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(b) Any employer may apply to the Occupational Safety and Health Standards Board for a permanent variance from an occupational safety and health standard, order, or portion thereof upon a showing of an alternative method, program, practice, means, device or process which will provide equal or superior safety for employees. Such application shall conform to the requirements of the California Administrative Code, Title 8, Chapter 3.5.
Note: Authority cited: Section 142.3, Labor Code.
s 753. Definitions.
Age: Period of time since date of manufacture or nearest estimate if date of manufacture is unknown.
ANSI Standards: Standards approved as American National Standards by the American National Standards Institute, Inc.
Appurtenance A device installed on and used in the normal operation of the boiler. This includes the piping between the boiler and device, but does not include piping beyond that point unless specifically required elsewhere in these Orders.
ASME: The American Society of Mechanical Engineers.
Automatic Safety Shutdown Devices: Safety controls (other than operating controls) which monitor certain essential operating conditions of a fired boiler and which will shut down the boiler in the proper sequence when any of the essential conditions vary from set limits and require the services of the attendant to place the boiler back in operation.
Automatically Controlled Boiler: A boiler equipped with devices to maintain the burner firing conditions, the pressure and/or temperature, and the water level or water content within the predetermined limits without manual manipulation.
Boiler: A fired or unfired pressure vessel used to generate steam pressure by the application of heat. (This definition is intended to include "steam generators" and "forced -circulation boilers" but excludes "unfired evaporators.") [Note definition of: Code Boiler, High Temperature Water boiler, Low Pressure Boiler, Miniature Boiler, Nuclear Boiler, Power Boiler, Secondhand Boiler].
Certificate of Competency: Certification issued by the Division to persons who have satisfactorily passed the written boiler inspector's examination prescribed by the Division.
Certified Inspector: a person who is qualified to make inspections or examinations of boilers or tanks according to the rules under which the vessel is constructed, who has an unrevoked certificate of competency issued pursuant to this part, and who is employed by any one of the following:
A county.
A city
An insurer.
An employer, for the purpose of inspecting only tanks and boilers under his jurisdiction.
Code: The applicable sections of the ASME Boiler and Pressure Vessel Code and of the ANSI Standards.
Power Boilers. Section I, 1977 edition, (except PG -39 and PW -35 for which the 1974 edition will be used).
Material Specification, Section II, 1977 edition.
Nuclear Power Plant Components, Section III, 1977 edition, Division 1 and 2 (except NB/NC/ND -3612(a)(3), for which the 1974 edition will be used).
Heating Boilers, Section IV, 1977 edition.
Pressure Vessels, Section VIII, 1977 edition.
Welding and Brazing Qualifications, Section IX, 1977 edition.
Rules for In service Inspection of Nuclear Power Plant Components, Section XI, 1977 edition.
Power Piping, ANSI B 31, 1, 1977 edition (except nonmetallic pipe such as plastic is not acceptable unless permitted by specific safety orders).
Code addenda shall become effective six months after the date of issuance unless exception to specific parts thereof are made in the interim by the Division.
Code Boiler: a boiler constructed, inspected, and stamped as required by the code.
Division: Division of Industrial Safety.
Evaporator: An apparatus, usually closed, for driving off superfluous liquid, as in concentration plants for sugar and syrup, in fruit drying, etc., or for evaporating liquid for subsequent condensation to purify it, as from salts held in solution.
Existing Installations: Boilers installed in California prior to the adoption of these orders and in compliance with the safety orders of the Division in effect at the time of installation.
External Inspection: An inspection of all visible external surfaces and appurtenance of an installed boiler or fired pressure vessel. Where practicable this inspection shall be made with the boiler in operation to permit the inspector to witness the operation of the controls.
Field Inspection: An inspection of an installed boiler or fired pressure vessel.
Fired Pressure Vessel: A metallic vessel other than a boiler in which vapor pressure is generated in excess of 15 psi by direct firing with a solid, liquid, or gaseous fuel or by electric heating elements. (This does not apply to a coil or tubular section in which a fluid or other product is being continuously circulated by means of a pump or other mechanical device, provided the pipes or tubes do not exceed 6 -inch size.)
Full Safety Pilot Control: A control that will shut off the fuel to the main burner and to the pilot burner and require manual resetting if:
The pilot burner flame should be extinguished, or
In the case of spark ignition, the main burner fails to light after 1 recycle of operation of the ignition mechanism.
High Temperature Water Boiler: A fired or unfired pressure vessel used to heat water to temperatures above 212 degrees F. At pressure exceeding 160 psi or to temperatures exceeding 250 degrees F regardless of pressure.
Internal Inspection: Inspection of all accessible internal and external surfaces of a boiler or fired pressure vessel and its appurtenances.
Low -pressure Boiler: A boiler which does not:
Operate at steam pressure or with steam safety valve settings exceeding 15 psi (low -pressure steam boiler), or
Operate at water pressure exceeding 160 psi or water temperatures exceeding 250 degrees F (hot water heating boiler).
This definition is not intended to include domestic type water heaters provided all of the following are complied with:
The heater does not have more than 120 -gallon water capacity.
The heater is used only for heating service water.
The operating control on all automatically controlled heaters is installed by the manufacturer and is of a type that cannot be regulated to increase the water temperature at the top of the heater to more than 200 degrees F.
A non -adjustable control is installed on all automatically controlled heaters by the manufacturer and set to shut off the heat input when the temperature at the top of the heater is 210 degrees F or less. This control and the necessary fuel valve, switch, etc., shall be separate from the operating mechanisms required in (C) above.
Automatically controlled gas or oil fired heaters shall have a safety pilot mechanism installed by the manufacturer and so arranged that fuel will be shut off to both the main burner and pilot burner in case of failure of the pilot burner flame or of the spark igniter.
The heater is approved by the American Gas Association or other testing laboratory acceptable to the American National Standards Institute.
The heater is protected against over -pressure than the maximum allowable working pressure of the heater and having a relieving capacity in BTU/hr at least equal to the burner output.
Coil -type swimming pool heaters at places of employment rated at or below 400,000 BTU/hr input need not be considered boilers provided all of the following conditions are complied with:
They are used to heat pool water to a maximum temperature of 140 degrees F, with a maximum pressure stamping of 150 psi.
The inside diameter of the tubes shall not exceed 1/8 ".
The water volume within the casing does not exceed 6 gallons.
Pool heaters with 200,000 BTU/hr input and less need not be ASME Code, but shall be built to good engineering practice, and have a minimum factor of safety of 4.
They shall have an ASME Code safety valve rated at the full BTU output, and set at or below the stamped maximum allowable working pressure of the heater.
The maximum voltage of the control circuit shall be 120 volts.
The burner shall have a safety pilot mechanism installed by the manufacturer that will shut off the fuel to both the main burner and pilot burner in case of failure of the pilot burner or of the spark ignitor. The maximum time until the fuel valve is fully closed shall be 90 seconds for burners not exceeding 400,000 BTU/hr input.
There shall be a flow switch or low water pressure switch installed by the manufacturer within the heater casing to monitor flow through the coil.
There shall be a high temperature limit switch set below the boiling point at atmospheric pressure. This is in addition to the operating temperature control, set at 140 degrees F.
There shall be two main burner fuel valves piped in series, or a single fuel valve having two seats.
Coil -type steam vapor cleaners need not be considered as boilers provided all of the following conditions are complied with:
The larges nominal pipe or tubing size is 3/4," and has no drums or headers attached. They shall be built to good engineering practice with a factor of safety of at least 4.
The nominal water containing capacity does not exceed 6 gallons.
A non -adjustable high limit temperature control shall be set to operate at or below 350 degrees F.
Steam is not generated within the coil.
A safety valve set at or below the stamped maximum allowable working pressure, with relief capacity at least equal to the BTU output of the burner, shall be installed near the outlet.
The burner shall have a safety pilot mechanism installed by the manufacturer that will shut off the fuel to both the main burner and pilot burner in case of failure of the pilot burner or of the spark ignitor. The maximum time until the fuel valve is fully closed shall be 90 seconds for burners not exceeding 400,000 BTU/hr input.
Miniature Boiler: A boiler which does not exceed any of the following limits:
16 inches inside diameter of shell.
5 cubic feet gross volume, exclusive of casing and insulation. (This volume includes the total volume of the steam and water containing parts of the boiler plus the volume of the combustion space and gas passages up to the point of attachment of the smokestack or chimney breeching.)
20 square feet water heating surface.
100 psi maximum allowable working pressures.
National Board: The National Board of Boiler and Pressure Vessel Inspectors.
New Installations: Boilers and fired pressure vessels installed or reinstalled after the effective date of these Orders.
Nuclear Boiler: A device consisting of a vessel or system of vessels in which nuclear fuel is present and a nuclear chain reaction may take place or in which the reactor coolant is circulated for the purpose of heating a fluid for generating useful energy. Such nuclear boiler shall include the interconnecting piping up to and including the required valve or valves needed to isolate the vessel or system of vessels.
Oil Field Recovery Heater: A forced -circulation, once -through, water tube steam generator, used only in oil field thermal recovery operations, having no fired pressure parts larger than 4 -inch pipe size and no other pressure part larger than 6 -inch pipe size.
Power Boiler: Steam boiler operated at pressure exceeding 15 psi.
Proved Pilot: a device that will not permit the fuel valve to the main burner to open until a proper source of ignition is established to light the main burner.
Psi: Pounds per square inch gage.
Qualified Inspector: Either a certified inspector or qualified safety engineer.
Qualified Safety Engineer: A person who is qualified to make inspections or examination of boilers or tanks according to the rules under which the vessel is constructed and who holds a valid certificate of competency issued by the Division.
Relief Valve: An automatic pressure relieving device actuated by the static pressure upstream of such device which opens further with the increase in pressure over the opening pressure. It is used primarily for liquid service.
Resale Inspection: The inspection of any used boiler to determine its maximum allowable working pressure when reinstalled in accordance with these Orders.
Safety Relief Valve: An automatic pressure actuated relieving device suitable for use either as a safety valved or relief valved, depending on application.
Safety Valve: An automatic pressure relieving device actuated by the static pressure upstream of such device and characterized by full opening pop action. It is used for gas or vapor service.
Secondhand Boiler: A boiler that has changed both ownership and location.
Shop Inspection: Inspection of boilers and fired pressure vessels in a fabricator's shop, or at the jobsite during erection, as required by the Code.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 754. Design and Construction of Power Boilers and High Temperature Water Boilers.
All new power boilers and high temperature water boilers shall be constructed, inspected, and stamped in full compliance with the applicable sections of the Code, unless the design and construction of the boiler are accepted by the Division as equivalent to Code.
s 755. Design and Construction of Fired Pressure Vessels.
(a) All fired pressure vessels shall be constructed, inspected, and stamped in accordance with the Code insofar as applicable. Those vessels not included in the scope of the Code shall be designed and constructed in accordance with good engineering practice regarding pressure vessel design for the pressure and temperature to be expected in service with a factor of safety of at least four.
(b) Good engineering practice as used in this article shall be construed to require the employer to provide details of design and construction which will be as safe as otherwise provided by the rules in the Code including shop inspection.
s 756. Design and Construction of Low-Pressure Boilers.
All new low-pressure boilers shall be constructed, inspected, and stamped in accordance with the Code, unless the design and construction are accepted by the Division as equivalent to Code.
s 757. Design and Construction of Nuclear Boilers.
All pressure vessels installed as a part of a nuclear boiler shall be constructed, inspected, and stamped in accordance with the Code, unless the design and construction are accepted by the Division as equivalent to Code.
All piping included as a part of a nuclear boiler, up to and including the valve or valves required to isolate the boiler system, shall be constructed, inspected, and stamped in accordance with the requirements for pressure piping in Section I of the Code -except that the Code symbol stamp may be omitted from the stamping required by that section of the Code.
Note: Authority cited: Section 6307, Labor Code. Additional authority cited: Section 142.3, Labor Code.
s 758. Maximum Allowable Working Pressure of Existing Installations.
(a) The maximum allowable working pressure of any code boiler shall be determined by the provisions of the code effective when the boiler was manufactured and upon its condition, determined after an internal inspection.
(b) The maximum allowable working pressure of any non-code power boiler shall be determined by the standards of the Code with a factor of safety not less than:
(1) Five if the boiler had been inspected and reported to the Division prior to January 1, 1936.
(2) Eight if the boiler had not been inspected and reported to the Division prior to January 1, 1936, and is of lap seam construction.
(3) Seven if the boiler had not been inspected and reported to the Division prior to January 1, 1936, and is of butt-strap construction.
(4) Six if of welded construction, providing it can be proven to the satisfaction of the Division that the material, workmanship, and details of construction are equivalent to the requirements for Code boilers.
(5) The factor of safety permitted at the time of last internal inspection prior to the adoption of these orders; provided, however, that a lower factor of safety may be allowed at the discretion of the Division.
(c) A higher factor of safety than provided for in (b) above may be applied at subsequent inspections by any qualified inspector when deterioration or other defects are found that affect the safety of the boiler.
(d) The maximum allowable working pressure of a fired pressure vessel constructed prior to the effect date of these orders shall be established in accordance with the rules of the code when applicable, or in accordance with good engineering practice regarding pressure vessel design.
s 761. Safety Valves and Pressure Relieving Devices, Boilers.
(a) Each power boiler, nuclear boiler, and high temperature water boiler shall have safety valves or pressure relieving devices constructed, stamped and installed in accordance with the applicable section of the Code, except:
(1) For existing installations the stamping required by the Code at the time of original installation may be accepted until the valves are replaced.
(2) Upon written request by the employer, the Division may permit three-way two-port valves to be installed under two safety valves, each with the required relieving capacity, provided they are so installed that both safety valves cannot be closed off from the boiler at the same time and provided the three-way valve will permit at least full flow to the safety valve in service at all time.
(b) The user shall maintain all pressure relieving devices in good operating condition. Where the valves cannot be tested in service, the user shall maintain and make available to the inspector records showing the test dates and set pressure for such valves.
(c) Pressure relieving devices with open discharge installations shall have piping and supports designed for pressure relief reaction forces in accordance with Appendix II of ANSI B 31.1.
The discharge from pressure relieving devices shall be piped to a safe location where:
(1) The discharge of steam or hot water will not present a hazard to employees.
(2) The discharge of steam or water will not be detrimental to any electrical or other machinery or equipment.
(3) The discharge pipe cannot be readily plugged or otherwise obstructed.
Note: Authority cited: Section 142.3, Labor Code . Reference: Section 142.3, Labor Code .
s 762. Safety Valves and Pressure Relieving Devices, Fired Pressure Vessels.
(a) Boilers (or vaporizers) of the Dow-therm, mercury vapor or similar types shall be fitted with adequate safety relieving devices to assure their safe operation. Safety valves of Dow-therm vaporizers and similar equipment shall be removed at least once each year for inspection and cleaning of any deposits that might affect their operation. (To eliminate the necessity of shutting the unit down for this inspection, a three-way stop valve may be installed under 2 safety valves, each with the required relieving capacity, and so installed that both safety valves cannot be closed off from the vaporizer at the same time; or 2 or more separate safety valves may be installed with individual shutoff valves, in which case the shutoff valve stems shall be mechanically interconnected in a manner which will allow full required flow at all times.)
(b) Fired pressure vessels other than those mentioned in (a) above shall be fitted with safety relieving devices of sufficient capacity to relieve all vapor that can be generated in the vessel during normal operation and shall be fitted with proper controls to assure their safe operation.
s 763. Low-Pressure Boilers.
(a) All low-pressure boilers shall be installed and fitted with the fittings and appliances required by the Code, and any additional appurtenances required in the following subsections.
(b) When a hot water heating boiler is equipped with an electrically operated circulating pump and electrically operated burner controls, the control switches shall be labeled to show which is for the burner circuit and which is for the pump circuit, or the electrically operated burner controls shall be connected in the electric circuit ahead of the automatic pump switch or the burner control switch shall be mechanically interlocked to the disconnect switch for the circulating pumps.
(c) All low-pressure boilers shall be equipped with one or more pressure relieving device adjusted and sealed so as to discharge at a pressure not to exceed the maximum allowable working pressure of the boiler. The combined capacity of these devices shall be such that with the fuel burning equipment installed and operating at maximum capacity the pressure cannot rise more than 5 psi for steam boilers or 10% for water boilers above the maximum allowable working pressure of the boiler. All pressure relieving devices shall be installed as required by the Code and be ASME stamped and rated and shall be installed with the valve spindle vertical and shall have a manual lifting device to permit periodic testing.
The discharge from all drains and pressure relieving devices shall be piped to a safe place of discharge and shall have no shutoff valves in the pipe between the pressure relieving device and point of discharge.
A safe place of discharge as used in this section shall be a location where:
(1) The discharge of steam or hot water will not present a hazard to employees.
(2) The discharge of steam or water will not be detrimental to any electrical or other machinery or equipment.
(3) The discharge pipe cannot be readily plugged or otherwise obstructed.
(d) All automatically controlled low-pressure boilers shall be equipped with:
(1) A low-water control that will close the main burner fuel valve when the water in the boiler reaches the lowest operating level, or for boilers with no fixed steam or water line, when the highest permissible operating temperature is reached.
(2) A low-water safety cutout that will shut off the fuel to the burner when the water in the boiler reaches a predetermined level which shall not be below the lowest permissible level, and manual resetting of the low-water control or of the fuel valve or of the emergency control system shall be required to place the boiler back in operation after it has been shut down due to the operation of the low-water safety cutout.
(3) An adjustable operating control and fuel valve to regulate the flow of fuel to the burner to maintain the pressure or temperature below the following limits:
(A) 15 psi gage pressure for steam boilers.
(B) 250 F water temperature for water boilers.
(4) A high-limit safety control that will shut off fuel to the burner when the pressure in a steam boiler reaches a predetermined maximum not to exceed 15 psi gage or when the temperature in a water boiler reaches a predetermined maximum not to exceed 250 F. The high-limit safety control mechanism shall be in addition to the operating control required in (d)(3) above and manual resetting of the high-limit control or of the fuel valve or of the emergency control system shall be required to place the boiler back in operation after it has been shut down due to the operation of the high-limit safety control.
(5) (A) A full safety pilot control on boilers equipped with standing pilot burners, other than those included in subsection 763 (d)(5)(B), that will shut off the fuel to the main burner and any extinguished pilot burners if a pilot light is extinguished.
Such device shall actuate to close the safety fuel shutoff valve required in Subsection 763 (d)(6) within the time limits specified for flame failure shutoff in Table 1.
(B) A programmed flame safeguard system on burners equipped with spark ignition that will include a flame failure shutoff time not greater than specified in Table 1. Such system shall require the services of the attendant to place the boiler back into operation if a flame failure should occur while in operation or if the flame is not established within the time limit programmed into the system. Such time limits shall not exceed that specified for flame failure shutoff in Table 1.
Table 1. Flame Follows Shutoff Times [FN1]
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Masimum Firing rate Maximum Firing Type of Ignition Maximum time until
Oil Gal. per hr. rate Gas valve is fully
BTU/hr. closed, seconds
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3 gallons or less ...................... Unproved Pilot or
Ignition ................ 90
-------------------- ------------------
Over 3 gallons to 7
gallons ....................................................... 30 [FN2]
-------------------- ------------------
Over 7 gallons to 20
gallons ....................................................... 10 [FN2]
-------------------- --------------------------------------
Over 20 gallons ........................ Proved Pilot ........... 60 [FN3]
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400,000 BTU and
under .......... Proved or Unproved
Pilot ................... 90
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400,001 BTU and
over ........... Proved Pilot [FN4] ........ 10
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[FNNote 1.] Flame failure shutoff as used in these Orders means the total
elapsed time from the time of flame failure or other abnormal condition
occurs until the fuel shutoff valve is closed.
[FNNote 2.] Where a burner is designed or equipped for a "starting firing rate"
of less than the maximum firing rate of the burner, the flame failure shutoff
time shown in Table 1 for the lesser firing rate may be used for establishing
ignition, provided that firing rate cannot be increased until ignition is
proven. The time limit for flame failure shutoff shall be determined by the
maximum burner input.
[FNNote 3.] The 60-second time limit for flame failure shutoff may be used for
burners having less than 20 gallons per hour input if equipped with a proved
pilot.
[FNNote 4.] In case of pilot flame failure, the proved pilot shall de-energize
the safety fuel shutoff valve electrical circuit and cause that valve to
close within 10 seconds.
(6) In addition to the operating fuel shutoff valve(s) required in 763 (d) (1) and (3), an additional safety fuel shutoff valve that will be operated by the controls required by Section 763 (d) (2), (4), and (5). This valve shall be of a type that will close within 2 seconds after being de-energized if the burner input rating exceeds 400,000 BTU/hr.
(7) A means for obtaining adequate combustion chamber purging and for limiting the burner "trial for ignition" time during start up to 15 seconds or that permitted for flame failure shutoff in Table 1, whichever is greater.
(e) All low-pressure boilers shall be equipped with a pressure or altitude gage as required by the code. All water boilers shall be equipped with a thermometer to indicate temperature conditions at or near the hot water outlet. These devices shall be visible to the operator from the operating area.
(f) All low-pressure steam boilers shall be equipped with one or more water gage glass with shutoff valves and drain cocks. These devices shall be located on the boiler, or on a water column, within the permissible water level range for the boiler (unless specifically exempted by the Code).
(g) All hot water heating systems shall be equipped with a suitable expansion tank that will be consistent with the volume, temperature, pressure, and capacity of the system as required by the Code. All such expansion tanks shall have an allowable working pressure at least equal to the maximum allowable working pressure of the boiler with which they are used, and the maximum allowable working pressure shall be stamped on a nameplate visible after installation.
All expansion tanks connected into systems having boilers designed for more than 30 psi working pressure shall be constructed, inspected, and stamped according to the Code, Section VIII, unless it can be proven to the satisfaction of the Division that the design and construction will provide equivalent safety. Expansion tanks connected into systems having boilers designed for 30 psi or less shall be designed, constructed, and stamped according to the Code, Section VIII, or according to good engineering practices with a factor of safety of at least 4.
All expansion tanks shall be fitted with either: (1) a water gage glass or other means for indicating visually the water level in the tank, or (2) a bladder-type expansion tank provided the tank is fitted with an airtight bladder inside the tank and it is provided with a means of determining the presence of air cushion in the tank. The hot water heating system shall be installed, inspected, and equipped with the required safety relief and shut-off devices in accordance with the Uniform Mechanical Code, Chapter 10, February 1997 Edition.
(h) When low-pressure boilers are equipped with a float-type automatic water feeder, such water feeder shall be fitted with a valved drain on the float chamber. Float chambers of other control devices shall also be provided with valved drains on the float chambers.
(i) All valves, fittings, and controls shall be suitable for the pressures and temperatures expected in service and all such devices used in the fuel system shall be suitable for and compatible with the fuel and fuel pressures used. All electrically operated fuel valves shall be of the normally closed type to open only when energized. Fuel valves of a type that will fail to close due to abnormal fuel pressure shall not be permitted. Automatically operated fuel valves shall not be designed with integral manually operated by-passes unless such by-pass is of the constant pressure type.
(j) The electrical circuit for boiler controls shall not exceed 120 volts and shall be 2-wire with 1-conductor grounded and have the controls in the ungrounded conductor.
(k) After installation and before being placed in operation, the employer shall require all controls and burners to be checked for proper operation by a responsible person familiar with burner controls.
Instruction for the proper method of lighting, relighting, and shutting down the burner, type of fuel or fuels to be used, and the maximum fuel pressure shall be shown on a permanent and legible plate attached to the boiler or boiler casing and an operating manual giving complete boiler operating instructions, shall be furnished by the installer for each installation. The employer shall require operating personnel to become thoroughly familiar with these operating instructions before they are permitted to operate the boiler. These instructions shall include an instruction to the operator that the boiler shall not be placed back in service after having been shut down by the operation of the safety fuel shutoff valve required in 763 (d) (6) until the cause of such shutdown has been determined and corrected and the combustion chamber is properly purged.
Note: Authority cited: Section 142.3, Labor Code . Reference: Section 142.3, Labor Code .
s 764. Blowoff Valves and Tanks.
(a) All boilers subject to these orders shall have blowoff valves and piping installed in accordance with the Code.
(b) All blowoff pipes shall terminate at a safe place of discharge and shall be adequately supported to prevent undue stresses on the valves or lines, and shall not be reduced in size between the blowoff valve and point of discharge.
Blowoff valves constructed with integrally threaded bonnets shall not be permitted.
No blowoff pipe shall discharge directly into a sewer. When the blowoff discharge is to be ultimately led to a sewer, local plumbing codes shall be consulted concerning requirements for discharging products into sewers.
When a blowoff tank is used, it shall be designed and constructed in accordance with good engineering practice for the maximum pressure and temperature expected during the blowdown period with a factor of safety of at least 4. All blowoff tanks shall be provided with means for cleaning and inspection.
s 765. Means of Feeding Water to Boilers.
All power boilers subject to these Orders shall be equipped with at least one means for feeding water to the boiler at the maximum allowable pressure. Boilers having more than 500 square feet of water heating surface shall have at least 2 means of feeding when required by paragraph PG-59(d)(2)(g) of the Code. A water supply system may be considered as a means of feeding water to the boiler where the water pressure in the system is not less than 6 percent above the pressure at which the safety valve is set to open. Feed piping, valves, and appurtenances shall be installed as required by the Code.
s 766. Water and Pressure Gages.
All power boilers and high-temperature water boilers subject to these Orders shall be equipped with water gages and pressure gages as required by the Code.
s 767. Reinstallation of Secondhand Power Boilers.
When a power boiler changes both ownership and location, the purchaser shall report the state serial number and the new proposed location to the division.
s 768. Access for Inspection and Cleaning.
(a) Where it is impracticable to remove the hood of any vertical fire-tube boiler for inspection purposes, an access opening of the following dimensions shall be provided in the hood:
(1) For boilers not exceeding thirty-six inches (36 ") diameter, not less than six inches by eight inches (6 " x 8 ") or equivalent area with a minimum dimension of six inches (6 ") in any direction.
(2) For boilers over thirty-six inches (36 ") diameter, not less than twelve inches by sixteen inches (12 " x 16 ") or equivalent area with a minimum dimension of eleven inches (11 ") in any direction and a minimum diameter of fifteen inches (15 ") for circular openings.
(b) Access for inspection and cleaning shall be provided in all boiler settings. The minimum dimension of access openings shall be 12 inches by 16 inches, unless the size and/or design of the boiler setting is such that inspection and cleaning can be adequately accomplished through smaller openings.
(c) When 2 or more steam, high-temperature water, or hot water heating boilers having manhole openings are installed in battery or connected to a common main or header, each boiler having a manhole opening shall be fitted with 2 stop valves between the boiler and the common main or header. An ample free blow drain shall be provided between the stop valves and the discharge from the drain shall be visible to the operator while manipulating the drain valve.
s 769. Boiler Installation.
(a) Effective for boiler installation and/or relocation building permits issued on or after November 1, 2002, all boiler supporting structures shall be designed for the following loads:
(1) The live and dead load of the boiler as prescribed in the 2001 California Building Code.
(2) Other imposed loads including those resulting from wind, and seismic forces, as prescribed in the 2001 California Building Code.
(b) Each member of a structural support shall be so located or insulated that the heat from the boiler cannot warp or impair its strength.
(c) The installation of water-tube boilers in battery settings shall be prohibited unless provisions are made at the time of installation to make possible the periodic inspection of the exterior surfaces of all heads installed in the common wall.
(d) The installation of horizontal tubular boilers in battery settings shall be prohibited, unless the boilers are suspended by independent outside suspension structures with top crossbeams sufficiently strong to safely carry all the boilers without intermediate supports.
(e) Each boiler shall be installed in such a manner that all external surfaces and all appurtenances can be made accessible for inspection, cleaning, maintenance, and operation.
(f) Adequate passageways or work areas at least 24 inches wide shall be provided for safe access to and operation of controls.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 770. Boilers Subject to Annual Inspection.
(a) All boilers subject to these Orders are subject to annual internal and external inspection, except as provided in subsection (b), and except those boilers exempted from annual inspection in Section 771.
(b) Boilers installed in turboelectric plants in such a manner that each boiler furnishes steam to a single turbine only shall be inspected internally at least once each eighteen (18) months. The permit to operate issued following internal inspection shall expire not more than twelve (12) months after the date of inspection. The boiler shall be externally inspected prior to or on the expiration date of the permit by a qualified inspector who may, if conditions warrant, issue a temporary permit which shall expire not more than six (6) months after the date of external inspection. A copy of the external inspection report shall be forwarded to the Division by the qualified inspector. Such report shall show the expiration date of the temporary permit to operate.
The Division, upon individual application from petroleum companies, chemical plants, public utilities or other industries considered by the Division as having superior preventive maintenance and examination programs, may grant a maximum interval of thirty-six (36) months between internal inspection of fired boilers. A fired boiler is defined for this section as one whose temperature input can cause metallurgical damage to the boiler, or whose combustion of fuel can cause a furnace explosion. For boilers other than fired boilers, the Division may grant a maximum interval of seventy-two (72) months between internal inspections, provided the temperature input cannot cause metallurgical damage. Boilers of the latter type are typically called process steam generators. Such applications, to be reviewed by the Division, shall contain as a minimum the following information and proposals:
(1) The history of the unit (or of a similar installation) that shows that there is no significant deterioration from scaling, corrosion, erosion or overheating.
(2) Wall thickness reference points shall be established. Following internal inspection of each boiler, a complete record showing the total corrosion and any other conditions found which need correction at the time of inspection shall be forwarded to the Division as part of the inspection report required by 774(a)(1). This record shall show the location and extent of any corrosion, erosion or other defects noted and shall be verified and signed by the certified inspector making the inspection required by Section 770(a).
(3) The "Permit to Operate" shall expire one (1) year from the date of the internal inspection, or the date of startup if so noted on the inspection report and the "Permit to Operate." Prior to or on the expiration date of this "Permit," a certified inspector, who will review the operating logs and water treatment records, shall inspect the boiler externally. If conditions warrant, the certified inspector may issue a temporary permit not to exceed six (6) months. Prior to or on the expiration date of the second permit, the boiler shall again be inspected externally by a certified inspector; if conditions warrant, a "Permit" may be issued for an additional six (6) months.
Boilers operating longer than twenty-four (24) months between internal inspections shall have a program of on-stream examination of corrosion points, and inspection of operations and safety controls that is acceptable to the Division, and the certified inspection agency. The maximum interval of each temporary permit shall be six (6) months.
If the boiler is located within a local jurisdiction that has regulations concerning boiler inspections, the jurisdiction must also be consulted concerning the acceptability of the inspection program.
The certified inspector shall submit reports to the Division of each external inspection, noting the expiration date of the permit issued, and recording any unusual condition found. The inspection report shall include a statement that water treatment records have been reviewed. Reports of on-stream wall thickness readings must also be submitted to the Division via the certified inspector.
(4) For boilers and process steam generators where metallurgical damage may occur, the Division may categorize the boiler or process steam generator as unfired upon acceptance of a risk engineering analysis submitted by the owner of the boiler to the Division. The risk engineering analysis shall include the design basis for categorizing the boiler as unfired, the potential consequences to the boiler and to the safety of the person(s) responsible for attending the boiler, and a discussion of protective devices and specific procedures to prevent the consequences.
(5) The boiler water treatment and specific chemical limits shall be prescribed by a competent water treatment specialist, such as a chemical engineer. The boiler water chemistry shall be maintained within desirable limits and documentary records shall be kept of the tests and methods used to maintain the water chemistry within the prescribed limits. A summary of weekly test results shall be kept, and the records shall be available to the certified inspector.
(6) A copy of the Division letter granting the longer interval between internal inspections shall be posted near the boiler, the boiler control center, or the process unit control room.
Note: Authority cited: Sections 142.3 and 7682, Labor Code. Reference: Sections 142.3 and 7682, Labor Code.
s 771. Boilers Not Subject to Annual Inspection.
(a) The following boilers are not subject to annual inspection and do not require a permit to operate providing they comply with all of the provisions of subsection (b):
(1) Low-pressure boilers.
(2) Miniature boilers.
(3) High-temperature water boilers.
(4) Boilers, including forced circulation boilers, in which none of the following are exceeded:
(A) One hundred square feet (100 sq. ft.) of heating surface.
(B) Steam drum does not exceed 16 inches inside diameter.
(C) Maximum allowable working pressure does not exceed 100 psi.
(D) Water capacity does not exceed 35 gallons when filled to normal operating level.
(E) The BTU input to the burners does not exceed 400,000 BTU/hr.
(b) Boilers exempt from annual inspection in subsection (a) shall comply with all of the following:
(1) All other provisions of these Orders including construction and installation.
(2) Automatically controlled fired boilers shall be fitted with all the applicable controls required for low-pressure boilers in 763(d).
(3) All automatic controls shall be maintained in operating condition.
(c) Nothing in sections (a) and (b) above shall prohibit any qualified safety engineer employed by the Division from requiring any boiler to be prepared for inspection when in his opinion such inspection is necessary to determine the safety of the boiler.
s 772. Preparation of Boilers for Inspection.
(a) The owner or user of a boiler or boilers herein required to be inspected shall, after 14 days' notice from the division, prepare the boiler for internal inspection.
If the owner or user finds the date set for inspection not to his convenience, he shall immediately advise the division, or qualified inspector, and ask for a postponement and state the reasons therefor, in which case the inspection date may be postponed for a period not to exceed thirty (30) days from the date first set for inspection.
(b) To prepare a boiler for internal inspection the water shall be drawn off and the boiler thoroughly washed. Manhole and handhold covers and washout plugs in the boiler feed lines and water column connections necessary for adequate inspection shall be removed and the furnace and combustion chamber thoroughly cooled and cleaned. Enough of the brickwork, refractory, or insulating material shall be removed to permit the qualified inspector to determine the condition of the boiler, furnace, or other parts and to enable the qualified inspector to obtain such data as is required at each annual inspection. The steam gage shall be removed for testing. At the discretion of the Division, data obtained by nondestructive examination may be used in lieu of visual inspection.
(c) The owner or user shall prepare the boiler for hydrostatic test when required by the qualified inspector. If the boiler to be hydrostatically tested is connected with other boilers that are under steam pressure, such connections shall be blanked off unless provided with double stop valves with a free blow drain between the valves.
(d) Before a resale inspection or other inspection of a secondhand boiler is made, the interior of the shell or drum may be required to be descaled and cleaned, such tubes shall be removed as the qualified inspector deems necessary to enable him to ascertain their condition, the lagging and brickwork shall be removed, and the exterior of the shell or drum shall be cleaned. No paint shall be applied before the inspection is made.
s 773. Identification of Boilers.
(a) Qualified inspectors making the first field inspection of boilers required by these Orders to have a permit to operate, shall stamp on the boiler a state serial number (unless a state serial number has previously been stamped thereon) which shall become a permanent means of identification. This assigned number shall be made either by steel die figures not less than 5/16-inch in height, or outlined by means of center punch dots, with figures not less than 3/4-inch in height, and shall be stamped adjacent to the manufacturer's code stamping.
(b) No state serial number or code stamping shall be permanently covered by insulating material, unless such number and stamping is transferred to a fixed plate where readily visible outside of all insulating material.
s 774. Boilers Exempt from Inspection by Qualified Safety Engineers Employed by the Division.
(a) Boilers annually inspected internally and externally by qualified inspectors employed by a company, city or county, may be exempt from annual inspections by qualified safety engineers employed by the division providing:
(1) Reports of inspection are submitted on prescribed forms to the Division within 21 days after the date of inspection.
(2) The boiler and all of its appurtenances complies with these orders as a minimum standard of safety.
(3) The report of inspection lists all repairs or changes ordered and the qualified inspector notifies the division when such repairs or changes have been satisfactorily completed.
(4) The permit to operate is posted on or near the boiler to which it applies.
(b) Nothing in this order shall prevent a qualified safety engineer employed by the division from inspecting any boiler. However, no fee shall be charged by the division where the annual inspection has been made and the report of inspection submitted to the division by a qualified inspector within the 21 days specified above and the permit to operate is posted on or near the boiler.
(c) Qualified inspectors employed by insurance companies shall notify the Division within 21 days of the name of the owner or user, as shown on the permit to operate, and the location and state serial number of every boiler requiring a permit to operate on which insurance has been refused, canceled, or discontinued, and shall give the reasons why.
(d) Qualified inspectors employed by other than insurance companies shall notify the Division within 21 days of the name of the owner or user and the location and state serial number of every boiler requiring a permit to operate and inspected by them which is removed from service or which is considered unsafe for further service as a boiler and shall give the reasons why.
s 775. Operation of Unsafe Boilers.
(a) If the operation of any boiler, including those exempt from annual inspection, constitutes a serious menace to the life or safety of any person employed about it, the division or any of its safety engineers, or any person affected thereby, may apply to the superior court of the county in which the boiler is situated for an injunction restraining its operation until the condition has been corrected.
(b) Whenever the condition of a boiler is such as to make it unfit for any pressure, a qualified safety engineer, employed by the division, may affix a rejection mark (o x) consisting of an "X" at least one inch (1 ") high with a circle at least one-half inch (1/2 ") diameter located between the upper arms of the "X." The rejection mark shall be outlined in center punch marks and located immediately above the state serial number.
s 776. Special Inspection of Lap Seam Boilers.
(a) Horizontal return tubular boilers over thirty-six-inch (36 ") diameter with longitudinal lap-riveted seams shall not be operated at a pressure in excess of fifty pounds (50 lbs.) per square inch unless all of the following are done every five (5) years of operation:
(1) Sufficient tubes are removed to permit the internal surfaces of the shell to be completely cleaned of scale.
(2) Sufficient brickwork is removed to permit the external surfaces of the longitudinal seam to be cleaned.
(3) Before the tubes and brickwork are replaced the boiler shall be thoroughly inspected internally and externally by a qualified inspector. The tubes shall then be replaced and the boiler shall be subject to a hydrostatic test of one and one-half (1 1/2) times the working pressure. This pressure shall be maintained for at least thirty (30) minutes after which a qualified inspector shall examine all riveted joints for leakage and/or cracks. (continued)