PRINCIPLES & PRACTICES OF PRESSURE VESSELS INSPECTION AND REPORTING FORMAT

Presented By
UCHENNA DUAKA, FIMarEST
ASNT Level III, PCN Level III, CSWIP 3.2
Inspection Principles

Legal Requirement
Contractual Requirement
Standards
Guidelines
Legal Requirements

Fire Tube Boiler

Built in Nigeria
Legal Requirements

Factories Act,2004
Subsection 13

No new steam boiler shall be taken into use in any factory

unless:

There has been obtained from an authorised boiler inspector a

certificate specifying the maximum permissible working pressure of
the steam boiler and stating the nature of the tests to which the
steam boiler and fittings have been submitted
Subsection 13

Implies

A review of the manufacturer's documentation and

process of manufacture and test of fittings, prior to
issuing a certificate to cover such boiler to operate
within Nigeria
Documents to be reviewed

Manufacturers Data Report ( MDR)

Material Certificates

Welding procedures

NDT reports

Report of hydrotest

Certificate of conformance of safety valves

Certificate of conformance of steam stop valve, blow down valve,

gauge glasses and other fittings
Subsection 12

No steam boiler which has previously been used shall be

taken into use in any factory for the first time in that factory
until it has been examined and reported on in accordance
with subsection (7), (8), (9), (10) and (11) of this section
Subsection 7

Every steam boiler and all the fittings and attachments

shall be thoroughly examined by an authorised boiler
inspector at least once in every period of fourteen months
and also after any extensive repair
Implication of subsection (7), (8), (9), (10), (11)

Examination is required on the shell, furnace, refractory,

tubes, all pressure and none pressure parts.
Examination is required after extensive repair
Examination can be extended up to 18months
Examination shall be carried out when boiler is cold and
when under pressure
Examination is to be conducted on all boiler fittings and
attachments
Examination includes supervision of safety valve setting
Mandatory Boiler Fittings / Attachments
to be inspected
A suitable safety valve
A suitable stop valve
A correct steam pressure gauge (in kg/cm2) with mark of
maximum permissible working pressure
At least one water gauge. Boiler operating at pressure
>3kg/cm2 should have an efficient guard
Name plate, bearing distinctive number
A means to attach a test pressure gauge
Provided with a suitable fusible plug or an efficient low-
water alarm device
When Boiler Inspection is required by
Factories Act

New boiler, before it is put to first use

Used boiler, every 14 months
Used boiler, upon transfer to another factory
Boiler under extensive repair
Re-Rating of Boiler

Sub-section 15

An authorised boiler inspector can reduce the maximum

permissible working pressure of a boiler or request for
repair to be carried out within as specific time, if the boiler
cannot be used continually with safety
Steam Receivers
Steam Receivers

Mandatory Fitting / Attachment on Steam Receivers

A suitable reducing valve or other suitable automatic

appliance to prevent the safe working pressure of the
receiver being exceeded
A suitable safety valve or suitable appliance for cutting off
automatically the supply of steam as soon as the safety
working pressure is exceeded
A correct steam pressure gauge (in kg/cm2)
A suitable stop valve
A plate bearing distinctive number
Inspection Period Provided

Oil heaters 12 months

Air receivers 26 months

Gas separators 5 years

Relief valves 26 months

ASME Code Architecture

Construction Codes

Reference Codes

In-Service Codes
ASME Construction Codes

Section I Power Boiler

Section III Nuclear Power
Section IV Heating Boiler
Section VIII Pressure Vessels
Section X Fiber Plastics
Section XII Transport Tanks
ASME B31.1 - Power Piping
ASME B31.3 Process Piping
Reference Codes

Section II Materials

Section V NDE

Section IX Welding
In-Service Code

Section VI Heating Boiler

Section VII Power Boiler

Section XI Nuclear Power

Requirements to Manufacture of Pressure Vessels to
ASME Code

ASME shop approval is a prerequisite

QC system according to the ASME Code

Audit by ASME, renewal every 3 years

Valid Inspection-Service-Agreement between manufacturer

and AIA

Authorization by ASME to use the code symbols stamp(s)

ASME Stamps

Section 1 Steam Boiler

S Steam boiler
A Assembly only
E Electric boilers
M Miniature boilers
PP Power piping
V Safety valves
Section IV Heating Boiler

H - Cast iron heating boiler

H Wrought steel heating boiler

HLW Potable water heaters

HV Safety valves
Section VIII Pressure Vessels

Section VIII Div. 1

U Pressure Vessels
UM Miniature Vessels
UV Safety Valves
UD Rupture Disk Devices

Section VIII Div. 2 Alternative Rules

U2 Pressure Vessels

Section VIII Div. 3

U3 High Pressure Vessels
UV3 Safety Valve
Section X Fibre Reinforced Plastic Pressure Vessels

RP Pressure Vessels
Section XII Transport Tanks

T Transport tanks

TV Safety Valves

TD Rupture Disk Devices

National Board Stamp

R Repair and alteration

VR Repair of safety valves

Authorised Inspector Responsibilities

To make all of the inspection specified by the rules of the

division
Monitoring the quality control and the examinations made
by the manufacturer
Make sure other inspections as in his judgment are
necessary to permit him to certify that the vessel has been
designed and constructed in accordance with the
requirements
Verifying that the applicable calculations have been made
and are on file at manufacturers plant at the time and date
report is signed
Any questions concerning the calculations raised by the
inspector must be resolved
Section I and Section IV Boilers

Power Boiler
Boiler in which steam or other vapour is generated at a pressure
exceeding 15psig
High temperature water boilers intended for operation at
pressures exceeding 160psig and / or temperatures exceeding
2500F (1200C)

Heating Boiler
Boiler in which steam or other vapour is generated at a pressure
not exceeding 15psig
High temperature water boilers intended for operation at
pressures not exceeding 160psig and / or temperatures not
exceeding 2500F (1200C)
In- Service Boiler Inspection

Cold examination

Hot examination
Hot Examination

Check boiler instrumentation

Test water level control

Test firing control

Test pressure controls

Test safety valve

Pressure Vessel Inspection Code

API 520 Pressure Vessel Inspection Code: Maintenance

inspection, Rating, Repair and Alteration

API 572 Inspection Practices For Pressure Vessels

API 576 Inspection of Pressure-Relieving Devices

API 510

Applies to vessels constructed in accordance with

API/ASME Code for unfired pressure vessels for petroleum
liquids and gases

Section VIII of ASME Code

Other vessel construction codes

Non-code vessels
Inspection of Pressure Vessels

Examine the surfaces of shells and heads for cracks,

blisters, bulges and signs of deterioration

Pay attention to skirt and support attachment and knuckle

regions of the head

Examine welded joints and the adjacent heat affected

zones for service-induced cracks or other cracks

Examine the surfaces of all manways, nozzles, and other

openings for distortion, cracks and other defects
Report of Examination When Cold of a Steam Boiler

a. Name of occupier
b. Address of factory

1.0 Description and distinctive number of boiler and type

2.0 Date of examination of boiler
3.0 Maximum permissible working pressure (psi)
4.0 Date of construction, and brief history the examiner shall state
whether he has seen the last previous report
5.0 Date of hydraulic test, pressure applied
REPORTING FORMAT
 Report of Examination When Cold of a Steam Boiler

6.0 Water Tube Boilers c) Headers

6.11. Have the headers been checked for
a) Down comer Tubes thickness?
6.1. Have the down comer tubes been checked 6.12. Have the headers been checked for signs of
for distortion? corrosion?
6.2. Have the down comer tubes been checked for 6.13. Do any need repair?
thickness? 6.14. Do any need replacement?
6.3. Have the down comer tubes been checked for
signs of corrosion? d) Header Caps
6.4. Do you need repair? 6.15. Has the header caps been checked for
6.5. Do you need replacement? thickness?
6.16. Have the header caps been checked for
b) Riser Tubes signs of corrosion?
6.6. Have the rise tubes been checked for 6.17. Do any need repair?
distortion? 6.18. Do any need replacement?
6.7. Have the riser tubes been checked for
thickness? e) Drums
6.8. Have the riser tubes been checked for signs 6.19. Has the exterior been checked for signs of
of corrosion? corrosion, etc.?
6.9. Do any need repair? 6.20. Has the interior been checked for signs of
6.10. Do any need replacement? corrosion, etc.?
6.21. Are any repairs required?
f) Condition of parts not listed above
Report of Examination When Cold of a Steam Boiler

7.0 Shell Boilers

a) Furnace and Smoke Tubes

7.1. Have the tubes been checked for distortion?
7.2. Have the tubes been checked for signs of corrosion, etc.?
7.3. Do any need repair?
7.4. Do any need replacement?

b) Tube Plates
7.5. Have the plates been checked for thickness?
7.6. Have the plates been checked for corrosion, etc.?
7.7. Do any need repair?
7.8. Do any need replacement?

c) Condition of parts not listed above

Report of Examination When Cold of a Steam Boiler

8.0 Boiler Fittings

8.1. Has the stop valve been examined?

8.2. Does it require repair/replacement?
8.3. Has the water gauge been examined?
8.4. Does it require repair/replacement?
8.5. Has the low-water alarm device been examined?
8.6. Does it require repair/replacement?
8.7. Has the safety valve been thoroughly examined?
8.8. Has it been set where the necessary?
8.9. Does it require repair/replacement?
8.10. Has the pressure gauge been tested for accuracy?
8.11. Does it require repair/replacement?
Report of Examination When Cold of a Steam Boiler

9.0 State any defects as a result of which:

The boiler cannot continue to be used with safety unless repairs are carried out
immediately, or within a specified time

The maximum permissible working pressure has been reduced

Report of Examination under normal steam pressure of
steam boiler

1.0 Name of occupier

2.0 Address of factory

3.0 Description and distinctive number of boiler and type

4.0 Date of examination

Report of Examination under normal steam pressure of
steam boiler

5.0 Examination

(i) General condition (external) of the boiler including fittings and

attachments
(ii) Fittings and attachments

Were the following operating satisfactorily?

Pressure gauge
Water level gauge
Blow down arrangements
Automatic water level control(s)
Safety valves
Report of Examination under normal steam pressure of
steam boiler

6.0 State any defects as a result of which:

The boiler cannot continue to be used with safety unless repairs are carried out
immediately or within a specified time
The maximum permissible working pressure has been reduced

7.0 Repairs (if any) required, and period within which they should be executed
and any other conditions which the person making the examination thinks is
necessary to specify for securing safe working.
THANKS