压力容器设计规范和规则

BOILER AND PRESSURE VESSEL RULES AND REGULATIONS 16 VAC 25-50-10 et seq. VIRGINIA SAFETY AND HEALTH CODES BOARD AND VIRGINIA DEPARTMENT OF LABOR AND INDUSTRY Effective Date: July 2, 2003 VIRGINIA SAFETY AND HEALTH CODES BOARD Page 2 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS PART I Definitions. 16 VAC 25-50-10 Definitions. The following words and terms, when used in this chapter, shall have the following meanings, unless the context clearly indicates otherwise: “Act” means the Boiler and Pressure Vessel Safety Act, Chapter 3.1 (§ 40.1-51.5 et seq. of Title 40.1) of the Code of Virginia. “Alteration” means any change in the item described on the original Manufacturers' Data Report which affects the pressure containing capability of the boiler or pressure vessel. Non-physical changes, such as an increase in the maximum allowable working pressure (internal or external) or design temperature of a boiler or pressure vessel, shall be considered an alteration. A reduction in minimum temperature such that additional mechanical tests are required shall also be considered an alteration. “Approved” means acceptable to the board, commissioner or chief inspector as applicable. “ASME Code” means the Boiler and Pressure Vessel Code of the American Society of Mechanical Engineers approved and adopted by the governing council of such society and approved and adopted by the board. “Authorized Inspection Agency” means one of the following: a. A department or division established by a state, commonwealth or municipality of the United States, or a province of Canada which has adopted one or more sections of the Boiler and Pressure Vessel Code of the ASME and whose inspectors hold valid commissions with the National Board of Boiler and Pressure Vessel Inspectors; or equivalent qualifications as defined and set forth in 16 VAC 25-50-50 and 16 VAC 25-50-70; b. An inspection agency of an insurance company which is authorized (licensed) to write boiler and pressure vessel insurance in those jurisdictions which have examined the agency's inspectors to represent such jurisdictions as is evident by the issuance of a valid certificate of competency to the inspector; c. An owner-user inspection agency as defined in this section; or d. A contract fee inspector. “Board” means the Virginia Safety and Health Codes Board. VIRGINIA SAFETY AND HEALTH CODES BOARD Page 3 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS “Boiler” means a closed vessel in which water is heated, steam is generated, steam is superheated, or any combination of them, under pressure or vacuum for use externally to itself by the direct application of heat. The term "boiler" shall include fired units for heating or vaporizing liquids other than water where these units are separate from processing systems and are complete within themselves. “Certificate of competency” means a certificate issued by the commissioner to a person who has passed the prescribed examination as provided in 16 VAC 25-50-50. See §§ 40.1-51.9 and 40.1-51.9:1 of the Act. “Certificate inspection” means an inspection, the report of which is used by the chief inspector to decide whether or not a certificate, as provided for in § 40.1-51.10 of the Act, may be issued. This certificate inspection shall be an internal inspection when required; otherwise, it shall be as complete an inspection as possible. “Chief inspector” means the chief boiler and pressure vessel inspector of the Commonwealth. “Commission, National Board” means the commission issued by the National Board to a holder of a Certificate of Competency for the purpose of conducting inspections in accordance with the National Board Bylaws and this chapter. The employer must submit the inspector's application to the National Board for a commission. “Commissioner” means the Commissioner of the Department of Labor and Industry. “Commonwealth inspector” means any agent appointed by the commissioner under the provisions of § 40.1-51.9 of the Act. “Condemned boiler or pressure vessel” means a boiler or pressure vessel that has been inspected and declared unsafe for use or disqualified by legal requirements and to which a stamping or marking designating its condemnation has been applied by the chief or commonwealth inspector. “Department” means the Department of Labor and Industry. “Division” means the Boiler Safety Enforcement Division of the Department of Labor and Industry. “Electric boiler” means a boiler in which the source of heat is electricity. “Examining Board” means persons appointed by the chief inspector to monitor examinations of inspectors. VIRGINIA SAFETY AND HEALTH CODES BOARD Page 4 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS “Existing installation” means and includes any boiler or pressure vessel constructed, installed, placed in operation or contracted for before July 1, 1974. “External inspection” means an inspection of the exterior of the boiler or pressure vessel and its appliances when the item is in operation. “Heating boiler” means a steam or vapor boiler operating at pressures not exceeding 15 psig, or a hot-water boiler operating at pressures not exceeding 160 psig or temperature not exceeding 250° F at or near the boiler outlet. “High-pressure, high-temperature water boiler” means a water boiler operating at pressures exceeding 160 psig or temperatures exceeding 250° F at or near the boiler outlet. “Hobby boiler” means a steam boiler which serves no commercial purpose and is used solely for hobby or display and operated solely for the enjoyment of the owner. “Hot-water supply boiler” means a boiler furnishing hot water to be used externally to itself at pressures not exceeding 160 psig or temperatures not exceeding 250° F at or near the boiler outlet, with the exception of boilers which are directly fired by oil, gas or electricity where none of the following limitations are exceeded: a. Heat input of 200,000 BTU per hour; b. Water temperature of 210° F; or c. Nominal water containing capacity of 120 gallons. “Hot-water supply storage tanks” means those heated by steam or any other indirect means where any one of the following limitations are exceeded: a. Heat input of 200,000 BTU per hour; b. Water temperature of 210° F; or c. Nominal water containing capacity of 120 gallons. “Inspection certificate” means a certificate issued by the chief inspector for the operation of a boiler or pressure vessel. “Inspector” means the chief inspector, commonwealth inspector or special inspector. “Internal inspection” means a complete examination of the internal and external surfaces of a boiler or pressure vessel and its appliances while it is shut down and manhole plates, handhole plates or other inspection openings removed. “Lap seam crack” means a failure in a lap joint extending parallel to the longitudinal joint and located either between or adjacent to rivet holes. VIRGINIA SAFETY AND HEALTH CODES BOARD Page 5 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS “Miniature boiler” means any boiler which does not exceed any one of the following limits: a. 16 inches inside diameter of shell; b. 20 square feet heating surface; c. 5 cubic feet gross volume, exclusive of casing and insulation; or d. 100 psig maximum allowable working pressure. “National Board” means the National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, OH 43229, whose membership is composed of the chief inspectors of government jurisdictions who are charged with the enforcement of the provisions of the ASME Code. “National Board Inspection Code” means the manual for boiler and pressure vessel inspectors published by the National Board. Copies of this Code may be obtained from the National Board. “New boiler or pressure vessel installation” means all boilers or pressure vessels constructed, installed, placed in operation or contracted for after July 1, 1974. “NFPA” means the National Fire Protection Association. “Nonstandard boiler or pressure vessel” means a boiler or pressure vessel that does not bear the stamp of Commonwealth of Virginia, the ASME stamp or the National Board stamp when applicable. “Owner or user” means any person, partnership, firm or corporation who is legally responsible for the safe operation of a boiler or pressure vessel within the Commonwealth. “Owner-user inspection agency” means any person, partnership, firm or corporation registered with the chief inspector and approved by the Board as being legally responsible for inspecting pressure vessels which they operate in this Commonwealth. “Portable boiler” means an internally fired boiler which is primarily intended for temporary location and whose construction and usage permit it to be readily moved from one location to another. “Power boiler” means a boiler in which steam or other vapor is generated at a pressure of more than 15 psig. “Pressure vessel” means a vessel in which the pressure is obtained from an external source, or by the application of heat from an indirect source, or from a direct source, other than VIRGINIA SAFETY AND HEALTH CODES BOARD Page 6 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS those boilers defined in Part I (16 VAC 25-50-10 et seq.) of this chapter. “PSIG” means pounds per square inch gauge. “R Certificate of Authorization” means an authorization issued by the National Board for the repair and alteration of boilers and pressure vessels. “Reinstalled boiler or pressure vessel” means a boiler or pressure vessel removed from its original setting and reinstalled at the same location or at a new location. “Repair” means work necessary to return a boiler or pressure vessel to a safe and satisfactory operating condition, provided there is no deviation from the original design. “Secondhand boiler or pressure vessel” means a boiler or pressure vessel which has changed both location and ownership since the last certificate inspection. “Special inspector” means an inspector holding a Virginia Certificate of Competency, and who is regularly employed by an insurance company authorized (licensed) to write boiler and pressure vessel insurance in this Commonwealth, an inspector continuously employed by any company operating pressure vessels in this Commonwealth used or to be used by the company, or a contract fee inspector. “Standard boiler or pressure vessel” means a boiler or pressure vessel which bears the stamp of the Commonwealth of Virginia, the ASME stamp and the National Board stamp when applicable. “Underwriters' Laboratories” means Underwriters' Laboratories, Inc., 333 Pfingsten Road, Northbrook, Illinois 60062, which is a nonprofit, independent organization testing for public safety. It maintains and operates laboratories for the examination and testing of devices, systems, and materials to determine their relation to life, fire, casualty hazards and crime prevention. “VR Certificate of Authorization” means an authorization issued by the National Board for the repair of pressure relief valves. “Water heater” means a vessel used to supply: (i) potable hot water; or (ii) both space heat and potable water in combination which is directly heated by the combustion of fuels, electricity, or any other source and withdrawn for use external to the system at pressures not to exceed 160 psi or temperatures of 210° F. This term also includes fired storage water heaters defined by the Virginia Uniform Statewide Building Code as a “water heater”. VIRGINIA SAFETY AND HEALTH CODES BOARD Page 7 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS PART II Administration. 16 VAC 25-50-15 Effective Date of Certain Requirements of the Regulation. The applicable requirements of the sections and subsections listed below shall not be enforced until April 1, 1999. On or after April 1, 1999, all sections and subsections of the published regulation shall be enforceable: 1. Subsection C of 16 VAC 25-50-70 regarding endorsement requirements for inspecting repairs or alterations; 2. 16 VAC 25-50-250 regarding endorsement requirements for inspecting repairs or alterations; 3. Subdivision F 11 of 16 VAC 25-50-360 regarding repairs conducted by holders of a “VR” stamp; 4. Subsection G of 16 VAC 25-50-370 regarding repairs conducted by holders of a “VR” stamp; 5. Subdivision E 2 of 16 VAC 25-50-380 regarding repairs conducted by holders of a “VR” stamp; and 6. Subsections A, B, and C of 16 VAC 25-50-480 regarding endorsement requirements for conducting and inspecting repairs or alterations. 16 VAC 25-50-20 Minimum construction standards for boilers and pressure vessels. A. Boilers and pressure vessels to be installed for operation in this Commonwealth shall be designed, constructed, inspected, stamped and installed in accordance with the applicable ASME Boiler and Pressure Vessel Code including all addenda and applicable code case(s), other international construction standards which are acceptable to the chief inspector, and this chapter. B. Boilers and pressure vessels shall bear the National Board stamping, except cast iron boilers and UM vessels. A copy of the Manufacturers' Data Report, signed by the manufacturer's representative and the National Board commissioned inspector, shall be filed by the owner or user with the chief inspector prior to its operation in the Commonwealth. C. Pressure piping - (including welded piping) - Piping external to power boilers extending VIRGINIA SAFETY AND HEALTH CODES BOARD Page 8 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS from the boiler to the first stop valve of a single boiler, and to the second stop valve in a battery of two or more boilers is subject to the requirements of ASME Power Boiler Code, Section I, and the design, fabrication, installation and testing of the valves and piping shall be in conformity with the applicable paragraphs of ASME code. Applicable ASME data report forms for this piping shall be furnished by the owner to the chief inspector. Construction rules for materials, design, fabrication, installation and testing both for the boiler external piping and the power piping beyond the valve or valves required by ASME Power Boiler Code, Section I, are referenced in ANSI B31.1, Power piping, and the code. D. Boilers and pressure vessels brought into the Commonwealth and not meeting code requirements shall not be operated unless the owner/user is granted a variance in accordance with § 40.1-51.19 of the Act. The request for variance shall include all documentation related to the boiler or pressure vessel that will provide evidence of equivalent fabrication standards, i.e., design specification, calculations, material specifications, detailed construction drawings, fabrication and inspection procedures and qualification records, examination, inspection and test records, and any available manufacturers' data report. In order to facilitate such a variance approval, the submission of documentation, in the English language and in current U.S. standard units of measure would be helpful. The following list of documents, while not all inclusive, would be useful in providing evidence of safety equivalent to ASME Code construction: 1. List of materials used for each pressure part; 2. The design calculations to determine the maximum allowable working pressure in accordance with the ASME Boiler and Pressure Vessel Code, applicable section, edition and addenda; 3. The design code used and the source of stress values for the materials used in the design calculations; 4. The welding procedures used and the qualification records for each procedure; 5. The material identification for each type of welding material used; 6. The performance qualification records for each welder or welding operator used in the construction of the boiler or pressure vessel; 7. The extent of any non-destructive examination (NDE) performed and the qualification records of NDE operators; VIRGINIA SAFETY AND HEALTH CODES BOARD Page 9 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS 8. Record of final pressure test signed by a third party inspector; 9. Name and organization of the third party inspection agency; 10. A certification from a licensed professional engineer stating that the boiler or pressure vessel has been constructed to a standard providing equivalent safety to that of the ASME Boiler and Pressure Vessel Code. A signature, date and seal of the certifying engineer is required; 11. Where applicable, a matrix of differences between the actual construction of the boiler or pressure vessel for which a variance is requested and a similar boiler or pressure vessel that is code stamped; and 12. Where applicable, a letter from an insurance company stating that it will insure the boiler or pressure vessel. After notification of a violation of these rules and regulations an owner/user desiring a variance shall submit a request for variance within 30 days. The chief inspector shall respond to any request for a variance within 30 days of receipt of all required documentation, and shall submit a recommendation to the commissioner, who will make the decision on the variance. E. Before secondhand equipment is installed, application for permission to install shall be filed by the owner or user with the chief inspector and approval obtained. F. Electric boilers, subject to the requirements of the Act and this chapter, shall bear the Underwriters' Laboratories label on the completed unit or assembly by the manufacturer. This label shall be in addition to the code symbol stamping requirements of the ASME and the National Board. 16 VAC 25-50-30 Frequency of inspections of boilers and pressure vessels. A. Power boilers and high-pressure, high-temperature water boilers shall receive an annual internal inspection for certification. Such boilers shall also receive, where possible, an annual external inspection, given while under representative operating conditions. B. Heating boilers shall receive a certificate inspection biennially. 1. Steam boilers shall receive an internal inspection where construction permits. VIRGINIA SAFETY AND HEALTH CODES BOARD Page 10 of 50 16 VAC 25-50-10 et seq. BOILER AND PRESSURE VESSEL RULES AND REGULATIONS 2. Water boilers shall receive an external inspection with an internal inspection at the discretion of the inspector where construction permits. C. Except as provided for in subsection E of this section, pressure vessels subject to internal corrosion shall receive a certificate inspection biennially. This inspection shall be an internal inspection conducted at the discretion of the inspector where construction permits. D. Except as provided for in subsection E of this section, pressure vessels not subject to internal corrosion shall receive a certificate inspection biennially. This inspection shall be an external inspection, with an internal inspection conducted at the discretion of the inspector where construction permits. E. Pressure vessels that are under the supervision of an authorized owner-user inspection agency shall be inspected at intervals in a manner as agreed upon between the Commissioner and that agency. F. Boiler and pressure vessel components of nuclear power plants, that are included in the Act, shall be inspected as provided by Section XI of the ASME Boiler and Pressure Vessel Code. G. Based upon documentation of such actual service conditions by the owner or user of the operating equipment, the Commissioner may permit variations in the inspection requirements as provided in the Act. 16 VAC 25-50-40 Notificati