16 Tex. Admin. Code § 65.100
Technical Requirements
Effective Dec 1, 200732 TexReg 8476Source Note: The provisions of this §65.100 adopted to be effective June 9, 2002, 27 TexReg 4685; amended to be effective December 1, 2003, 28 TexReg 10452; amended to be effective December 8, 2005, 30 TexReg 8061; amended to be effective September 1, 2006, 31 TexReg 6717; amended to be effective December 1, 2007, 32 TexReg 8476.Texas Secretary of State
(a) Conditions not covered by rules.
- (1) Any owner or operator of boilers or any deputy inspector, authorized inspector, or interested party may submit in writing an inquiry to the executive director for an opinion or clarification.
- (2) All conditions not specifically covered by these requirements shall be treated as new installations or be referred to the chief inspector for instruction.
(b) General safety.
- (1) If, in the judgment of the inspector, a boiler is unsafe for operation at the pressure previously approved, the pressure shall be reduced and proper repair made, or the boiler shall be removed from service.
- (2) Before internal access is made to a boiler by an inspector, the inspector shall deem the environment within the boiler to be safe for occupancy.
(c) Ventilation.
- (1) The boiler room must have an adequate and uninterrupted air supply to assure proper combustion and ventilation.
- (2) The combustion and ventilation air may be supplied by either an unobstructed opening or by power ventilators or fans.
- (3) 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.
- (4) 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.
- (5) The boiler and the fans shall be interlocked so that the burners will not operate unless an adequate number of fans are in operation.
- (d) Location of discharge outlets. The discharge of safety valves and safety relief valves, blowdown pipes, and other outlets shall be located to prevent injury to personnel.
(e) Electric steam boilers.
- (1) A cable at least as large as one of the incoming power lines to the generator shall be provided for grounding the generator shell. This cable shall be permanently fastened on some part of the generator and shall be grounded in an approved manner.
- (2) A suitable screen or guard shall be provided around high-voltage bushings, and a sign posted warning of high voltage. This screen or guard shall be so located that it will be impossible for anyone working around the generator to accidentally come in contact with the high voltage circuit.
- (3) In electric boilers of the submerged-electrode type, the water gage glass shall be located to indicate the water levels both at start-up and under maximum load conditions as established by the manufacturer.
- (4) Electric boilers of the resistance-element type shall have at least one gage glass. The lowest visible water level in the gage glass shall be at least 1 inch (25 millimeters) above the lowest permissible water level as determined by the manufacturer. Each boiler of this type shall be equipped with an automatic low-water cutoff to cut off the power supply before the surface of the water falls below the visible level in the gage glass.
- (5) Tubular gage glasses on electric boilers shall be equipped with protective rods or shields.
- (6) The minimum safety valve or safety relief valve relieving capacity for electric boilers shall be 3 1/2 pounds (24 kilopascals) of steam per hour per kilowatt input.
- (7) All electric boilers shall be internally examined through the electric heating element, removable cover, inspection opening or handhole as construction allows.
(f) Atmospheric vents, gas vents, bleed or relief lines for power boilers, unfired steam boilers and process steam generators with supplemental firing (extensions only, where applicable).
(1) 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. These lines shall be sized in accordance with the component manufacturer's instructions. The vent or relief line shall be at least the same size as the vent outlet of the device.
- (A) 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 paragraphs (2) and (3) following).
- (B) A gas pressure regulator shall not be vented into the boiler flue or exhaust system.
- (2) 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.
- (3) Atmospheric vent lines shall not be connected to any common or manifolded gas vent, bleed, or relief lines.
- (4) 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.
- (5) Vent and relief lines shall be 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 and shall extend sufficiently above any structure so that gaseous discharge does not present a fire hazard. A means shall be provided at the terminating point to prevent blockage of the line by foreign material, moisture, or insects.
(g) Power boilers, excluding unfired steam boilers and process steam generators.
(1) Safety valves and safety relief valves.
- (A) The use of weighted-lever safety valves, or safety valves having either the seat or disk of cast iron, is prohibited.
- (B) 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.
- (C) Safety valves or safety 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 safety relief valve shall have at least the area of the valve inlet.
- (D) 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.
- (E) No valve(s) of any description shall be placed between the required safety valve or safety relief valve or valves and the boiler, nor in the discharge pipe between the safety valve or safety relief valve or valves and the atmosphere. When a discharge pipe 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 pipe. When an elbow is placed on a safety valve discharge pipe, it shall be located close to the safety valve outlet. The discharge pipe shall be securely anchored and supported. 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. All safety valve or safety relief valve discharges shall be located or piped to a safe point of discharge clear from walkways or platforms.
- (F) 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 maximum allowable working pressure. 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.
- (G) One or more safety valves on every boiler shall be set at or below the maximum allowable working pressure. The remaining valve(s) may be set within a range of 3.0% above the maximum allowable working pressure, but the range of setting of all the safety valves on a boiler shall not exceed 10% of the highest pressure to which any valve is set.
- (H) 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.
- (I) 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.
(2) Feedwater supply.
(A) 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:
- (i) the boiler is "M" stamped per ASME Code, Section I;
- (ii) the boiler is designed to be fed manually;
- (iii) the boiler is provided with a means to prevent cold water from entering into a hot boiler; and
- (iv) the boiler is equipped with a warning sign visible to the operator not to introduce cold feedwater into a hot boiler.
- (B) 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.
- (C) 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.
- (D) 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.
- (E) 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. It is recommended that no stop valve be placed in the supply and return pipe connections of a single boiler installation.
- (F) 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.
(3) Water level indicators.
- (A) 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.
- (B) Except for electric boilers of the electrode type, boilers with a maximum allowable working pressure (MAWP) over 400 psig (three megapascals) shall be provided with two water gage glasses, which may be connected to a single water column or connected directly to the drum.
- (C) 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 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.
- (D) 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.
- (E) The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (diameter nominal 15).
- (F) 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 therefrom, shall be placed in the pipes connecting a water column or gage glass to a boiler.
- (G) The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (diameter nominal 20). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (diameter nominal 20) and shall be piped to a safe point of discharge.
- (H) Connections from the boiler to remote level indicators shall be at least 3/4 inch nominal pipe size (diameter nominal 20), to and including the isolation valve, and at least 1/2 inch (13 millimeters) 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.
(4) Low-water fuel cutoff and water feeding devices.
- (A) 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. 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. The low-water fuel cutoff devices shall be tested regularly by lowering the water level in the boiler sufficiently to shut off the fuel supply to the burner when the water level reaches the lowest safe level for operation. The low-water cutoff shall be rated for a pressure and temperature equal to or greater than the maximum allowable working pressure and temperature of the boiler.
- (B) When a low-water fuel cutoff and feedwater pump control are 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.
- (C) 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 (diameter nominal 20). 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.
- (D) 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.
(5) Pressure gages.
- (A) Each boiler shall have a pressure gage that is easily 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. 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.
- (B) Each boiler must have a valved connection at least 1/4 inch nominal pipe size (diameter nominal 8) 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.
(6) Stop valves.
- (A) 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.
- (B) 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.
- (C) 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. The stop valves shall consist preferably of one automatic nonreturn valve (set next to the boiler) and a second valve of the outside-screw-and-yoke type.
(7) Blowdown connection.
- (A) 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.
- (B) 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 readily or easily.
- (C) 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.
- (D) When the maximum allowable working pressure 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.
- (E) 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.
- (F) It is recommended that blowdown tanks be designed, constructed, and installed in accordance with National Board recommended rules for boiler blowoff equipment.
- (8) 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.
(h) Unfired steam boilers.
- (1) Unfired steam boilers referred to in Section 65.10 are shown in Exhibits 5C and 5D.
Attached Graphic
Attached Graphic
- (2) Unfired steam boilers shall be constructed in accordance with the American Society of Mechanical Engineers (ASME), Section I, or ASME, Section VIII, Division 1.
(3) Safety valves and safety relief valves
- (A) The use of weighted-lever safety valves, or safety valves having either the seat or disk of cast iron, is prohibited.
(B) Each ASME Code, Section VIII, Division 1 unfired steam boiler shall have at least one pressure relieving device. Safety valves for ASME, Section VIII, Division 1 unfired steam boilers shall be V or UV stamped. ASME, Section VIII, Division 1 does not require that the relief device be attached directly to the boiler.
- (i) The installation of isolation valves between the unfired steam boiler and the safety valve is permitted for systems designed and installed as depicted in Exhibit 5C.
- (ii) Full-area stop valves may be installed on the inlet side of a safety valve as shown in Exhibit 5C. 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.
- (iii) One or more safety valves on every unfired steam boiler shall be set at or below the maximum allowable working pressure. The remaining valves, if any, shall be set within the range specified and have the capacity required by the applicable ASME code.
(C) 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. ASME Code, Section I safety valves shall be V stamped.
- (i) 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.
- (ii) No valves of any description shall be placed between the required safety valve or safety relief valve or valves and the boiler, nor on the discharge pipe between the safety valve or safety relief valve and the atmosphere.
- (iii) 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 maximum allowable working pressure.
- (D) 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.
- (E) 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.
(F) Safety valve and safety relief valve mountings.
- (i) For ASME Code, Section I installations, safety valves or safety 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 safety relief valve shall have at least the area of the valve inlet.
(ii) For ASME Code, Section VIII, Division 1 installations, safety valves or safety 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.
(4) Feedwater supply.
- (A) Each unfired steam boiler shall have a feedwater supply which will permit it to be fed at any time while under pressure.
- (B) 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.
- (C) 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.
(5) Water level indicators.
- (A) ASME Code, Section I unfired steam boilers with a maximum allowable working pressure (MAWP) of 400 psig (three megapascals) or less shall have at least one gage glass. For a MAWP over 400 psig (three 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.
- (B) 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.
- (C) 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.
- (D) The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (diameter nominal 15).
- (E) 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.
- (F) The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (diameter nominal 20). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (diameter nominal 20) and shall be piped to a safe point of discharge.
- (G) Connections from the unfired steam boiler to remote level indicators shall be at least 3/4 inch nominal pipe size (diameter nominal 20), to and including the isolation valve, and at least 1/2 inch (13 millimeters) 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.
(6) Low-water cutoffs, alarms and feed regulating devices.
- (A) 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 or greater than the maximum allowable working pressure of the unfired steam boiler.
- (B) 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 (diameter nominal 20). 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.
- (C) 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.
(7) Pressure gages.
- (A) Each unfired steam boiler shall have a pressure gage that is easily 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.
- (B) Each unfired steam boiler must have a valved connection at least 1/4 inch nominal pipe size (diameter nominal 8) 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.
(8) Stop valves.
- (A) 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.
- (B) 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.
- (C) 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.
(i) Process steam generators.
- (1) Some process steam generators referred to in Section 65.10 are shown in Exhibits 5A and 5B.
Attached Graphic
Attached Graphic
- (2) 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 or Division 2, and shall be stamped with the U or U2 symbol. As an alternate the process steam generator may be constructed to ASME Code, Section I.
- (3) When the owner/operator elects to construct a process steam generator to ASME Code, Section I, the limits as shown in Exhibits 5A and 5B are as defined in the rules of ASME Section I.
(4) Safety valves and safety relief valves.
- (A) The use of weighted-lever safety valves, or safety valves having either the seat or disk of cast iron is prohibited.
(B) 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 with the V or UV stamp. The valve body drain shall be open and piped to a safe point of discharge.
- (i) 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 Exhibit 5A and 5B. 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.
- (ii) One or more safety valves on every steam collection or liberation drum of a process steam generator shall be set at or below the maximum allowable working pressure. The remaining valves, if any, shall be set within the range specified and have the capacity required by the applicable ASME code.
(C) 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 V stamped.
- (i) 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.
- (ii) No valves of any description shall be placed between the required safety valve or safety relief valve or valves and the steam collection or liberation drum, nor on the discharge pipe between the safety valve or safety relief valve and the atmosphere.
- (iii) The safety valve capacity of each process steam generator must 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 maximum allowable working pressure.
- (D) 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.
- (E) 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 process steam generators.
(F) Safety valve and safety relief valve mountings.
- (i) For ASME Code, Section I installations, safety valves or safety 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 safety relief valve shall have at least the area of the valve inlet.
(ii) For ASME Code, Section VIII, Division 1 or Division 2 installations, safety valves or safety 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.
(5) Feedwater supply.
- (A) 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.
- (B) 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.
- (C) 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.
(6) Water level indicators.
- (A) ASME Code, Section I process steam generators with a MAWP of 400 psig (three megapascals) or less shall have at least one gage glass. For a MAWP over 400 psig (three 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.
- (B) Each steam collection or liberation drum of an ASME Code, Section VIII, Division 1 or Division 2 process steam generator, irrespective of pressure and temperature, as shown in Exhibit 5A and 5B 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.
- (C) 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.
- (D) The gage glass cock connections shall not be less than 1/2 inch nominal pipe size (diameter nominal 15).
- (E) 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.
- (F) The water column shall be fitted with a drain cock or drain valve of at least 3/4 inch nominal pipe size (diameter nominal 20). The water column blowdown pipe shall not be less than 3/4 inch nominal pipe size (diameter nominal 20) and shall be piped to a safe point of discharge.
- (G) 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 diameter nominal 20), to and including the isolation valve, and at least 1/2 inch (13 millimeters) 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.
(7) Low-water cutoffs, alarms and feed regulating devices.
- (A) 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 maximum allowable working pressure and temperature of the process steam generator steam collection or liberation drum.
- (B) 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 (diameter nominal 20). 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.
- (C) 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 fail safe design, it shall be provided with a low-water cutoff as required for power boilers.
(8) Pressure gages.
- (A) Each steam collection or liberation drum of a process steam generator shall have a pressure-indicating device that is easily 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.
- (B) Each steam collection or liberation drum of a process steam generator must have a valved connection at least 1/4 inch nominal pipe size (diameter nominal 8) 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.
(9) Stop valves.
- (A) Each steam outlet from a 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.
- (B) 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.
- (C) 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.
(j) Nuclear boilers.
- (1) Nuclear boilers shall be inspected inservice by the owner or operator in accordance with ASME Boiler and Pressure Vessel Code, Section XI.
- (2) The owner or operator shall engage the services of an inspection agency, qualified in accordance with American National Standards Institute/American Society of Mechanical Engineers (ANSI/ASME) N626.1, licensed by the Texas State Board of Insurance, and authorized to provide inspection services by the executive director.
(3) The chief inspector shall assign, after receipt of the completed N-3 owner's data report, a state serial number to the nuclear boiler.
- (A) All N-5 data reports for piping systems and N-3 owner's data reports shall be filed with the chief inspector.
- (B) National Board registration described in Section 65.50(a) or Section 65.20(c)(1)(D) is not required.
- (4) The certificate of operation will be issued after receipt of the preservice inspection summary report and prior to commercial service. The summary report shall include all activities required by ASME Code, Section XI, except for the results of examinations or test of items obtainable only during power ascension testing. These items shall be filed as an amendment to the summary report within 60 days of the completion of the power ascension testing. The items identified to be submitted in the amendment shall be agreed upon by mutual consent as provided for in paragraph (11) of this subsection prior to power ascension testing and issuance of the certificate of operation.
- (5) The inservice inspection plan shall be submitted to the chief inspector by the owner or operator prior to commercial service.
- (6) The chief inspector shall review the inservice inspection plan and select those items necessary to verify compliance with the Health and Safety Code, Chapter 755 and ASME Code, Section XI. Items selected for verification shall be from within the verification boundary of the nuclear boiler consisting of the components and component supports of the systems illustrated in Exhibit 6.
Attached Graphic
- (7) The chief inspector shall, upon reasonable notification by the owner or operator of inservice inspection activities to be accomplished during any outage on items selected in subsection (h) of this section, coordinate with the owner or operator the verification activities.
- (8) The chief inspector shall review and maintain summary reports of the inservice inspections that are submitted by the owner or operator in accordance with ASME Code, Section XI.
- (9) Repairs and/or replacements shall conform to the requirements of ASME Code, Section XI.
- (10) The owner or operator shall, in case of serious accidents to a nuclear boiler involving a breach of the pressure boundary integrity of components included in Exhibit 6 immediately notify the chief inspector by the most expeditious means available and apprise him of the nature of the accident. The chief inspector shall assess the nature of the accident, formulate inspection activities as required, and coordinate these activities with the owner or operator and as necessary with other state and federal agencies having jurisdiction.
- (11) If exceptions or situations arise which are not specifically addressed in this section or other sections of the Boiler Law and Rules, or in ASME Code, Section XI, the owner or operator shall contact the chief inspector for guidance or interpretation.
(k) Heating boilers.
(1) Steam heating.
(A) Safety valves.
- (i) Each steam boiler shall have one or more officially rated safety valves of the spring pop type adjusted and sealed to discharge at a pressure not to exceed 15 psig (103 kilopascals). Seals shall be attached in a manner to prevent the valve from being taken apart without breaking the seal. The safety valves shall be arranged so that they cannot be reset to relieve at a higher pressure than the maximum allowable working pressure of the boiler. A body drain connection below seat level shall be provided. For valves exceeding 2 1/2 inch nominal pipe size (diameter nominal 65), the drain hole or holes shall be tapped not less than 3/8 inch nominal pipe size (diameter nominal 10). For valves 2 1/2 inch nominal pipe size (diameter nominal 65) or less, the drain hole shall not be less than 1/4 inch (6 millimeters) in diameter.
- (ii) Each safety valve 3/4 inch nominal pipe size (diameter nominal 20) or over used on a steam boiler shall have a substantial lifting device which will positively lift the disk from its seat at least 1/16 inch (1.6 millimeters) when there is no pressure on the boiler. The seats and disks shall be of suitable material to resist corrosion.
- (iii) No safety valve for a steam boiler shall be smaller than 1/2 inch nominal pipe size (diameter nominal 15). No safety valve shall be larger than 4 1/2 inches nominal pipe size (diameter nominal 115). The inlet opening shall have an inside diameter approximately equal to, or greater than, the seat diameter.
- (iv) The minimum relieving capacity of valve or valves shall be governed by the capacity marking on the boiler.
- (v) The minimum valve capacity in pounds per hour shall be the greater of that determined by dividing the maximum Btu output at the boiler nozzle obtained by the firing of any fuel for which the unit is installed by 1,000, or shall be determined on the basis of the pounds of steam generated per hour per square foot of boiler heating surface as given in Table 1 of Exhibit 2. For cast iron boilers, the minimum valve capacity shall be determined by the maximum output method. In every case, the safety valve capacity for each steam boiler shall be such that with the fuel burning equipment installed, and operated at maximum capacity, the pressure cannot rise more than five psig (35 kilopascals) above the maximum allowable working pressure.
Attached Graphic
- (vi) Safety valve piping. No valve shall be placed between the safety valve and the boiler or on the discharge pipe between the safety valve and the atmosphere. When a discharge pipe is used, it shall be full size and fitted with an open drain to prevent water from lodging in the upper part of the safety valve or relief valve or in the discharge pipe. When an elbow is placed on the safety valve discharge pipe, it shall be located close to the valve outlet. The discharge pipe shall be securely anchored and supported, independent of the valve.
- (vii) Safety valves and safety relief valves shall be installed on the boiler with their spindles vertical. The opening or connection between the boiler and any safety valve or safety relief valve shall have at least the area of the valve inlet.
(B) Feedwater connections.
- (i) Feedwater, or water treatment shall be introduced into a boiler through the return piping system or through an independent feedwater connection which does not discharge against parts of the boiler exposed to direct radiant heat from the fire. Feedwater, or water treatment shall not be introduced through openings or connections provided for inspection or cleaning, safety valve, surface blowoff, water column, water gage glass, pressure gage, or temperature gage.
- (ii) Feedwater pipe shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler or return pipe system.
(C) Low-water fuel cutoffs and water feeding devices.
- (i) 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 automatic low-water fuel cutoffs installed in such a manner that they cannot be rendered inoperative by the manipulation of any manual control or regulating apparatus. The low-water fuel cutoff devices shall be tested regularly by lowering the water level in the boiler sufficiently to shut off the fuel supply to the burner when the water level reaches the lowest safe level for operation.
- (ii) The MAWP of all low water fuel cutoff devices shall be set at or above the boiler stamped MAWP.
- (iii) When low-water fuel cutoff and feedwater pump controls are 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.
- (iv) 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 (diameter nominal 20). 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 fuel cutoff device.
- (v) 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.
(D) Pressure gages.
- (i) Each steam heating boiler shall have a pressure gage connected to the device exterior to the boiler. The gage shall be of sufficient capacity to keep the gage tube filled with water and arranged so that the gage cannot be shut off from the boiler except by a cock with tee or lever handle placed in a pipe near the gage. The handle of the cock shall be parallel to the pipe in which it is located when the cock is open.
- (ii) The scale on the dial of a steam heating boiler pressure gage shall be graduated to not less than 30 psig (207 kilopascals) nor more than 60 psig (414 kilopascals). The travel of the pointer from zero to 30 psig (207 kilopascals) pressure shall be at least three inches.
(E) Stop valves.
- (i) Single steam heating boilers. When a stop valve is used in the supply pipe connection of a single steam heating boiler, there shall be one used in the return pipe connection.
- (ii) Supply and return line. Each supply and return line to a steam heating boiler, which may be entered while adjacent boilers are in operation, shall be fitted with either two stop valves with ample drain between or a stop valve and figure 8 blank. The blank shall be installed between the stop valve and the boiler.
- (iii) Type of stop valve. When stop valves over two inches in size are used, they shall be of the outside screw-and-yoke rising stem type or of such other type as to indicate at a distance whether it is closed or open by the position of its stem or other operating mechanism. The wheel may be carried either on the yoke or attached to the stem. If the valve is of the plug cock type, it shall be fitted with a slow opening mechanism and an indicating device and the plug shall be held in place by a guard or gland.
(F) Bottom blowdown or drain valve.
- (i) Bottom blowoff valve. Each steam heating boiler shall have a bottom blowoff connection fitted with a valve or cock connected to the lowest water space practicable with a minimum size as shown in Table 2 of Exhibit 2 in Figure 65.100(k)(1)(A)(v). The discharge piping shall be full size to the point of discharge. Boilers having a capacity of 25 gallons (95 liters) or less are exempt from these requirements.
- (ii) Drain valve. Each boiler shall have one or more drain connections, fitted with valves or cocks connecting to the lowest water containing spaces. The minimum size of the drain piping, valves, and cocks shall be 3/4 inch nominal pipe size (diameter nominal 20). The discharge piping shall be full size to the point of discharge. When the blowoff connection is located at the lowest water containing space, a separate drain connection is not required.
- (iii) Minimum pressure rating. The minimum pressure rating of valves and cocks used for blowoff or drain purposes shall be at least equal to the pressure stamped on the boiler, but in no case less than 30 psig (207 kilopascals). The temperature rating of such valves and cocks shall not be less than 250 degrees Fahrenheit (121 degrees Celsius).
(G) Water gage glasses.
- (i) Each steam heating boiler shall have one or more water gage glasses attached to the water column or boiler by means of valved fittings not less than 1/2 inch nominal pipe size (diameter nominal 15). The lower fitting shall have a drain valve of the straightway type with opening not less than 1/4 inch (6 millimeters) diameter to facilitate cleaning. Gage glass replacement shall be possible under pressure.
- (ii) Transparent material, other than glass, may be used for the water gage provided that the material will remain transparent and has proved suitable for the pressure, temperature, and corrosive conditions encountered in service.
(2) Hot water heating.
(A) Safety relief valves.
- (i) Each hot water heating boiler shall have at least one officially rated safety relief valve set to relieve at or below the maximum allowable working pressure of the boiler.
- (ii) When more than one safety relief valve is used on a hot water heating boiler, the additional valve or valves shall be officially rated and may have a set pressure within a range not to exceed six psig (42 kilopascals) above the maximum allowable working pressure of the boiler up to and including 60 psig (414 kilopascals), and 5.0% for those having a maximum allowable working pressure exceeding 60 psig (414 kilopascals).
- (iii) Safety relief valves shall be spring loaded. Safety relief valves shall be set and sealed so that they cannot be reset without breaking the seal. A body drain connection below seat level shall be provided. For valves exceeding 2 1/2 inch nominal pipe size (diameter nominal 65), the drain hole or holes shall be tapped not less than 3/8 inch nominal pipe size (diameter nominal 10). For valves of 2 1/2 inch nominal pipe size (diameter nominal 65) or less, the drain hole shall not be less than 1/4 inch (6 millimeters) diameter.
- (iv) Each safety relief valve shall have a substantial lifting device which will positively lift the disk from its seat at least 1/16 inch (1.6 millimeters) when there is no pressure on the boiler.
- (v) Seats and disks of safety relief valves shall be made of a suitable material to resist corrosion. No materials likely to fail due to deterioration or vulcanization, when subjected to saturated steam temperature corresponding to capacity test pressure, shall be used for any part.
- (vi) No safety relief valve shall be smaller than 3/4 inch nominal pipe size (diameter nominal 20) nor larger than 4 1/2 inch nominal pipe size (diameter nominal 115) except that boilers having a heat input not greater than 15,000 Btu/hr (4.4 kilowatts) may be equipped with a rated safety relief valve of 1/2 inch nominal pipe size (diameter nominal 15). The inlet opening shall have an inside diameter approximately equal to, or greater than, the seat diameter. In no case shall the minimum opening through any part of the valve be less than 1/4 inch (6 millimeters) diameter or its equivalent area.
- (vii) The required steam relieving capacity, in pounds per hour, of the pressure relieving device or devices on a boiler shall be the greater of that determined by dividing the maximum output in Btu at the boiler nozzle obtained by the firing of any fuel for which the unit is installed by 1,000, or shall be determined on the basis of pounds of steam generated per hour per square foot of boiler heating surface as given in Table 1 Exhibit 2 as shown in Figure 65.100(k)(1)(A)(v). For cast iron boilers the minimum valve capacity shall be determined by the maximum output method.
- (viii) In every case, the safety relief valve capacity for each boiler with a single safety relief valve shall be such that, with the fuel burning equipment installed and operated at maximum capacity, the pressure cannot rise more than 10% above the maximum allowable working pressure. When more than one safety relief valve is used, the overpressure shall be limited to 10% above the set pressure of the highest set valve.
- (ix) Safety relief valve piping. No valve shall be placed between the safety relief valve and the boiler or on the discharge pipe between the safety relief valve and the drain. When a discharge pipe is used, it shall be full size and fitted with an open drain to prevent water from lodging in the upper part of the safety relief valve or in the discharge pipe. When an elbow is placed on the safety relief valve discharge pipe, it shall be located close to the valve outlet. The discharge pipe shall be securely anchored and supported, independent of the valve.
- (x) Safety relief valves and safety valves shall be installed on the boiler with their spindles vertical. The opening or connection between the boiler and any safety relief valve or safety valve shall have at least the area of the valve inlet.
(B) Makeup water connections.
- (i) Makeup water, or water treatment shall be introduced into a boiler through the return piping system or through an independent makeup water connection which does not discharge against parts of the boiler exposed to direct radiant heat from the fire. Makeup water, or water treatment shall not be introduced through openings or connections provided for inspection or cleaning, safety relief valve, pressure gage, or temperature gage.
- (ii) Makeup water pipe shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler or between the check valve and the piping system.
(C) Low-water fuel cutoffs and water feeding devices.
- (i) All automatically fired hot water heating boiler shall have an automatic low-water fuel cutoff that has been designed for hot water service, and it shall be so located as to automatically cut off the fuel supply when the surface of the water falls to a level below the normal waterline established.
- (ii) The MAWP of all low water fuel cutoff and flow sensing devices shall be set at or above the boiler stamped MAWP.
- (iii) When low-water fuel cutoff and feedwater pump controls are 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.
- (iv) 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 (diameter nominal 20). 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 fuel cutoff device.
- (v) As there is no normal water line to be maintained in a hot water heating boiler, any location of the low-water fuel cutoff above the lowest safe water level established by the boiler manufacturer is satisfactory.
- (vi) All automatically fired hot water heating boilers, when installed in a forced circulation system and not under continuous attendance, shall be equipped in the manner described in this subsection. A coil-type boiler or a water-tube boiler requiring forced circulation to prevent overheating of the coils or tubes shall have a flow sensing device which is listed by a nationally recognized testing agency to prevent burner operation at a flow rate inadequate to protect the boiler unit against overheating.
- (vii) 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.
(D) Pressure gages.
- (i) Each hot water heating boiler shall have a pressure or altitude gage connected to it or to its flow connection which cannot be shut off from the boiler except by a cock with tee or lever handle placed in a pipe near the gage. The handle of the cock shall be parallel to the pipe in which it is located when the cock is open.
- (ii) The scale on the dial of the pressure or altitude gage shall be graduated to not less than 1 1/2 nor more than 3 1/2 times the pressure at which the safety relief valve is set. The gage shall be provided with effective stops for the indicating pointer at the zero point and at the maximum pressure point.
- (iii) Piping and tubing for pressure or altitude gage connections shall be of nonferrous metal when smaller than 1 inch nominal pipe size (diameter nominal 25).
(E) Stop valves.
- (i) Stop valves shall be located at an accessible point in the supply and return pipe connections near the boiler nozzle of a single hot water heating boiler installation to permit draining the boiler without emptying the system.
- (ii) When the boiler is located above the system and can be drained without draining the system, stop valves may be eliminated.
- (iii) Type of stop valve. When stop valves over two inches in size are used, they shall be of the outside screw-and-yoke rising stem type or of such other type as to indicate at a distance whether it is closed or open by the position of its stem or other operating mechanism. The wheel may be carried either on the yoke or attached to the stem. If the valve is of the plug cock type, it shall be fitted with a slow opening mechanism and an indicating device and the plug shall be held in place by a guard or gland.
(F) Drain valve.
- (i) Each hot water heating boiler shall have one or more drain connections, fitted with valves or cocks connecting to the lowest water containing spaces. The minimum size of the drain piping, valves, and cocks shall be 3/4 inch nominal pipe size (diameter nominal 20). The discharge piping shall be full size to the point of discharge. When the blowoff connection is located at the lowest water containing space, a separate drain connection is not required.
- (ii) Minimum pressure rating. The minimum pressure rating of valves and cocks used for blowoff or drain purposes shall be at least equal to the pressure stamped on the boiler, but in no case less than 30 psig (207 kilopascals). The temperature rating of such valves and cocks shall not be less than 250 degrees Fahrenheit (121 degrees Celsius).
(G) Provisions for thermal expansion.
- (i) Heating systems with open expansion tank - An indoor overflow from the upper portion of the expansion tank shall be provided in addition to an open vent, the indoor overflow to be carried within the building to a suitable plumbing fixture or basement.
- (ii) Closed heating system - If the system is of closed type, an airtight tank or other suitable air cushion that is consistent with the volume and capacity of the system shall be installed. If the system is designed for a working pressure of 30 psi (207 kilopascals) or less, the tank shall be suitably designed for a minimum hydrostatic pressure of 75 psi (520 kilopascals). Expansion tanks for systems designed to operate above 30 psig (207 kilopascals) shall be constructed in accordance with the ASME Code, Section VIII, Division 1. Alternatively, a tank built to ASME Section X requirements may be used if the pressure and temperature ratings of the tank are equal to or greater than the pressure and temperature ratings of the system. Provision shall be made for draining the tank without emptying the system, except for pre-pressurized tanks.
(3) Hot water supply.
(A) Safety relief valves.
- (i) Each hot water supply boiler shall have at least one officially rated safety relief valve set to relieve at or below the maximum allowable working pressure of the boiler.
- (ii) When more than one safety relief valve is used on a hot water supply boiler, the additional valve or valves shall be officially rated and may have a set pressure within a range not to exceed six psig (42 kilopascals) above the maximum allowable working pressure of the boiler up to and including 60 psig (414 kilopascals), and 5.0% for those having a maximum allowable working pressure exceeding 60 psig (414 kilopascals).
- (iii) Safety relief valves shall be spring loaded. Safety relief valves shall be set and sealed so that they cannot be reset without breaking the seal. A body drain connection below seat level shall be provided. For valves exceeding 2 1/2 inch nominal pipe size (diameter nominal 65), the drain hole or holes shall be tapped not less than 3/8 inch nominal pipe size (diameter nominal 10). For valves of 2 1/2 inch nominal pipe size (diameter nominal 65) or less, the drain hole shall not be less than 1/4 inch (6 millimeters) diameter.
- (iv) Each safety relief valve shall have a substantial lifting device which will positively lift the disk from its seat at least 1/16 inch (1.6 millimeters ) when there is no pressure on the boiler.
- (v) Seats and disks of safety relief valves shall be made of a suitable material to resist corrosion. No materials likely to fail due to deterioration or vulcanization, when subjected to saturated steam temperature corresponding to capacity test pressure, shall be used for any part.
- (vi) No safety relief valve shall be smaller than 3/4 inch nominal pipe size (diameter nominal 20) nor larger than 4 1/2 inch nominal pipe size (diameter nominal 115) except that boilers having a heat input not greater than 15,000 Btu/hr (4.4 kilowatts) may be equipped with a rated safety relief valve of 1/2 inch nominal pipe size (diameter nominal 15). The inlet opening shall have an inside diameter approximately equal to, or greater than, the seat diameter. In no case shall the minimum opening through any part of the valve be less than 1/4 inch (6 millimeters) diameter or its equivalent area.
- (vii) The required steam relieving capacity, in pounds per hour, of the pressure relieving device or devices on a boiler shall be the greater of that determined by dividing the maximum output in Btu at the boiler nozzle obtained by the firing of any fuel for which the unit is installed by 1,000, or shall be determined on the basis of pounds of steam generated per hour per square foot of boiler heating surface as given in Table 1 Exhibit 2 as shown in Figure 65.100(k)(1)(A)(v). For cast iron boilers the minimum valve capacity shall be determined by the maximum output method.
- (viii) In every case, the safety relief valve capacity for each boiler with a single safety relief valve shall be such that, with the fuel burning equipment installed and operated at maximum capacity, the pressure cannot rise more than 10% above the maximum allowable working pressure. When more than one safety relief valve is used, the overpressure shall be limited to 10% above the set pressure of the highest set valve.
- (ix) Safety relief valve piping. No valve shall be placed between the safety relief valve and the boiler nor on the discharge pipe between the safety relief valve and the drain. When a discharge pipe is used, it shall be full size and fitted with an open drain to prevent water from lodging in the upper part of the safety relief valve or in the discharge pipe. When an elbow is placed on the safety relief valve discharge pipe, it shall be located close to the valve outlet. The discharge pipe shall be securely anchored and supported, independent of the valve.
- (x) Safety relief valves and safety valves shall be installed on the boiler with their spindles vertical. The opening or connection between the boiler and any safety relief valve or safety valve shall have at least the area of the valve inlet.
(B) Makeup water connections.
- (i) Makeup water, or water treatment shall be introduced into a boiler through the return piping system or through an independent makeup water connection which does not discharge against parts of the boiler exposed to direct radiant heat from the fire. Makeup water, or water treatment shall not be introduced through openings or connections provided for inspection or cleaning, safety relief valve, pressure gage, or temperature gage.
- (ii) Makeup water pipe shall be provided with a check valve near the boiler and a stop valve or cock between the check valve and the boiler or between the check valve and the piping system.
(C) Low-water fuel cutoffs and water feeding devices.
- (i) All automatically fired hot water supply boiler shall have an automatic low-water fuel cutoff that has been designed for hot water service, and it shall be so located as to automatically cut off the fuel supply when the surface of the water falls to a level below the normal waterline established.
- (ii) The MAWP of all low water fuel cutoff and flow sensing devices shall be set at or above the boiler stamped MAWP.
- (iii) When low-water fuel cutoff and feedwater pump controls are 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.
- (iv) 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 (diameter nominal 20). 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 fuel cutoff device.
- (v) As there is no normal water line to be maintained in a hot water supply boiler, any location of the low-water fuel cutoff above the lowest safe water level established by the boiler manufacturer is satisfactory.
- (vi) All automatically fired hot water heating boilers, when installed in a forced circulation system and not under continuous attendance, shall be equipped in the manner described in this subsection. A coil-type boiler or a water-tube boiler requiring forced circulation to prevent overheating of the coils or tubes shall have a flow sensing device which is listed by a nationally recognized testing agency to prevent burner operation at a flow rate inadequate to protect the boiler unit against overheating.
- (vii) 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.
(D) Pressure gages.
- (i) Each hot water supply boiler shall have a pressure or altitude gage connected to it or to its flow connection which cannot be shut off from the boiler except by a cock with tee or lever handle placed in a pipe near the gage. The handle of the cock shall be parallel to the pipe in which it is located when the cock is open.
- (ii) The scale on the dial of the pressure or altitude gage shall be graduated to not less than 1 1/2 nor more than 3 1/2 times the pressure at which the safety relief valve is set. The gage shall be provided with effective stops for the indicating pointer at the zero point and at the maximum pressure point.
- (iii) Piping and tubing for pressure or altitude gage connections shall be of nonferrous metal when smaller than 1 inch nominal pipe size (diameter nominal 25).
(E) Stop valves.
- (i) Stop valves shall be located at an accessible point in the supply and return pipe connections near the boiler nozzle of a single hot water supply boiler installation to permit draining the boiler without emptying the system.
- (ii) When the boiler is located above the system and can be drained without draining the system, stop valves may be eliminated.
- (iii) Type of stop valve. When stop valves over two inches in size are used, they shall be of the outside screw-and-yoke rising stem type or of such other type as to indicate at a distance whether it is closed or open by the position of its stem or other operating mechanism. The wheel may be carried either on the yoke or attached to the stem. If the valve is of the plug cock type, it shall be fitted with a slow opening mechanism and an indicating device and the plug shall be held in place by a guard or gland.
(F) Drain valve.
- (i) Each hot water supply boiler shall have one or more drain connections, fitted with valves or cocks connecting to the lowest water containing spaces. The minimum size of the drain piping, valves, and cocks shall be 3/4 inch nominal pipe size (diameter nominal 20). The discharge piping shall be full size to the point of discharge. When the blowoff connection is located at the lowest water containing space, a separate drain connection is not required.
- (ii) Minimum pressure rating. The minimum pressure rating of valves and cocks used for blowoff or drain purposes shall be at least equal to the pressure stamped on the boiler, but in no case less than 30 psig (207 kilopascals). The temperature rating of such valves and cocks shall not be less than 250 degrees Fahrenheit (121 degrees Celsius).
- (G) Provisions for thermal expansion. If a system is equipped with a check valve or pressure reducing valve in the cold water inlet line, consideration should be given to the installation of an airtight expansion tank or other suitable air cushion. Otherwise, due to the thermal expansion of the water, the safety relief valve may lift periodically. If an expansion tank is provided, it shall be constructed in accordance with the ASME Code, Section VIII, Division 1 or Section X. Except for pre-pressurized tanks, which should be installed on the cold water side, provisions shall be made for draining the tank without emptying the system.
(4) Potable water heaters.
(A) Safety relief valves.
- (i) Potable water heaters (tank type) shall have at least one officially rated pressure temperature safety relief valve of the automatic reseating type set to relieve at or below the maximum allowable pressure of the heater. No safety relief valve shall be smaller than 3/4 inch nominal pipe size (diameter nominal 20).
- (ii) The relief valve shall have a capacity equal to or exceeding the rated burner input of the heater. The relieving capacity for electric water heaters shall be 3,500 Btu/hr (1.0 kilowatts) per kilowatt of input.
- (iii) The ASME Btu rating on the valve shall be used to determine the relieving capacity.
- (iv) Relief valves shall be connected directly to the heater within the top six inches of the tank.
- (v) Relief valves may be installed vertically or horizontally. The center line of the horizontal connection shall be no lower than four inches from the top of the shell.
- (vi) Relief valves shall not be connected to an internal pipe in the heater, or to a cold water feed line connected to the heater.
- (vii) Safety relief valve piping. No valve shall be placed between the safety relief valve and the boiler nor on the discharge pipe between the safety relief valve and the drain. When a discharge pipe is used, it shall be full size and fitted with an open drain to prevent water from lodging in the upper part of the safety relief valve or in the discharge pipe. When an elbow is placed on the safety relief valve discharge pipe, it shall be located close to the valve outlet. The discharge pipe shall be securely anchored and supported, independent of the valve.
(B) Water supply.
- (i) Water supply shall be introduced into a water heater through an independent water supply connection. Water shall not be introduced through openings or connections provided for cleaning, safety relief valves, drains, pressure gage or temperature gage.
- (ii) If the water supply pressure to a hot water heater exceeds 75% of the set pressure of the safety relief valve, a pressure reducing valve is required.
(C) Flow sensing device.
- (i) All automatically fired potable water heater, when installed in a forced circulation system and not under continuous attendance, shall be equipped in the manner described in this subsection. A coil-type boiler or a water-tube boiler requiring forced circulation to prevent overheating of the coils or tubes shall have a flow sensing device which is listed by a nationally recognized testing agency to prevent burner operation at a flow rate inadequate to protect the boiler unit against overheating.
- (ii) The MAWP of all flow sensing devices shall be set at or above the boiler stamped MAWP.
(D) Gages.
- (i) Temperature gages. Each hot water heater shall have a thermometer located and connected at or near the outlet that is easily readable. The thermometer shall at all times indicate the temperatures of the water in the hot water heater.
- (ii) Pressure gages. Each hot water heater that is of the coil type or water tube shall have a pressure gage that is graduated to not less than 1 1/2 or more than 3 1/2 times the pressure at which the safety relief valve is set.
- (E) Stop valves. Stop valves should be placed in the supply and discharge pipe connections of the hot water heater installation to permit draining the heater without emptying the system.
- (F) Drain valves. Each hot water heater shall have a bottom drain pipe connection fitted with a valve or cock connected to the lowest water space practical. The minimum size bottom drain shall be 3/4 inch nominal pipe size (diameter nominal 20).
- (G) Provisions for thermal expansion. If a system is equipped with a check valve or pressure reducing valve in the cold water inlet line, consideration should be given to the installation of an airtight expansion tank or other suitable air cushion. Otherwise, due to the thermal expansion of the water, the safety relief valve may lift periodically. If an expansion tank is provided, it shall be constructed in accordance with the ASME Code, Section VIII, Division 1 or Section X. Except for pre-pressurized tanks, which should be installed on the cold water side, provisions shall be made for draining the tank without emptying the system.
(l) Repairs and alterations.
(1) Repairs and alterations shall conform to the current edition of the National Board Inspection Code (NBIC) and addenda; and shall be acceptable to the inspector, except that repairs and alterations may be performed by the following provided the intended work is within the scope of the issued certificate of authorization:
- (A) holders of a certificate of authorization from the National Board of Boiler and Pressure Vessel Inspectors for use of the R repair symbol stamp; or
(B) owner/operators of boilers who have been issued a certificate of authorization by the Texas Department of Licensing and Regulation.
- (i) Issuance of the certificate of authorization will be made upon submission of an application, on forms provided by the department.
(ii) Review of the applicant's program and facilities initially and at subsequent three-year intervals will be done.
- (I) The review will determine the applicant has a documented program to control repairs and/or alterations conforming to minimum requirements established by the department.
- (II) The review will require demonstration of the applicant's ability to perform repairs and/or alterations by implementing on representative work the requirements of the written program.
(2) Non-welded repairs.
- (A) Replacement parts made of plate material used for pressure retaining shall require material test reports (MTR). Traceability to the MTR must be maintained at all times.
- (B) Replacement parts fabricated by welding shall be certified, stamped with the appropriate ASME Code symbol and inspected by an authorized inspector as required by the ASME Code.
- (C) When a non-welded repair involves the replacement of cast or forged parts that are identified with the ASME Code symbol at the time of casting or forging, these parts shall be replaced with cast or forged parts that are identified with the ASME Code symbol or so certified by the manufacturer to be in accordance with the original code of construction.
- (D) All other materials shall not require MTR's, provided the material is identified with the material specification, grade, lot and rating as required by the material or product specification and the ASME Code.
- (E) When used parts are utilized for non-welded repairs, it is the repair entity's responsibility to ensure the parts are identified as required above.
- (m) Lap seam cracks. The shell or drum of a boiler in which a typical lap seam crack is discovered along a longitudinal riveted lap-type joint shall be immediately and permanently discontinued for use under pressure. A lap seam crack is the typical crack frequently found in lap seams, which extends parallel to the longitudinal joint and is located either between or adjacent to rivet holes.
(n) Hydrostatic pressure tests.
- (1) When there is a question or doubt about the extent of a defect found in a boiler, the inspector may require a hydrostatic pressure test.
- (2) In preparing a boiler for a hydrostatic pressure test, the boiler shall be filled with water to the stop valve and all air vented off. If the boiler to be tested is connected with other boilers that are under pressure, such connections shall be blanked off unless they have double stop valves on all connection pipes with a drain between.
- (3) During a hydrostatic pressure test of a boiler, the safety valve or valves shall be removed or each valve disc shall be held to its seat by means of a testing clamp and not by screwing down the compression screw under the spring.
- (4) The metal temperature for the pressure test shall not be less than 60 degrees Fahrenheit (16 degrees Celsius) unless the owner provides information on the toughness characteristics of the material for a lower test temperature, but the maximum metal temperature shall not exceed 120 degrees Fahrenheit (50 degrees Celsius) unless a higher temperature is specified and is acceptable to the inspector.
(5) When a hydrostatic pressure test is to be applied after inspection, the pressure shall be as follows.
- (A) For all cases involving the question of tightness, the pressure shall be no more than the set pressure of the safety valve or valves having the lowest setting.
- (B) For all cases involving the question of safety, the pressure applied shall not exceed the lesser of that which was required by the original code of construction, or the pressure equal to that which results in an applied stress no greater than 90% of the specified minimum yield stress at test temperature of the material as published by ASME Code, Section II, Part D, current edition and addenda.
(o) Authority to set and seal safety appliances. All safety and safety relief valves for ASME Sections I, IV, and VIII Division 1 boilers must be repaired, tested, set, and sealed by one of the following, provided the scope of the issued certificate of authorization covers the work to be performed:
- (1) an organization holding a valid V, HV, or UV certificate of authorization, as appropriate, issued by the American Society of Mechanical Engineers (ASME); or
- (2) an organization holding a valid VR certificate of authorization issued by the National Board of Boiler and Pressure Vessel Inspectors; or
(3) an organization holding a valid owner/operator certificate of authorization issued by the department. Such authorization may be granted or withheld by the executive director.
- (A) If authorization is granted and proper administrative fees as provided for in Section 65.80(b) are paid, a certificate of authorization will be issued, expiring on the triennial anniversary date. The certificate shall indicate authorization to repair ASME Sections I, IV, or VIII valves, as verified by testing and as covered by the repair organization's quality control manual. The certificate will be signed by the executive director and the chief inspector.
- (B) The applicant should apply to the department for renewal of authorization and reissuance of the certificate six months prior to the date of expiration.
- (C) The owner/operator certificate of authorization is renewable every three years. Before issuance or renewal of the certificate of authorization, the repair organization and its facilities are subject to a review and demonstration of its quality control system by an inspector.
(D) Before the owner/operator certificate of authorization may be issued or renewed, two valves which have been repaired by the applicant must successfully complete operational verification tests as follows:
- (i) visual examination to ensure the quality of material and workmanship;
- (ii) verification that critical parts meet the valve manufacturer's specifications. Critical parts that are replaced must be fabricated to the valve manufacturer's specifications. Critical parts which require repair shall meet the valve manufacturer's specifications;
- (iii) tightness tests and verification;
- (iv) set pressure test and verification.
- (E) The purpose of the tests is to ensure that the function and operation of the valves meet the requirements of the applicable section of the ASME Code to which they are manufactured. Should any of the valves fail to meet the applicable requirements, the test shall be repeated on two valves for each valve that failed. Failure of any of these valves shall cause the applicant to investigate and document the cause of failure and state what corrective action has been taken to prevent future recurrences. Retest of the original valve is acceptable. Following proper implementation of this corrective action and after satisfactory performance, permission to receive the certificate of authorization will be granted.
(F) Field repairs are defined as any repair conducted outside a fixed repair shop location. Field repairs may be conducted with the aid of mobile facilities with repair capabilities with or without testing capabilities. Field repairs may be conducted in owner/operator facilities without the use of mobile facilities. Organizations that obtain the owner/operator certificate of authorization for in-shop/plant repairs may also perform field repairs to safety and safety relief valves provided that:
- (i) qualified technicians perform such repairs;
- (ii) an acceptable quality control system covering field repairs is maintained;
- (iii) periodic audits of the work carried out in the field are made by quality control personnel of the certificate of authorization holder to ensure that the requirements of the quality control system are met.
- (G) Provided the provisions in paragraph (F)(i)-(iii) of this paragraph are met, verification testing of field repaired valves shall not be required.
- (H) Organizations that perform field repairs only must demonstrate their field repair capabilities to an inspector before the certificate of authorization may be issued or renewed. Two valves must be repaired in the field and successfully complete verification tests as described in subparagraph (D) of this paragraph. A quality control manual as required in subparagraph (J) of this paragraph must be prepared describing all field repair activities.
- (I) Repair of a safety and safety relief valve is considered to be the replacement, remachining, or cleaning of any part, lapping of seat and disc, or any other operation which may affect the flow passage, capacity, function, or pressure retaining integrity. Disassembly, reassembly, and/or adjustments which affect the safety or safety relief valve function are also considered a repair. The initial installation, testing, and adjustments of a new safety valve or a safety relief valve in a boiler are not considered a repair.
(J) In general, the quality control system shall describe and explain what documents and procedures the owner/operator will use to validate a valve repair. Before issuance or renewal of the owner/operator certificate of authorization, the applicant must meet all requirements, including an acceptable written quality control system. The basic elements of a written quality control system shall be those described in Exhibit 1.
- (i) The written quality control system shall also include provisions for making revisions, enabling the system to be kept current as required.
- (ii) A review of the applicant's quality control system will be performed by an inspector. The review will include a demonstration of the implementation of the applicant's quality control system.
- (iii) Each applicant to whom a certificate of authorization is issued shall maintain thereafter a controlled copy of the accepted quality control manual with the inspector. Except for changes which do not affect the quality control program, revisions to the quality control manual shall not be implemented until such revisions are acceptable to the inspector.
(K) It is essential that owner/operator valve repair organizations ensure that personnel making repairs to safety and safety relief valves are knowledgeable and qualified. The owner/operator shall provide documented training with minimum qualification requirements for the valve repair position. Specific requirements to be included in an individual's training are as follows:
- (i) working knowledge of the organization's quality control manual;
- (ii) working knowledge of the applicable requirements; and
- (iii) working knowledge of the technical aspects and mechanical skills for valves being repaired or tested.
(L) Performance testing of repaired valves.
- (i) For shop valves, a test stand shall be used. The test stand shall be of a size and design to ensure clean, consistent, and repetitive pop action and response to blowdown adjustment, if possible. Test gages shall be connected to the test stand in such a manner as to indicate true pressure at the inlet of the valve being tested. Test gages shall be maintained and calibrated, at least every 90 days, to a minimum of one-half of 1.0% accuracy over the upper 80% of full scale range. The use of digital gages is acceptable. All calibrations shall be documented and traceable to national standards.
- (ii) Valves marked for liquid service shall be set according to the applicable manufacturer's specification.
- (iii) Valves marked for steam service or having special internal parts for steam should be tested with steam. However, valves for steam service may be tested with air or nitrogen for correct opening (popping), pressure setting, and, if possible, blowdown adjustment, provided the differential in popping pressure between steam and air or nitrogen, as specified in the quality control manual, are applied to the popping point.
- (iv) Valves which are repaired in place shall be tested to demonstrate set pressure.
- (v) For valves which are repaired in place, a device (hydraulic, pneumatic, etc.) may be used to apply an auxiliary lifting load on the spring to a valve for testing purposes and/or making adjustments. Calibrated testing equipment shall be used and detailed testing procedures followed. In such cases, the manufacturer's recommendations shall be used to establish blowdown.
- (M) When a safety or safety relief valve is repaired, a metal repair tag, as described in the quality control manual, shall be attached to the valve. As a minimum, the information on the tag will include the valve identification number, set pressure, date of repair, and certificate of authorization number.
Source Note:The provisions of this §65.100 adopted to be effective June 9, 2002, 27 TexReg 4685; amended to be effective December 1, 2003, 28 TexReg 10452; amended to be effective December 8, 2005, 30 TexReg 8061; amended to be effective September 1, 2006, 31 TexReg 6717; amended to be effective December 1, 2007, 32 TexReg 8476.