are provided under §60.83 of this title (relating to Late Renewal Fees).

(e) Authorized Inspection Agency/Letter of Recognition. The authorized Inspection Agency shall make payment for the following fees:

(1) Original Application--$100

(2) Renewal Application--$100

(f) Variances. The owner or operator shall make a $50 fee payment.

(g) Extensions. The owner or operator shall make a $100 fee payment.

(h) Re-Stamping. The owner or operator shall make a $50 fee payment.

(i) Boiler Installation Reports. The owner or operator shall make a $25 fee payment.

(j) Overdue Boiler Inspection Fee. The owner or operator shall make a $260 fee payment to the agency assigned by the department in accordance with §65.91.

(k) Temporary Operating Permit Fee. The owner or operator shall make a $50 fee payment.

Subchapter R. Technical Requirements

65.601. General Safety

(a) A boiler that is deemed unsafe for operation by the inspector shall be removed from service or placed in a safe condition in the following manner:

(1) the Inspector must notify the owner/operator about:

(A) the prohibition against operating an unsafe boiler;

(B) any insurance policy provisions, if any, that may exclude insurance coverage for operating an unsafe boiler;

(C) possible administrative penalties for operating an unsafe boiler; and

(D) request the immediate but voluntary shut-down of the boiler;

(2) if the owner/operator refuses to immediately shut the boiler down, before leaving the premise on which the unsafe boiler is located, the Inspector must notify the Chief Boiler Inspector about the condition of the unsafe boiler.

(b) Upon receipt of the notice required by subsection (a)(2), the Chief Inspector shall assign a Deputy Inspector to confirm that an unsafe condition exists and, if confirmed, to declare the boiler unsafe for operation by placing a red tag on the boiler prohibiting continued operations of the boiler.

(c) The continued operation of an unsafe boiler shall subject the owner/operator to administrative penalties as provided for in this chapter.

65.603 Boiler Room Ventilation

(a) The boiler room must have an adequate and uninterrupted air supply to assure proper combustion and ventilation.

(b) The combustion and ventilation air may be supplied by either an unobstructed opening or by power ventilators or fans.

(1) For a single opening, the opening shall be sized on the basis of one square inch (645 square millimeters) of free area for each 2,000 Btu/hour (.586 kilowatts) input of the combined burners located in the boiler room. For two openings, one commencing not more than 12 inches (304.8 millimeters) from the ceiling of the room and one commencing not more than 12 inches (304.8 millimeters) from the floor of the room, the opening shall be sized on the basis of one square inch (645 square millimeters) of free area for each 3,000 Btu/hour (.879 kilowatts) input per opening of the combined burners located in the boiler room.

(2) The power ventilator or fans shall be sized on the basis of 0.2 cfm. (5.6 liters per minute) for each 1,000 Btu/hour (.29 kilowatts) fuel input for the combined burners located in the boiler room. The boiler and the fans shall be interlocked so that the burners will not operate unless a supply of combustion, ventilation and dilution air as required by the boiler manufacturer's recommendations.

(c) Boilers of a sealed combustion design by the manufacture.

(1) When a boiler(s) in the boiler room is of a sealed combustion design by the manufacture of the boiler and the required ventilation opening is not provided, the boiler room shall be equipped with a manual reset type Carbon Monoxide Detector. The Carbon Monoxide Detector and boiler shall be interlocked so that the burners will not operate when the measured level of CO rises above 100ppm. The Carbon Monoxide detector shall disable the appliance burners upon loss of power to the detector.

(2) When the boiler room is configured to include both designs, i.e. a boiler(s) of a sealed combustion design by the manufacture of the boiler and a boiler(s) that is not of a sealed combustion design by the manufacture of the boiler, the requirements in A or B below shall be met.

(A) The boiler room shall be in compliance with subsection (b)(1) or (b)(2).

(B) The boiler(s) that is not of the sealed combustion design is required to meet the ventilation requirement of subsection (b)(1) or (b)(2). The boiler(s) that are of the sealed combustion design are required to meet the ventilation requirement of subsection (c)(1).

(d) Carbon Monoxide Detectors shall be calibrated every eighteen months and a record of calibration shall be posted at or near the boiler, or readily accessible to an inspector.

65.606. Atmospheric Vents, Gas Vents, Bleed or Relief Lines for Power Boilers, Unfired Steam Boilers and Process Steam Generators with Supplemental Firing (extensions only)

(a) Gas pressure regulators not incorporating integral vent limiters, and all other gas train components requiring atmospheric air pressure to balance a diaphragm or other similar device, shall be provided with a connection for a vent line.

(1) The vent lines in subsection (a) shall be:

(A) sized in accordance with the component manufacturer's instructions; and

(B) at least the same size as the vent outlet of the device.

(2) Where there is more than one gas pressure regulator at a location, each gas pressure regulator shall have a separate vent. The vent lines may be manifolded in accordance with accepted engineering practices to minimize back pressure in the event of a diaphragm failure (see subsections (c) and (d)).

(3) A gas pressure regulator shall not be vented into the boiler flue or exhaust system.

(b) Gas pressure relief valves may discharge into common manifolding only with other gas vent, bleed, or relief lines. When manifolded, the common vent line shall have a cross-sectional area not less than the area of the largest vent line plus 50% of the areas of the additional vent lines.

(c) Atmospheric vent lines, when manifolded, shall be connected into a common atmospheric vent line, having a cross-sectional area not less than the area of the largest vent line, plus 50% of the areas of the additional vent lines.

(d) Atmospheric vent lines shall not be connected to any common or manifolded gas vent, bleed, or relief lines.

(e) All vent and relief lines shall be:

(1) piped to the outdoors at a safe point of discharge, so there is no possibility of discharged gas being drawn into the air intake, ventilating system, or openings of any structure or piece of equipment;

(2) shall extend sufficiently above any structure, so that gaseous discharge does not present a fire hazard; and

(3) a means shall be provided at the terminating point to prevent blockage of the line by foreign material, moisture, or insects.

65.607. Power Boilers, Excluding Unfired Steam Boilers and Process Steam Generators

(a) Safety valves and pressure relief valves.

(1) The use of weighted-lever safety valves, or safety valves having either the seat or disk of cast iron, is prohibited.

(2) Each boiler shall have at least one safety valve and, if it has more than 500 square feet (47 square meters) of water heating surface or has electric power input more than 1,100 kilowatts, it shall have two or more safety valves. These valves shall be "V" stamped per ASME Code.

(3) Safety valves or pressure relief valves shall be connected so as to stand in the upright position, with spindle vertical. The opening or connection between the boiler and the safety valve or pressure relief valve shall have at least the area of the valve inlet.

(4) The valve or valves shall be connected to the boiler, independent of any other steam connection, and attached as close as practicable to the boiler without unnecessary intervening pipe or fittings.

(5) Except for changeover valves as defined in §65.1(13), other valve (s) shall not be placed:

(A) between the required safety valve or pressure relief valve or valves and the boiler; or

(B) in the discharge pipe between the safety valve or pressure relief valve or valves and the atmosphere.

(6) When a discharge pipe is used, it shall be:

(A) at least full size of the safety valve discharge; and

(B) fitted with an open drain to prevent water lodging in the upper part of the safety valve or discharge pipe.

(7) When an elbow is placed on a safety valve discharge pipe:

(A) it shall be located close to the safety valve outlet; and

(B) the discharge pipe shall be securely anchored and supported.

(8) In the event multiple safety valves discharge into a common pipe, the discharge pipe shall be sized in accordance with ASME Code, Section I, PG-71.

(9) All safety valve or pressure relief valve discharges shall be located or piped to a safe point of discharge, clear from walkways or platforms.

(10) If a muffler is used on a pressure relief valve, it shall have sufficient area to prevent back pressure from interfering with the proper operation and discharge capacity of the valve. Mufflers shall not be used on High-Temperature Water Boilers.

(11) The safety valve capacity of each boiler must allow the safety valve or valves to discharge all the steam that can be generated by the boiler without allowing the pressure to rise more than 6.0% above the highest pressure to which any valve is set, and to no more than 6.0% above the MAWP. For forced-flow steam generators with no fixed steam and waterline, power-actuated relieving valves may be used in accordance with ASME Code, Section I, PG-67.

(12) One or more safety valves on every drum type boiler shall be set at or below the MAWP. The remaining valve (s) may be set within a range of 3.0% above the MAWP, but the range of setting of all the drum mounted pressure relief valves on a boiler shall not exceed 10% of the highest pressure to which any valve is set.

(13) When two or more boilers, operating at different pressures and safety valve settings, are interconnected, the lower pressure boilers or interconnected piping shall be equipped with safety valves of sufficient capacity to prevent overpressure, considering the maximum generating capacity of all boilers.

(14) In those cases where the boiler is supplied with feedwater directly from water mains without the use of feeding apparatus (not to include return traps), no safety valve shall be set at a pressure higher than 94% of the lowest pressure obtained in the supply main feeding the boilers.

(b) Feedwater supply.

(1) Each boiler shall have a feedwater supply, which will permit it to be fed at any time while under pressure, except for automatically fired miniature boilers that meet all of the following criteria:

(A) the boiler is "M" stamped per ASME Code, Section I;

(B) the boiler is designed to be fed manually;

(C) the boiler is provided with a means to prevent cold water from entering into a hot boiler; and

(D) the boiler is equipped with a warning sign visible to the operator not to introduce cold feedwater into a hot boiler.

(2) A boiler having more than 500 square feet (47 square meters) of water heating surface, shall have at least two means of feeding, one of which should be a pump, injector, or inspirator. A source of feed directly from water mains at a pressure of at least 6.0% greater than the set pressure of the safety valve with the highest setting may be considered as one of the means of feeding. Boilers fired by gaseous, liquid, or solid fuel in suspension may be equipped with a single means of feeding water, provided means are furnished for the immediate shutoff of heat input if the feedwater is interrupted.

(3) Feedwater shall not be discharged close to riveted joints of shell or furnace sheets or directly against surfaces exposed to products of combustion or to direct radiation from the fire.

(4) Feedwater piping to the boiler shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler. When two or more boilers are fed from a common source, there shall also be a stop valve on the branch to each boiler between the check valve and the source of supply. Whenever a globe valve is used on the feedwater piping, the inlet shall be under the disk of the valve.

(5) In all cases where returns are fed back to the boiler by gravity, there shall be a check valve and stop valve in each return line, the stop valve to be placed between boiler and the check valve, and both shall be located as close to the boiler as is practicable. Best practice is that no stop valve be placed in the supply and return pipe connections of a single boiler installation.

(6) Where deaerating heaters are not used, best practice is that the temperature of the feedwater be not less than 120 degrees Fahrenheit (49 degrees Celsius), to avoid the possibility of setting up localized stress. Where deaerating heaters are used, best practice is for the minimum feedwater temperature be not less than 215 degrees Fahrenheit (102 degrees Celsius), so that dissolved gases may be thoroughly released.

(c) Water level indicators.

(1) Each boiler, except forced-flow steam generators with no fixed steam and waterline, and high-temperature water boilers of the forced circulation type that have no steam and waterline shall have at least one water gage glass.

(2) Except for electric boilers of the electrode type, boilers with a MAWP over 400 psig (three (3) megapascals) shall be provided with two water gage glasses, which may be connected to a single water column or connected directly to the drum.

(3) Two independent remote level indicators may be provided instead of one of the two required gage glasses for boiler drum water level indication, when the MAWP is above 400 psig (three (3) megapascals). When both remote level indicators are in reliable operation, the remaining gage glass may be shut off, but shall be maintained in serviceable condition.

(4) In all installations where direct visual observations of the water gage glass(es) cannot be made, two remote level indicators shall be provided at operational level.

(5) The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (15 mm).

(6) No outlet connections, except for damper regulator, feedwater regulator, drains, steam gages, or apparatus of such form as does not permit the escape of an appreciable amount of steam or water there from, shall be placed in the pipes connecting a water column or gage glass to a boiler.

(7) The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (20 mm). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (20 mm), and shall be piped to a safe point of discharge.

(8) Connections from the boiler to remote level indicators shall be at least 3/4 inch nominal pipe size (20 mm), to and including the isolation valve, and at least 1/2 inch (13 mm) OD tubing from the isolation valve to the remote level indicator. These connections shall be completely independent of other connections for any function other than water level indication.

(d) Low-water fuel cutoff and water feeding devices.

(1) All automatically fired steam boilers, except boilers having a constant attendant, who has no other duties while the boiler is in operation, shall be equipped with approved low-water fuel cutoffs.

(A) These devices shall be installed in such a manner that they cannot be rendered inoperative by the manipulation of any manual control or regulating apparatus.

(B) In boilers with a fixed water line, the low-water fuel cutoff devices shall be tested regularly by lowering the water level sufficiently to shut off the fuel supply to the burner when the water level reaches the lowest safe level for operation. Boilers that do not have a fixed water line shall be equipped with a flow sensing device, thermal couple or expansion ring that is listed by a nationally recognized testing agency to prevent burner operation at a flow rate inadequate to protect the boiler unit against overheating.

(C) The low-water cutoff shall be rated for a pressure and temperature equal to or greater than the MAWP and temperature of the boiler.

(D) For High-Temperature Water Boilers requiring forced flow circulation, an approved flow sensing device shall be installed on the outlet, as close to the boiler as possible.

(2) When a low-water fuel cutoff and feedwater pump control is combined in a single device, an additional separate low-water fuel cutoff shall be installed. The additional control shall be wired in series electrically with the existing low-water fuel cutoff.

(3) When a low-water fuel cutoff is housed in either the water column or a separate chamber it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (20 mm). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the lower-water fuel cutoff device.

(4) If a water feed device is utilized, it shall be constructed to prevent feedwater from entering the boiler through the water column or separate chamber of the low-water fuel cutoff.

(e) Pressure gages.

(1) Each boiler shall have a pressure gage that is readable.

(A) The dial of the pressure gage shall be graduated to approximately double the pressure at which the safety valve is set, but in no case, less than one and one-half times this pressure.

(B) The pressure gage shall be connected to the steam space, to the water column, or its steam connection.

(C) A valve or cock shall be placed in the gage connection adjacent to the gage.

(D) An additional valve or cock may be located near the boiler providing it is locked or sealed in the open position.

(E) No other shutoff valves shall be located between the gage and the boiler.

(F) The pipe connection shall be of ample size and arranged so that it may be cleared by blowing down.

(G) For a steam boiler, the gage or connection shall contain a siphon or equivalent device which will develop and maintain a water seal that will prevent steam from entering the gage tube.

(2) Each boiler shall have a valved connection at least 1/4 inch nominal pipe size (6 mm) connected to the steam space for the exclusive purpose of attaching a test gage when the boiler is in service to test the accuracy of the pressure gage.

(f) Stop valves.

(1) Each steam outlet from a boiler (except safety valve connections) shall be fitted with a stop valve located as close as practicable to the boiler.

(2) When a stop valve is located that allows water to accumulate, ample drains shall be provided. The drain shall be piped to a safe location and shall not be discharged on the boiler or its setting.

(3) When boilers provided with manholes or other similar opening that permits access for human occupancy and that are connected to a common steam main, the steam connection from each boiler shall be fitted with two stop valves, with an ample drain between them. The discharge of the drain shall be visible to the operator while manipulating the valves and shall be piped clear of the boiler setting. Best practice is for the first valve to be an automatic nonreturn valve (set next to the boiler), and a second valve of the outside-screw-and-yoke type.

(g) Blowdown connection.

(1) The construction of the setting around each blowdown pipe shall permit free expansion and contraction. These setting openings must be sealed without restricting the movement of the blowdown piping.

(2) All blowdown piping, when exposed to furnace heat, shall be protected by firebrick or other heat-resisting material, and constructed to allow the piping to be inspected.

(3) Each boiler shall have a blowdown pipe, fitted with a valve or cock, in direct connection with the lowest water space. The piping shall be run full size without the use of a reducer or bushings and shall not be galvanized. Cocks shall be of gland or guard type and suitable for the pressure allowed. The use of globe valves shall be in accordance with ASME code.

(4) When the MAWP exceeds 100 psig (700 kilopascals), the piping shall be at least schedule 80 steel and shall not be galvanized. Each blowdown pipe shall be provided with two valves or a valve and cock, such valves and cocks shall be adequate for design conditions of the boiler.

(5) All fittings between the boiler and blowdown valve shall be of steel or extra-heavy malleable iron. In case of renewal of blowdown pipe or fittings, they shall be installed in accordance with the requirements of the applicable section of the ASME code.

(6) It is recommended that blowdown tanks be designed, constructed, and installed in accordance with National Board recommended rules for boiler blowoff equipment.

(h) Boiler external piping. All boiler external piping, as referenced in the ASME code, shall be examined for compliance to the boiler's code of construction and shall be documented in the appropriate block on the inspection report.

(i) Provisions for thermal expansion for High-Temperature Water Boilers.

(1) An airtight tank or other suitable air cushion that is consistent with the volume and capacity of the system shall be installed. Expansion tanks shall be constructed in accordance with the ASME Code, Section VIII, Division 1, and the pressure and temperature ratings of the tank shall be equal to or greater than the pressure and temperature ratings of the system pressure. A pressure relief valve shall be installed with a set pressure at or below the MAWP of the expansion tank. Alternately the boiler pressure relief valve may be used provided the expansion tank's MAWP is equal to or lower than the set pressure of the pressure relief valve.

(2) Provisions shall be made for draining the tank without emptying the system, except for pre-pressurized tanks.

(3) If the expansion tank was originally equipped with a sight glass, the sight glass and sight glass valves shall be in working condition at all times, and the water level shall be maintained as per the manufacturer's recommendations.

65.608. Unfired Steam Boilers

(a) Unfired steam boilers referred to in §65.2 are shown in §65.615, Exhibits 2 and 3.

(b) Unfired steam boilers shall be constructed in accordance with ASME Code, Section I, or ASME Code, Section VIII, Division 1, 2 or 3.

(1) Unfired steam boilers constructed to ASME Code, Section VIII, Division 1, 2 or 3, shall meet jurisdictional limits established in §65.615, Exhibit 2.

(2) Unfired steam boilers constructed to ASME Code, Section I, shall meet jurisdictional limits established in §65.615, Exhibit 3.

(c) Safety valves and pressure relief valves.

(1) The use of weighted-lever safety valves, or safety valves having either the seat or disk of cast iron, is prohibited.

(2) Each ASME Code, Section VIII, Division 1, 2 or 3, unfired steam boiler shall:

(A) have all pressure relief valves fabricated in accordance with ASME Code, Section VIII, Division 1 or Section I; and

(B) have at least one pressure relief valve.

(C) Isolation valves may be installed between the unfired steam boiler and the safety valve in accordance with §65.615, Exhibit 2.

(D) Full-area stop valves may be installed on the inlet side of a safety valve in accordance with §65.615, Exhibit 2. A full-area stop valve may be installed on the discharge of the safety valve when connected to a common header. Stop valves shall be car sealed or locked in the open position.

(E) One or more safety valves on every unfired steam boiler shall be set at or below the MAWP. The remaining valves, if any, shall be set within the range specified and have the capacity required by the applicable section of the ASME Code.

(3) Each ASME Code, Section I, unfired steam boiler shall have one safety valve and if it has more than 500 square feet (47 square meters) of water heating surface, it shall have two or more safety valves.

(A) The valve or valves shall be connected to the boiler, independent of any other steam connection, and attached as close as practicable to the boiler without unnecessary intervening pipe or fittings.

(B) Valves, except a changeover valve as defined in §65.2(14), shall not be placed between the required safety valve or pressure relief valve or valves and the boiler nor on the discharge pipe between the safety valve or pressure relief valve and the atmosphere.

(C) The safety valve capacity of each unfired steam boiler must allow the safety valve or valves to discharge all the steam that can be generated by the boiler without allowing the pressure to rise more than 6.0% above the highest pressure to which any valve is set, and to no more than 6.0% above the MAWP.

(4) When a discharge pipe open to the atmosphere is used, it shall be at least full size of the safety valve discharge and fitted with an open drain to prevent water lodging in the upper part of the safety valve or discharge piping. The drain or drains shall be piped to a safe point of discharge. When an elbow or fitting is installed on the discharge pipe it shall be located close to the safety valve outlet. The discharge pipe shall be securely anchored and supported. All safety valve discharges shall be located or piped to a safe point of discharge clear from walkways or platforms. If a muffler is used on a pressure relief valve, it shall have sufficient area to prevent back pressure from interfering with the proper operation and discharge capacity of the valve.

(5) When two or more unfired steam boilers operating at different pressures and safety valve settings are interconnected, the lower pressure boilers or interconnected piping shall be equipped with safety valves of sufficient capacity to prevent overpressure, considering the maximum generating capacity of all boilers.

(6) Safety valve and pressure relief valve mountings.

(A) For ASME Code, Section I installations, pressure relief valves shall be connected so as to stand in the upright position, with spindle vertical. The opening or connection between the boiler and the pressure relief valve shall have at least the area of the valve inlet.

(B) For ASME Code, Section VIII, Division 1 installations, pressure relief valves normally should be installed in the upright position, with spindle vertical. Where space or piping configurations preclude such an installation, the valve may be installed in other than the vertical position, provided that:

(i) the valve design is satisfactory for such position;

(ii) the media is such that material will not accumulate at the inlet of the valve; and

(iii) drainage of the discharge side of the valve body and discharge piping is adequate.

(d) Feedwater supply.

(1) Each unfired steam boiler shall have a feedwater supply which will permit it to be fed at any time while under pressure.

(2) Feedwater piping to the unfired steam boiler constructed to ASME Code, Section I, shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler. When two or more boilers are fed from a common source there shall also be a stop valve on the branch to each boiler between the check valve and the source of supply. Whenever a globe valve is used on the feedwater piping, the inlet shall be under the disk of the valve.

(3) Where deaerating heaters are not used, it is recommended that the temperature of the feedwater be not less than 120 degrees Fahrenheit (49 degrees Celsius), to avoid the possibility of setting up localized stress. Where deaerating heaters are used, it is recommended that the minimum feedwater temperature be not less than 215 degrees Fahrenheit (102 degrees Celsius), so that dissolved gases may be thoroughly released.

(e) Water level indicators.

(1) ASME Code, Section I, unfired steam boilers with a MAWP of 400 psig (three (3) megapascals) or less, shall have at least one gage glass. For a MAWP over 400 psig (three (3) megapascals), shall have two required gage glasses. When two gage glasses are required, one of the gage glasses may be replaced by two independent remote level indicators that are maintained in simultaneous operation while the boiler is in service.

(2) Each steam drum of an ASME Code, Section VIII, Division 1 unfired steam boiler, irrespective of pressure and temperature, shall be provided with one direct reading water level indicator (water gage glass), or two independent remote level indicators, that are maintained in simultaneous operation while the boiler is in service.

(3) In all installations where direct visual observations of the water gage glass(es) cannot be made, two remote level indicators shall be provided at operational level.

(4) The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (15 mm).

(5) No outlet connections, except for feedwater regulators, drains, steam gages, or apparatus of such form as does not permit the escape of an appreciable amount of steam or water therefrom, shall be placed in the pipes connecting a water column or gage glass to a boiler.

(6) The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (20 mm). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (20 mm) and shall be piped to a safe point of discharge.

(7) Connections from the unfired steam boiler to remote level indicators shall be at least 3/4 inch nominal pipe size (20 mm), to and including the isolation valve, and at least 1/2 inch (13 mm) OD tubing from the isolation valve to the remote level indicator. These connections shall be completely independent of other connections for any function other than water level indication.

(f) Low-water cutoffs, alarms and feed regulating devices.

(1) The owner/operator is responsible for the design and installation of any low water protection devices as required to prevent damage to the unfired steam boiler. All installed low water cutoffs, alarms and feeding devices shall be designed for pressure and temperature equal to or greater than the MAWP of the unfired steam boiler.

(2) When a low-water cutoff, and/or alarm is housed in either the water column or a separate chamber, it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (20 mm). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the low-water cutoff and/or alarm device.

(3) Should an unfired steam boiler be installed in a system without a local and constant attendant, and it is not a fail-safe design, it shall be provided with a low-water cutoff as required for power boilers.

(g) Pressure gages.

(1) Each unfired steam boiler shall have a pressure gage that is readable. The dial of the pressure gage shall be graduated to approximately double the pressure at which the safety valve is set, but in no case, less than one and one-half times this pressure. The pressure gage shall be connected to the steam space, to the water column, or its steam connection. A valve or cock shall be placed in the gage connection adjacent to the gage. An additional valve or cock may be located near the boiler providing it is locked or sealed in the open position. No other shutoff valves shall be located between the gage and the boiler. The pipe connection shall be of ample size and arranged so that it may be cleared by blowing down. The gage or connection shall contain a siphon or equivalent device which will develop and maintain a water seal that will prevent steam from entering the gage tube.

(2) Each unfired steam boiler, must have a valved connection at least 1/4 inch nominal pipe size (8 mm), connected to the steam space for the exclusive purpose of attaching a test gage when the boiler is in service to test the accuracy of the pressure gage.

(h) Stop valves.

(1) Each steam outlet from an ASME Code, Section I unfired steam boiler, shall be fitted with a stop valve located as close as practicable to the boiler.

(2) When a stop valve is located such that it allows water to accumulate, ample drains shall be provided. The drain shall be piped to a safe location and shall not be discharged on the boiler or its setting.

(3) When boilers that are provided with manholes or other similar openings that permit access for human occupancy are connected to a common steam main, the owner or operator shall ensure that the boiler to which entry is being made is completely isolated from the steam main. This may be accomplished with the use of two stop valves with an ample drain between them, with a full isolation blind or removal of piping such that the boiler is no longer connected to the steam main.

65.609. Process Steam Generators

(a) Some process steam generators referred to in §65.2, are shown in §65.615, Exhibits 4 and 5.

(b) The steam collection or liberation drums of a process steam generator shall be constructed in accordance with the American Society of Mechanical Engineers (ASME) Section VIII, Division 1, Division 2, or Division 3. As an alternate, the process steam generator may be constructed to ASME Code, Section I.

(c) When the owner/operator elects to construct a process steam generator to ASME Code, Section I, the limits as shown in §65.615, Exhibits 4 and 5, are as defined in the rules of ASME Section I.

(d) Safety valves and pressure relief valves.

(1) The use of weighted-lever safety valves or safety valves having either the seat or disk of cast iron is prohibited.

(2) Each ASME Code, Section VIII, Division 1 or Division 2, steam collection or liberation drum of a process steam generator, shall have at least one safety valve designed for steam service in accordance with applicable ASME Code of Construction. The valve body drain shall be open and piped to a safe point of discharge.

(A) The installation of full-area stop valves between the steam collection or liberation drum of a process steam generator and the safety valve is permitted as depicted in §65.615, Exhibits 4 and 5. A full-area stop valve may be installed on the discharge of the safety valve when connected to a common header. Stop valves shall be car sealed or locked in the open position.

(B) One or more safety valves on every steam collection or liberation drum of a process steam generator shall be set at or below the MAWP. The remaining valves, if any, shall be set within the range specified and have the capacity required by the applicable ASME code.

(3) Each ASME Code, Section I, process steam generator, shall have one safety valve and if it has more than 500 square feet (47 square meters) of water heating surface, it shall have two or more safety valves. ASME Code, Section I, safety valves shall be applicably stamped.

(A) The valve or valves shall be connected to the steam collection or liberation drum of the process steam generator, independent of any other steam connection, and attached as close as practicable to the steam collection or liberation drum without unnecessary intervening pipe or fittings.

(B) No valves, except as defined in §65.2(14), of any description shall be placed between the required safety valve or pressure relief valve or valves and the steam collection or liberation drum, nor on the discharge pipe between the safety valve or pressure relief valve and the atmosphere.

(C) The safety valve capacity of each process steam generator, shall allow the safety valve or valves to discharge all the steam that can be generated by the process steam generator without allowing the pressure to rise more than 6.0% above the highest pressure to which any valve is set, and to no more than 6.0% above the MAWP.

(4) When a discharge pipe open to the atmosphere is used, it shall be at least full size of the safety valve discharge and fitted with an open drain to prevent water lodging in the upper part of the safety valve or discharge piping. The drain or drains shall be piped to a safe point of discharge. When an elbow or fitting is installed on the discharge pipe it shall be located close to the safety valve outlet. The discharge pipe shall be securely anchored and supported. All safety valve discharges shall be located or piped to a safe point of discharge clear from walkways or platforms. If a muffler is used on a pressure relief valve, it shall have sufficient area to prevent back pressure from interfering with the proper operation and discharge capacity of the valve.

(5) When two or more steam collection or liberation drums of process steam generators, operating at different pressures and safety valve settings are interconnected, the lower pressure process steam generator(s) or interconnected piping shall be equipped with safety valves of sufficient capacity to prevent overpressure, considering the maximum generating capacity of all of the process steam generators.

(6) Safety valve and pressure relief valve mountings.

(A) For ASME Code, Section I installations, safety valves or pressure relief valves shall be connected so as to stand in the upright position, with spindle vertical. The opening or connection between the boiler and the safety valve or pressure relief valve shall have at least the area of the valve inlet.

(B) For ASME Code, Section VIII, Division 1 or Division 2 installations, safety valves or pressure relief valves normally should be installed in the upright position, with spindle vertical. Where space or piping configurations preclude such an installation, the valve may be installed in other than the vertical position, provided that:

(i) the valve design is satisfactory for such position;

(ii) the media is such that material will not accumulate at the inlet of the valve; and

(iii) drainage of the discharge side of the valve body and discharge piping is adequate.

(e) Feedwater supply.

(1) Each steam collection or liberation drum of a process steam generator shall have a feedwater supply which will permit it to be fed at any time while under pressure.

(2) Feedwater piping to a process steam generator constructed to ASME Code, Section I, shall be provided with a check valve near the process steam generator and a stop valve or cock between the check valve and the process steam generator. When two or more process steam generators are fed from a common source there shall also be a stop valve on the branch to each process steam generator between the check valve and the source of supply. Whenever a globe valve is used on the feedwater piping, the inlet shall be under the disk of the valve.

(3) Where deaerating heaters are not used, best practice is that the temperature of the feedwater be not less than 120 degrees Fahrenheit (49 degrees Celsius), to avoid the possibility of setting up localized stress. Where deaerating heaters are used, best practice is that the minimum feedwater temperature be not less than 215 degrees Fahrenheit (102 degrees Celsius), so that dissolved gases may be thoroughly released.

(f) Water level indicators.

(1) ASME Code, Section I, process steam generators with a MAWP of 400 psig (three (3) megapascals) or less shall have at least one gage glass. For a MAWP over 400 psig (three (3) megapascals), shall have two required gage glasses. When two gage glasses are required, one of the gage glasses may be replaced by two independent remote level indicators that are maintained in simultaneous operation while the process steam generator is in service.

 (2) Each steam collection or liberation drum of an ASME Code, Section VIII, Division 1, Division 2, or Division 3 process steam generator, irrespective of pressure and temperature, as shown in §65.615, Exhibits 4 and 5, shall be provided with one direct reading water level indicator (water gage glass) or two independent remote level indicators that are maintained in simultaneous operation while the process steam generator is in service.

(3) In all installations where direct visual observations of the water gage glass(es) cannot be made, two remote level indicators shall be provided at operational level.

(4) The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (15 mm).

(5) No outlet connections, except for feedwater regulator, drains, steam gages, or apparatus of such form as does not permit the escape of an appreciable amount of steam or water therefrom, shall be placed on the pipes connecting a water column or gage glass on the steam collection or liberation drum of a process steam generator.

(6) The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (20 mm). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (20 mm) and shall be piped to a safe point of discharge.

(7) Connections from the steam collection or liberation drum of a process steam generator to remote level indicators shall be at least 3/4 inch nominal pipe size (20 mm), to and including the isolation valve, and at least 1/2 inch (13 mm) OD tubing from the isolation valve to the remote level indicator. These connections shall be completely independent of other connections for any function other than water level indication.

(g) Low-water cutoffs, alarms and feed regulating devices.

(1) The owner/operator is responsible for the design and installation of any low water protection devices as required, to prevent damage to the process steam generator. All installed low water cutoffs, alarms and feeding devices, shall be designed for a pressure and temperature equal to or greater than the MAWP and temperature of the process steam generator steam collection or liberation drum.

(2) When a low-water cutoff, and/or alarm is housed in either the water column or a separate chamber, it shall be provided with a blowdown pipe and valve not less than 3/4 inch nominal pipe size (20 mm). The arrangement shall be such that when the water column is blown down, the water level in it will be lowered sufficiently to activate the low-water cutoff and/or alarm device.

(3) Should a steam collection or liberation drum of a process steam generator be installed in a system without a local and constant attendant, and it is not a failsafe design, it shall be provided with a low-water cutoff as required for power boilers.

(h) Pressure gages.

(1) Each steam collection or liberation drum of a process steam generator shall have a pressure-indicating device that is readable from the primary operating station. The range shall be graduated to approximately double the pressure at which the safety valve is set, but in no case, less than one and one-half times this pressure. The pressure-indicating device shall be connected to the steam space, or to the water column, or its steam connection. A valve or cock shall be placed in the gage connection adjacent to the gage. An additional valve or cock may be located near the steam collection or liberation drum of the process steam generator. No other shutoff valves shall be located between the gage and the steam collection or liberation drum of the process steam generator. The pipe connection shall be of ample size and arranged so that it may be cleared by blowing down or flushing. The pressure-indicating device shall be provided with a siphon or equivalent device, which will develop and maintain a water seal that will prevent steam from entering the pressure-indicating device.

(2) Each steam collection or liberation drum of a process steam generator, shall have a valved connection at least 1/4 inch nominal pipe size (8 mm), connected to the steam space for the purpose of attaching a test gage when the process steam generator is in service, to test the accuracy of the pressure-indicating device.

(i) Stop valves.

(1) Each steam outlet from an ASME Code, Section I, process steam generator, shall be fitted with a stop valve located as close as practicable to the steam collection or liberation drum of the process steam generator.

(2) When a stop valve is located that allows water to accumulate, ample drains shall be provided. The drain shall be piped to a safe location and shall not be discharged on the process steam generator or its setting.

(3) When boilers that are provided with manholes or other similar openings that permit access for human occupancy are connected to a common steam main, the owner or operator shall ensure that the boiler to which entry is being made is completely isolated from the steam main. This may be accomplished with the use of two stop valves with an ample drain between them, with a full isolation blind or removal of piping such that the boiler is no longer connected to the steam main.

The repeal is adopted under Texas Occupations Code, Chapter 51, which authorize the Commission, the Department’s governing body, to adopt rules as necessary to implement these chapters and any other law establishing a program regulated by the Department.

The statutory provisions affected by the repeal are those set forth in Texas Occupations Code, Chapter 51 and Health and Safety Code, Chapter 755.  No other statutes, articles, or codes are affected by the adoption.

[65.63. Extension of Interval between Internal Inspections.]

This agency hereby certifies that the adoption has been reviewed by legal counsel and found to be a valid exercise of the agency's legal authority.


 Filed with the Office of the Secretary of State, on December 21, 2017.
Brian E. Francis
Executive Director
Texas Department of Licensing and Regulation