Current through Register 2024 Notice Reg. No. 38, September 20, 2024
(a) All unfired pressure vessels, boilers,
and fired pressure vessels shall meet all applicable requirements of the
Unfired Pressure Vessel Safety Orders and the Boiler and Fired Pressure Vessel
Safety Orders unless the design, material and construction of the pressure
vessel or boiler is accepted by the Division as equivalent to the ASME
Code.
(b) Maximum allowable working
pressure.
(1) The employer shall establish, or
cause to be established, the maximum allowable working pressure of each boiler
or pressure vessel in accordance with the rules of recognized pressure vessel
codes applicable to the pressure vessel service involved.
(2) No pressure vessel shall be operated
above its maximum allowable working pressure at coincident design
temperature(s).
(3) The maximum
allowable working pressure for each vessel shall be evaluated at intervals
sufficiently frequent to give due consideration to corrosion and other factors
causing deterioration. The original code of construction shall be used to
establish the allowable stresses and joint efficiencies when re-rating,
de-rating or calculating the pressure boundary minimum thickness of a
vessel.
(c) Maintenance,
inspection, and repair procedures of unfired pressure vessels shall comply with
API 510, Pressure Vessel Inspection Code, Eighth Edition, June 1997, Addendum
4, August 2003; or the ANSI/NB-23, American National Standard/National Board
Inspection Code, 2004 Edition; which are hereby incorporated by reference.
(1) A written risk-based inspection program,
as described in API 510-2003 and API 580, Risk-based Inspection, Recommended
Practice, First Edition, May 2002, which is hereby incorporated by reference,
may be used to increase the internal or on-stream inspection limits required by
API 510-2003 Section 6.4 to a maximum of 15 years, or the external inspection
interval described by API 510-2003, Section 6.3 to a maximum of 10 years,
provided it is reviewed and accepted by the Division before the program is
implemented, and every three years thereafter. Any revisions made to the
accepted risk-based inspection program must also be submitted, reviewed, and
accepted by the Division prior to implementation of these revisions.
(A) The risk-based inspection program shall
be submitted to the Division in writing, and shall be reviewed and accepted by
the Division before the program is implemented, and every three years
thereafter. Any revisions made to the accepted risk-based inspection program
must also be submitted, reviewed and accepted by the Division prior to
implementation of these revisions.
(B) The risk-based inspection program shall
not be used for pressure vessels and boilers that require "Permits to Operate"
issued by the Division.
(C) The
plan shall not be used for safety relief devices.
(D) The program shall indicate:
1. Acceptance by signature of plant
management.
2. Involvement of plant
operating, engineering, inspection, and maintenance personnel by
signature.
3. The type of vessels
covered.
4. The methodology used to
create the program.
5. A listing of
the vessels covered by the program, with a clear indication of those vessels
that have an inspection interval beyond the 10-year or half remaining life as
required by API 510-2003, Section 6.4.
(2) If a written fitness-for-service program,
as described in Section 5.8 of API 510-2003, is used to evaluate pressure
vessels for continued service when found to have degradation that could affect
their load carrying capability, it shall comply with API 579,
Fitness-for-Service, Recommended Practice, First Edition, January 2000, which
is hereby incorporated by reference.
(A) The
fitness-for-service program shall be submitted to the Division in writing, and
shall be reviewed and accepted by the Division before the program is
implemented, and every three years thereafter. Any revisions made to the
accepted fitness-for-service program must also be submitted, reviewed and
accepted by the Division prior to implementation of these revisions.
(B) The program shall indicate:
1. Acceptance by signature of plant
management.
2. The type of vessels
covered.
3. How fitness-for-service
results are documented. As a minimum, this documentation shall include
acceptance of the fitness-for-service evaluation by signature of a technically
competent company employee that is designated to review and accept the
evaluation.
4. Involvement of plant
operating, engineering, inspection, and maintenance personnel by
signature.
5. The procedures in
place for notifying the Division no later than the next business day of
initiating a level 2 or 3 fitness-for-service evaluation as described in API
579-2000. Level 2 and 3 evaluations are subject to the acceptance by the
Division. If the review is subsequent to returning the vessel to service, the
Division may, in its reasonable discretion, require the unit be removed from
service.
(d) Repair and alterations.
(1) Repair and alteration of boilers and
pressure vessels shall meet all applicable requirements of the Unfired Pressure
Vessel Safety Orders and the Boiler and Fired Pressure Vessel Safety Orders,
and shall comply with API 510, Pressure Vessel Inspection Code, Eighth Edition,
June 1997, Addendum 4, August 2003; or the ANSI/NB-23, American National
Standard/National Board Inspection Code, 2004 Edition; which are hereby
incorporated by reference.
(2)
Repairs and alterations of pressure vessels performed in a state other than
California shall be done by a company with a valid National Board 'R' stamp and
inspected by an inspector holding a valid National Board Commission and
Certificate of Competency (or equivalent) for the state in which the work is
being performed. The repair or alteration shall conform to all the requirements
of this section and be stamped in accordance with ANSI/NB-23-2004.
(3) Repairs.
(A) Repairs shall be performed by one of the
following:
1. An organization in possession of
a valid ASME Certificate of Authorization; or
2. An organization in possession of a valid
National Board Certificate of Authorization.
(B) The API 510-2003 Code shall not be used
for the repair of boilers and pressure vessels as follows:
1. Boilers and fired pressure vessels as
defined in the Boiler and Fired Pressure Vessel Safety Orders.
2. Vessels as defined in the Unfired Pressure
Vessel Safety Orders, Section
460.
3. Vessels used in compressed air, LPG, CNG,
LNG and NH3 services as defined in the Unfired Pressure Vessel Safety
Orders.
(C) The employer
making the repair in accordance with API 510-2003 or ANSI/NB-23-2004, shall
provide for inspection, documentation and certification of the work and shall
ensure prior authorization for the repair by a Qualified Inspector as defined
in the Unfired Pressure Vessel Safety Orders.
1. Inspection and certification of repairs
shall be made by an inspector regularly employed by one of the following:
a. The Division;
b. A City or County;
c. The Authorized Inspection Agency of the
organization making the repair;
d.
The Authorized Inspection Agency which insures the boiler or pressure vessel;
or,
e. The owner/user inspection
agency.
(D)
Fillet weld patches shall not be permitted unless acceptable to the Division.
Acceptance by the Division will be based on the materials, design and
construction providing safety equivalent to the original code of
construction.
(4)
Alterations.
(A) Alterations to pressure
vessels shall be performed in compliance with ANSI/NB-23, 2004, unless the
material design and construction are accepted by the Division as equivalent to
the ASME Code.
1. No alteration to a pressure
vessel shall be made until authorized by a Qualified Inspector as defined in
the Unfired Pressure Vessel Safety Orders.
2. Alterations shall be performed by one of
the following:
a. An organization in
possession of a valid ASME Certificate of Authorization, provided that the
alteration is within the scope of such authorization, and provided that the
organization's alteration program has been reviewed and accepted by the
Division.
b. An organization in
possession of a valid Certificate of Authorization issued by the National Board
of Boiler and Pressure Vessel Inspectors to use the National Board "R" symbol
stamp provided that the alteration is within the scope of such authorization,
and provided that the organization's alteration program has been reviewed and
accepted by the Division.
3. For alterations performed at a field site,
the scope of such authorization shall include field fabrication.
4. The employer making the alteration shall
provide for inspection, documentation and certification of the work and shall
ensure prior authorization of the alteration by a Qualified Inspector holding a
valid Certificate of Competency issued by the Division.
5. Inspection and certification of
alterations shall be made by a Qualified Inspector, employed by one of the
following:
a. The Division;
b. A City or County;
c. The Authorized Inspection Agency of the
organization making the alteration;
d. The Authorized Inspection Agency which
insures the boiler or pressure vessel; or,
e. The owner/user inspection agency, provided
the work was not performed by the Qualified Inspector's
employer.
6. A pressure
test shall be applied after an alteration as required by the applicable ASME
Code section. An alternate test or examination may be used subject to prior
acceptance by the Division.
1.
Amendment of article 15 heading and section heading, repealer and new section
filed 5-8-95; operative 6-7-95 (Register 95, No. 19).
2. Amendment
of section heading and section filed 6-26-2006; operative 7-26-2006 (Register
2006, No. 26).
Note: Authority cited: Section
142.3, Labor
Code. Reference: Section
142.3, Labor
Code.