Current through Register Vol. 39, No. 6, September 16, 2024
(a)
G.S.
95-69.16 and
13 NCAC
13 .0211(l) of this Chapter
allows the Commissioner, as delegated to the Chief Inspector, to modify the
inspection frequency for individual pressure equipment if it is determined that
the new frequency will provide for the safety attained by the normal inspection
frequency as defined in this Chapter. Maintenance programs, the condition of
the pressure equipment, and a baseline inspection help to determine if the
equipment is eligible for extended certification. The Chief Inspector may allow
certificate renewal frequencies of up to three years. Companies wishing to have
their pressure equipment given an extended certification must apply by letter
to the Chief Inspector requesting extended certification.
(b) For a first time extended inspection
frequency, the following shall apply to both new and existing equipment:
(1) Base Line Inspections: At the outset of
an extended inspection frequency, a base line inspection must be conducted of
all inside and outside accessible pressure boundaries. The inspected area shall
be examined visually by a North Carolina Department of Labor, Boiler Safety
Bureau Inspector Supervisor along with a Deputy Inspector for evidence of
cracking, discoloration, wear, pitting, bulging, blistering, corrosion and
erosion, arc strikes, gouges, dents, and other signs of surface irregularities.
Areas that are suspect shall be non-destructively examined, as defined in this
Chapter, by a method acceptable to the Inspector Supervisor and Deputy
Inspector. For areas that are still suspect after such examination, a more
thorough supplemental examination and engineering evaluation of the
discontinuities shall be conducted and discussed with the Chief Inspector or
designee;
(2) Inspection Mapping
and Records: An inspection grid map shall be constructed for each pressure
component detailing the areas found suspect. The grid shall not exceed four
inch square. Suspect area shall be described in detail and photographs of such
areas shall be taken. These records shall be kept and made available to the
Deputy Inspector prior to the next required inspection;
(3) Base Line Inspection of Boiler Tubes: The
boiler tubes shall be examined by nondestructive examination. Tubes shall be
examined for wear, corrosion, erosion, thinning, bulging, blistering, dents,
discoloration, cracking and any other surface irregularities. Areas that are
suspect shall be noted and discussed with the Inspector Supervisor and Deputy
Inspector; and
(4) Boiler Tube
Inspection Mapping and Record: Where suspect tubes are identified, the boiler
tubes shall be numbered in a logical sequence and the location of any suspect
area shall be precisely defined and described in detail. Photographs of such
areas shall be taken. These records shall be kept and made available to the
Inspector Supervisor and Deputy Inspector prior to the next required
inspection.
(c)
Scheduling of Inspections for Extended Certificate: Approximately two months
prior to a scheduled outage in which the boiler can be inspected, and prior to
the current certificate expiration, the owner shall do the following in order
to initiate the inspection process:
(1) Send
a letter addressed to the Chief Inspector requesting the extended
certificate;
(2) Contact the North
Carolina Department of Labor, Boiler Safety Bureau at 919-707-7918 and request
to speak with an Inspector Supervisor for the purpose of scheduling the
inspections required for extending the boiler inspection certificate expiration
for to up to 36 months; and
(3)
Agree with the Inspector Supervisor and Deputy Inspector on a date to meet for
the external inspection of the boiler and to review reports. The boiler must be
operating when the external inspection is done. Heat recovery boilers with less
than one percent capacity factor per year may be excluded from the need to
operate during the external inspection but a letter requesting the exclusion
must be sent to the Chief Inspector stating the capacity factor for the year
before such an exclusion request can be granted.
(d) External Inspection: All report forms may
be obtained from either NBIC or ASME. The following reports must be available
to the Inspector Supervisor and Deputy Inspector at the external inspection:
(1) NBIC R1 forms for the past five years for
initial inspections and since the previous inspection for renewals;
(2) A list of alterations scheduled, and
those alterations done since the last internal inspection with the NBIC R2
forms;
(3) Safety valve testing and
repair reports for the past five years for initial inspections and since the
previous inspection for renewals;
(4) Fitness for Service reports for headers
for the past five years for initial inspections and since the previous
inspection for renewals. All Fitness for Service reports shall be documented on
the National Board Form NB-403 or other created form that includes all
information required on the Form NB-403;
(5) Side elevation drawing of the boiler (8
1/2 inches by 11 inches);
(6)
Steam & Mud drums - Original drum thickness, drawings, and manufacturer's
data reports if available;
(7) Copy
of the last operating certificate and copies of the last three years of
inspection reports;
(8) Reports of
annual external inspections by owner's insurance company or a Boiler Safety
Bureau Deputy Inspector.
(e) Equipment inspection requirements during
outage or shut-down:
(1) An operational test
for all safety valves shall be conducted after the equipment has been
restarted. After the operational test, the organization performing the test
shall affix an updated inspection tag to the valve. The Deputy Inspector shall
verify the updated inspection tag and review any associated test report. In
lieu of operational tests, it is acceptable to replace safety valves with new
valves or valves reworked by a National Board "VR" or "NVR" authorized
company;
(2) Inspect the pressure
equipment internally; and
(3)
Inspect the drums and shells using the following methods:
(A) Examine penetrations into the drum or
shell wall for cracking: if the nozzles are visible from inside the drum or
shell, then a visual examination is satisfactory; otherwise ultrasonically
examine the nozzles, from the outside surface, of at least 20 percent of the
pressure equipment nozzles;
(B)
Visually examine inside the heads; and
(C) When access permits, crawl through the
drum or shell for a visual examination.
(f) Setting the Certificate Interval: If the
requirements of this Rule are met, the Deputy Inspector shall submit an
inspection report to the Chief Inspector with the recommendation for the
extended certificate.
(g) Follow-up
and Interim Inspections: External inspections of high pressure boilers are
required six months after the certificate renewal, and then annually
thereafter. The external inspections may be performed by the Boiler Safety
Bureau Deputy Inspectors or by the owner's insurance inspector. The results of
the inspection shall be documented on an inspection report and submitted to the
Chief Inspector, North Carolina Department of Labor, Boiler Safety
Bureau.
Authority
G.S.
95-69.11;
95-69.14;
95-69.16;
Eff. July 1,
2011;
Pursuant to
G.S.
150B-21.3A, rule is necessary without
substantive public interest Eff. July 22, 2018;
Amended Eff. April
1, 2022; January 1, 2020.
