Current through Register Vol. 50, No. 9, March 1, 2024
RELATES TO: KRS Chapter 236
NECESSITY, FUNCTION, AND CONFORMITY:
KRS
236.030 requires the commissioner to
promulgate administrative regulations that establish standards for the safe
construction, installation, inspection, and repair of boilers, pressure
vessels, and associated pressure piping.
KRS
236.040 requires all boiler and pressure
vessels to conform to the rules and regulations formulated by the commissioner
and establishes the standards for pressure piping and pressure vessels for
human occupancy.
KRS
236.110 establishes the inspection
requirements for boilers, pressure vessels, and pressure piping. This
administrative regulation establishes the design, construction, and inspection
requirements of the boiler inspection section for all boilers and pressure
vessels not exempted by
KRS
236.060.
Section
1. Minimum Standards.
(1) Boilers
and pressure vessels. All new boilers and new pressure vessels shall comply
with applicable provisions of 815 KAR Chapter 15 and the ASME Boiler and
Pressure Vessel Code, 2013 Edition or subsequent editions, as established by
KRS
236.040(2), except new
boilers and new pressure vessels approved as state specials pursuant to Section
4 of this administrative regulation. All pressure vessels for human occupancy
shall comply with the ASME Safety Standard for Pressure Vessels for Human
Occupancy, 2012 Edition or subsequent editions, as established by
KRS
236.040(3).
(2) ASME stamps. New boilers and new pressure
vessels shall be stamped with the applicable certification mark of the ASME
Boiler and Pressure Vessel Code.
(3) Installation standard. Installation of
all boilers and pressure vessels shall conform to the National Board Inspection
Code Part 1, 2015 edition or subsequent editions.
(4) Pressure piping.
(a) All new pressure piping installations
connected to the boiler or pressure vessel shall conform to the National Board
Inspection Code Part 1, 2015 edition, and the applicable standards referenced
in this subsection, as established by
KRS
236.040(2):
1. ASME Code for Power Piping, B31.1, 2012
edition or subsequent editions;
2.
ASME Code for Process Piping, B31.3, 2012 edition or subsequent
editions;
3. ASME Code for
Refrigeration Piping and Heat Transfer Components, B31.5, 2013 edition or
subsequent editions;
4. ASME Code
for Building Services Piping, B31.9, 2011 edition or subsequent editions;
and
5. ASME Code for Hydrogen
Piping and Pipelines, B31.12, 2014 edition or subsequent editions.
(b) The maximum allowable design
temperature and pressure of the piping system and all of its component parts
shall meet or exceed the operating control settings of the boiler or pressure
vessel.
(c) If the maximum
allowable design temperature or pressure of the boiler exceeds the maximum
design limits of the piping system or any of its component parts, the pipe and
its components shall not be used unless the following conditions are met:
1. The temperature and pressure controls on
the boiler are permanently set to prevent operation in excess of the design
limits of the piping system; and
2.
Safety valve or valves shall be installed on the boiler, pressure vessel, or
the piping system to protect the system from excess pressure or
temperature.
(5) Welded piping joints. Welded joints in
pressure piping shall be installed by qualified welders in accordance with the
ASME Code, Section IX, as required by the standards referenced in subsection
(4) of this section.
Section
2. Manufacturer's Data Report.
(1) A manufacturer's data report on all
boilers of steel construction and all pressure vessels constructed in
accordance with the ASME Boiler and Pressure Vessel Code shall be filed with
the National Board of Boiler and Pressure Vessel Inspectors unless the boiler
or pressure vessel is exempted by
KRS
236.060 or the pressure vessel has an ASME
"UM" certification mark. A pressure vessel with an ASME "UM" certification mark
may be registered with the National Board of Boiler and Pressure Vessel
Inspectors.
(2) The boilers and
pressure vessels required to be filed with the National Board in subsection (1)
of this section shall include the National Board registration number on the
manufacturer's date plate.
Section
3. Installation Inspection or First Inspection and State
Registration of New Boilers and Pressure Vessels.
(1) Installation inspection. New
installations of boilers, pressure vessels, and associated pressure piping
shall be inspected by the department for compliance with applicable ASME Boiler
and Pressure Vessel Code requirements, the National Board Inspection Code, and
this administrative regulation.
(2)
Notification of inspection.
(a) If an
inspection is required by this administrative regulation, the owner or user
shall prepare each boiler, pressure vessel, and pressure piping system for
inspection pursuant to this administrative regulation and the National Board
Inspection Code, Part I.
(b) The
owner or user shall prepare for and apply a hydrostatic pressure or other leak
test on the date if requested by the boiler inspector, special boiler
inspector, or owner-user inspector.
(c) Inspections shall be conducted within
seven (7) days of the date of notification.
(3) Inspection times. Except as established
in
815
KAR 15:027, inspections made by boiler inspectors
shall be conducted during normal business hours of the department between 8:00
a.m. and 4:30 p.m. Monday through Friday.
(4) Contractor availability. The boiler and
pressure vessel contractor shall be available to the boiler inspector,
physically or electronically, at the time of the inspections.
(5) State registration. Upon completion of
the installation or at the time of first inspection, a Commonwealth of Kentucky
registration number shall be assigned to the boiler or pressure vessel and
shall be applied to the boiler or pressure vessel with a metal tag showing the
registration number. This tag shall be securely affixed near the manufacturer's
name plate or data plate.
(6)
Non-registered boilers and non-registered pressure vessels. Boiler inspectors,
special boiler inspectors, and owner-user inspectors shall notify the
department within thirty (30) days of locating any non-registered boiler or
non-registered pressure vessel.
(7)
General welding.
(a) If welded assembly has
been used, the installing boiler and pressure vessel contractor shall produce
the following for the boiler inspector's, special boiler inspector's, or
owner's piping inspector's review:
1. The
welding procedures; and
2. Proof of
qualification and continuity records for the welders and welding
operators.
(b) The
boiler and pressure vessel contractor shall be responsible for the quality of
the welding.
(8) Welded
piping joints. Welded joints in pressure piping shall be visually inspected for
complete and full root penetration, soundness of the weld and freedom from
undercutting, cracking, or other surface imperfections in accordance with the
requirements of the applicable ASME B31 Code section. If the visual inspection
reveals a potential defect, the boiler inspector, special boiler inspector, or
owner's piping inspector may require other nondestructive tests, such as
radiography, to be performed by the contractor to verify the soundness of the
weld. All tests or retests required by the boiler inspector, special boiler
inspector, or owner's piping inspector shall be at the owner's or boiler and
pressure vessel contractor's expense.
(9) Hydrostatic pressure test for boilers and
pressure vessels.
(a) A hydrostatic pressure
test, when applied to a boiler or pressure vessel, shall conform to the testing
procedures and pressures as specified in the original code of construction. The
pressure shall be under proper control so that in no event shall the required
test pressure exceed the testing requirements listed in the original code of
construction.
(b) During the
hydrostatic pressure test, the safety valve or valves shall be removed. If the
safety valve or valves cannot be removed, then each valve disc shall be held
down by means of a testing clamp and not by screwing down the compression screw
upon the spring.
(c) The minimum
temperature of the water used to apply a hydrostatic test shall not be less
than ambient temperature, but in no case less than seventy (70) degrees
Fahrenheit, and the maximum temperature shall not exceed 120 degrees
Fahrenheit.
(d) If the only purpose
of the test is to determine tightness, the test pressure shall be equal to the
relieving pressure of the safety valve having the lowest relief
setting.
(10) Pressure
test for pressure piping. Pressure piping systems installed in association with
the boiler or pressure vessel shall be inspected for proper materials, adequate
pressure, and temperature ranges for the boiler or pressure vessel operation
and for adequate support and tightness as established in this subsection.
(a) Hydrostatic and pressure leak tests.
1. Except as stated in paragraph (b),
hydrostatic or other leak tests shall be performed on the pressure piping
system connected to the boiler or pressure vessel and shall conform to the
procedures and test pressures outlined in the original code of
construction.
2. Non-destructive
testing shall be used if hydrostatic or leak testing cannot be
performed.
3. Original mill
material stencils and markings used to verify material shall be legible at the
time of inspection. Pipe, including welding joints, shall not be painted or
covered prior to inspection.
(b) Alternative testing.
1. The following piping systems shall be
inspected visually under in-service conditions:
a. Compressed air systems with a MAWP of
200psi or less, a pipe diameter of two (2) inches or less, and no welded
joints;
b. Hydronic heating or
process systems with a MAWP of 100psi or less, a pipe diameter of two (2)
inches or less, and no welded joints;
c. Steam condensate systems with a MAWP of
50psi or less, a pipe diameter of two (2) inches or less, and no welded
joints;
d. Non-ammonia
refrigeration with a pipe diameter of two (2) inches or less and no welded
joints; and
e. Cryogenic piping with
a pipe diameter of two (2) inches or less and no welded joints.
2. Sufficient openings shall be
made in any insulation to determine pipe material. Welded piping joints shall
not be covered with insulation prior to inspection.
3. Pipe may be painted prior to inspection if
the owner or user provides documentation of materials that make up the pipe to
the inspector. Welded joints shall not be painted prior to
inspection.
(c) Code
compliance. Pressure piping inspections shall include determining compliance
with applicable ASME B31 Code including material specifications for the piping
and component parts. The boiler and pressure vessel contractor shall provide
documentation to the boiler inspector, special boiler inspector, owner's piping
inspector, or owner-user inspector showing that:
1. The materials used and method of
construction meets the manufacturer's procedures and specifications;
and
2. The system is utilizing the
materials and equipment specified within the temperature and pressure ranges
set forth in the design and as required by this administrative
regulation.
Section 4. State Special.
(1) Boilers and pressure vessels of special
design, which are equivalent to but are not eligible to be stamped to the ASME
Code, shall meet the requirements of this section. The prospective owner or
user who desires approval of the boiler installation or pressure vessel
installation as a state special shall comply with the procedures established in
this administrative regulation for each case.
(a) Prior to installation and operation of
the boiler or pressure vessel, the proposed owner, user, or the owner's
authorized agent shall make written application for permission to install the
boiler or pressure vessel. The application shall be submitted to the
commissioner.
(b) To establish ASME
Boiler and Pressure Vessel Code equivalency, the following data, material, and
information shall be submitted with the application for state special approval:
1. Detailed shop drawings and welding details
of the proposed construction. All materials shall be in the English language
and United States units of measurements listed in the ASME Code;
2. Design calculations and supporting data,
which shall include pressure (psi), temperature (deg. F.), use, and other
service conditions;
3.
Specifications for all construction materials shall conform to the applicable
ASME Code standards or their suitable equivalent. If reference is made to a
standard or specification of a country other than the United States, a copy
shall be attached to indicate how the material is considered
equivalent;
4. Copies of the
welding procedures to be used and welding qualification test reports for each
welding operator or welder to be used. The procedures and tests required in
this paragraph shall be made in accordance with the ASME Boiler and Pressure
Vessel Code, Section IX, "Welding Qualifications;"
5. If the design exceeds ASME Boiler and
Pressure Vessel Code limitation, then API 579/ASME FFS-1, 2007 or later edition
shall be used to determine equivalency of the submission;
6. Design drawings and calculations shall be
certified by a mechanical engineer holding a professional engineer
certification with a background in boilers and pressure vessels;
7. The manufacturer of the vessel shall
identify the inspection agency responsible for the shop inspections and shall
submit an equivalent ASME manufacturer's data report for the proposed vessel;
and
8. The shop inspection agency
shall furnish the qualifications of the authorized inspector assigned to make
the shop inspections.
(2) Upon completion of the boiler or pressure
vessel, a manufacturer's data report, signed by the manufacturer and authorized
inspector, shall be submitted to the jurisdictional authorities containing the
equivalent type data required by the ASME Boiler and Pressure Vessel Code. ASME
Boiler and Pressure Vessel Code data report forms shall not be used.
(3) Upon arrival in the Commonwealth of
Kentucky, the boiler or pressure vessel shall be inspected before installation
by a boiler inspector to verify compliance with this section.
Section 5. General Requirements.
(1) Safety appliances. The safety appliances
required by these administrative regulations shall not be removed or tampered
with except for the purpose of making repairs. The resetting of safety valves
shall be done by a V-R stamp holder.
(2) Additional Hazards. If an additional
hazard is possible by exposure of a pressure vessel to fire or other unexpected
sources of external heat, supplemental pressure relieving devices shall be
installed capable of protecting against excessive pressure. These supplemental
pressure relieving devices shall be capable of preventing the pressure from
rising more than twenty-one (21) percent above the MAWP.
(3) Pressure relieving device.
(a) A pressure relieving device shall be
constructed, located, and installed so that the device is readily accessible
for inspection and repair and cannot be readily rendered inoperative;
and
(b) A pressure relieving device
shall be selected so that the intended service of the pressure relieving device
corresponds with the boiler or pressure vessel on which the pressure relieving
device is installed.
(4)
Relieving capacity. The minimum relieving capacity of the safety valve(s) or
safety relief valve(s) shall be equal to or exceed the maximum output of the
boiler.
(5) Omission or removal of
pressure relieving device.
(a) If a pressure
relieving device is omitted or removed, the device shall be omitted or removed
in accordance with ASME Section VIII, Division 1, UG-140, Appendix M and ASME
Section VIII, Division 2, Part 9, or Division 3, Part KR.
(b) If a pressure relieving device is omitted
or removed pursuant to the standards established in subparagraph 1. of this
paragraph, except ASME Section VIII, Division 1, Appendix M., the Boiler
Inspection Section shall be notified prior to the omission or removal, and
prior to the pressure vessel being placed in service.
(c) The required documentation of
calculations pursuant to paragraph (a) in this subsection shall be submitted to
the Boiler Inspection Section for review and acceptance or rejection of the
proposed omission or removal.
(6) Location of discharges to atmosphere. The
discharge of safety valves, blowoff pipes, and other outlets shall be located
to prevent injury to persons and property.
(7) Boiler external piping.
(a) Boiler external piping shall be attached
in accordance with ASME Section I and B31.1.
(b)
1. If
two (2) or more boilers with manholes are connected to a common steam or high
temperature water main or header, all welded external piping from the boiler
out to the second stop valve shall be installed by a manufacturer or contractor
authorized to use any one (1) of the ASME Code symbol stamps for pressure
piping, power boilers, or assembly stamps.
2. The piping or fittings, adjacent to the
welded joint farthest from the boiler, shall be stamped with the pressure
piping, power boiler, or assembly code symbol stamp of the ASME when approved
by the boiler inspector, special inspector, or owner-user inspector.
(8) Manually fired
boilers.
(a) Gauge cocks. Each manually fired
boiler shall comply with ASME Section I, except a manually fired boiler built
before the publication of the 1991 Addenda to ASME Section I (1989 Edition),
shall have three (3) or more gauge cocks located within the range of the
visible length of the water glass, except if the boiler has two (2) water
glasses with independent connections to the boiler located on the same
horizontal lines and not less than two (2) feet apart. Two (2) gauge cocks
shall be sufficient for boilers not over thirty-six (36) inches in diameter in
which the heating surface does not exceed 100 square feet.
(b) Fusible plugs. A fire-actuated fusible
plug, if used, shall conform to the requirements of ASME Section I, Paragraphs
A-19, A-20 and A-21.
(9)
Clearance.
(a) If boilers or pressure vessels
are replaced or new boilers or new pressure vessels installed in either
existing or new buildings, a minimum of two (2) feet shall be provided on all
service sides. Boiler and pressure vessels having manholes shall have five (5)
feet clearance between the manhole opening and any wall, ceiling, or piping
that will prevent a person from entering the boiler or pressure
vessel.
(b) Boilers shall be
installed to:
1. Allow adequate space for
their proper operation and their appurtenances;
2. Allow inspection of all surfaces, tubes,
water walls, economizer, piping, valves, and other equipment; and
3. Allow for necessary maintenance and
repair.
(c) A boiler or
pressure vessel subject to external corrosion shall be installed so that there
is sufficient access to all parts of the exterior to permit proper inspection
of the exterior surfaces, or the boiler or pressure vessel shall have a
connection so that the vessel can be readily removed from its location for
inspection.
(d) If a cylindrical
vessel is installed in a vertical position and subject to corrosion, the bottom
head, if dished, shall be concave to pressure to facilitate proper
drainage.
(e) The installed boiler
or pressure vessel shall be located so that the data plate shall be accessible
to the boiler inspector, special inspector, or owner-user inspector and shall
not be obstructed by insulation or other covering not readily
removable.
(10)
Emergency shutdown switches.
(a)
1. Installations of power boilers, heating
boilers, or hot water supply boilers shall have a manually operated remote
boiler shutdown switch or circuit breaker located near the boiler room door,
inside or outside of the boiler room, and marked for easy identification.
Consideration shall also be given to the type and location of the switch to
safeguard against tampering.
2. If
there is more than one (1) door to or from the boiler room, a switch shall be
located at each door.
3. A cover
plate may be used to prevent accidental activation of the shutdown switch, if
the cover plate is easily opened or removed.
4. If a shutdown switch is activated, the
shutdown switch shall require a manual reset.
5. The shutdown switch shall cause the
display or indicator lights on a boiler to turn off, or otherwise indicate that
the boiler has been shut down.
6.
If a new boiler is installed in an existing boiler room, all existing boilers
shall be connected to the emergency shutdown switch.
(b) A power boiler or heating boiler
installed prior to July 1, 2015 shall be exempt from paragraph (a) of this
subsection unless the power boiler or heating boiler installed prior to July 1,
2015 is located in a hospital, rest home, school, day care, jail, mental
institution, or similar institutional facility.
(c) Paragraph (a) of this subsection shall
not apply to manufacturing and power generating facilities.
Section 6.
Incorporation by Reference.
(1) The "National
Board Inspection Code", 2015 Edition, is incorporated by reference.
(2) This material may be inspected, copied,
or obtained, subject to applicable copyright law, at the Department of Housing,
Buildings and Construction, Division of Plumbing, Boiler Section, 500 Mero
Street, Frankfort, Kentucky 40601, Monday through Friday, 8 a.m. to 4:30
p.m.
STATUTORY AUTHORITY:
KRS
236.030,
236.040,
236.060,
236.110,
236.120,
236.240