512 EM 385-1-1 Chapters 16-22

20-8. General Requirements.

Boilers and Systems

Construct, operate, maintain, and inspect boilers and pressure vessels as per ASME BPVC.
When boilers are placed in service or restored to service after repairs, an operator must be in constant attendance until controls have successfully functioned through several cycles or for a 24-hour period, whichever is greater.
Operators must attend to boilers during service restoration, record all relevant data, and submit records to the USACE supervisor/KO or COR.
Install fusible plugs as required, replacing them in accordance with ASME BPVC, and provide reports on replacement to the boiler inspector.

Compressed Gas Cylinders

Color-code government-owned cylinders and identify the gas, storing them as per MIL-STD 101B and specific storage guidelines.
Maintain proper handling and storage practices to protect cylinders from damage, heat, and improper use.
Ensure cylinders are used, handled, transported, and stored safely and as per manufacturer's instructions and safety standards.

Testing Using Pressurized Gases or Air

Use pressurized gases or air for testing only as allowed by the manufacturer’s specifications or applicable codes.
Comply with codes and specifications for tests involving pressurized gases, with a Competent Person (CP) developing and overseeing the testing procedures.
Conduct a supplemental preparatory meeting before testing if there's a significant gap between installation and testing dates.

20-9. Figures and Tables.

Not Applicable.

20-10. Checklists and Forms.

Not Applicable.

Knowledge Check Choose the best answer for the question.

20-5. When boilers are placed in service or restored to service after repairs, an operator must be in constant attendance _____.

for two cycles of operation

at least a 24-hour period

until relieved by another operator

for two days or more

You forgot to answer the question!

EM 385-1-1 Paragraph 20-8 (c.–e.).

20-8. General Requirements. (c.–e.).

c.  Boilers and Systems.  (20-8.c)

(1)  Construct, operate, maintain, and inspect steam boilers and pressure vessels according to the ASME BPVC.

(2)  When any boiler is being placed in service or restored to service after repairs to control circuits or safety devices are made, an operator must be in constant attendance until controls have successfully functioned through several cycles or for a 24-hour period, whichever is greater.  The operator must read and record all indicating instruments at half-hour intervals to include time, date, and duration of test; water pressure at boiler; boiler make, type, and serial number; design pressure and rated capacity; gas pressure at burner; flue gas temperature at boiler outlet; and the surface temperature of the boiler jacket.  Provide the completed record to the USACE supervisor/KO or COR.

(3)  Provide fusible plugs on all boilers except water tube type.

(a)  Replacement of fusible plugs must coincide with the inspections recommended by the ASME BPVC.

(b)  When it is necessary to replace fusible plugs between inspections, prepare and forward to the responsible boiler inspector a written report that includes the circumstances, the make, part number, and the temperature rating for each of the plugs removed and replaced.

(4)  Equip all boilers with water columns, gauge glass, and try cocks approved by a NRTL.

(a)  Guard gauge glasses and water columns.

(b)  When shutoffs are used on the connections to a water column, they must be of an approved locking or sealing type.  See NBBI NBIC code for definition of an approved type.

(5)  Equip all boilers with blowoff cocks or valves approved by a NRTL.  Arrange the blowoff line so that leakage can be observed by the operator.

d.  Compressed Gas Cylinders.  (20-8.d)

(1)  All Government-owned cylinders must be color-coded, and the gas contained identified by name according to MIL-STD 101B.

(2)  Storage. Any cylinder in which gas will not be drawn from the cylinder within 24 hours must be stored according to the following:

(a)  Store cylinders in well-ventilated locations.

(b)  Store cylinders containing the same gas in a segregated group.  Label empty cylinders as “EMPTY” and store in the same manner.

(c)  Separate stored cylinders from flammable or combustible liquids and from easily ignitable materials (for example, wood, paper, packaging materials, oil, grease) by at least 40 feet (12.2 m) or by a fire-resistive partition having at least a 1-hour rating.

(d)  Separate cylinders containing oxygen or oxidizing gases from cylinders in storage containing fuel gases by at least 20 feet (6.1 m) or by a fire-resistive partition having at least a 1-hour rating.

(e)  Areas containing hazardous gas in storage must be appropriately placarded according to CGA P-1.
        Note. Exception. If it is reasonably anticipated that gas will be drawn from a cylinder within 24 hours of initial storage, then it is considered “in-service” and these storage requirements do not apply.

(3)  Smoking is prohibited wherever cylinders are stored, handled, or used. Separate all sources of ignition, including smoking, at least 50 feet (15.2 m) from areas where cylinders are stored, handled, or used.  Conspicuously post with legible signs stating, “NO SMOKING, MATCHES, or OPEN FLAME.”  (See chapter 9)

(4)  Protect cylinders from physical damage, electric current, and extremes of temperature.  Cylinder temperature must not exceed 125°F (51.7°C).

(5)  Do not take cylinders containing oxygen and acetylene (or other fuel gas) into confined spaces.

(6)  Cylinder Valves and Valve Caps.

(a)  Close cylinder valves when cylinders are in storage, in transit, not in use, or empty.

(b)  Cylinder valve caps must be in place when cylinders are in storage or transit, or whenever the regulator is not in place.

(7)  Secure all in-service compressed gas cylinders within substantial fixed or portable racks or hand trucks.

(8)  Secure compressed gas cylinders in an upright position at all times, except when being hoisted. Do not store or transport acetylene cylinders horizontally.

(9)  Compressed gas cylinders transported by crane, hoist, or derrick must be securely transported in cradles, nets, or skip pans and never directly by slings, chains, or magnets, unless the cylinder manufacturer’s handling instructions specifically allows other handling methods.

(10)  Valve wrench or wheel must be in operating position when cylinder is in use.

(a)  Open valves slowly.

(b)  Do not open quick closing valves on fuel gas cylinders more than 1-1/2 turns.

(11) Use cylinders only for their designed purpose of containing a specific compressed gas.

(12)  Only QPs may refill cylinders.

(13) Handle cylinders in a manner that will not weaken or damage the cylinder or valve.

(14) If a cylinder is leaking and can be safely moved, transport it to an isolated location out of doors and crack the valve to allow the gas to slowly escape.

(a)  Keep personnel and all sources of ignition at least 100 feet (30.5 m) away from leaking cylinders.

(b)  Use monitors to assure protection of personnel from health and flammability hazards.

(15) Do not simultaneously bleed cylinders containing different gases while in close proximity to each other.

(16) A QP must supervise the bleeding of cylinders containing toxic gases. Perform the work according to applicable environmental regulations and the accepted safety plans (for example, APP, AHA).

(17)  Keep oxygen cylinders and fittings away from oil or grease.

(a)  Keep cylinders, cylinder valves, couplings, regulators, hose, and other apparatus free from oil or greasy substance and do not handle with oily hands or gloves.

(b)  Do not direct oxygen at oily surfaces, greasy cloths, or within a fuel oil or other storage tank or vessel.

(18) Oxygen and fuel gas pressure regulators, including their related gauges, must be in proper working order while in use.

e.  Testing Using Pressurized Gases or Air.  (20-8.e)

(1)  Do not use pressurized gases or air during structural integrity or leak testing, except when permitted by the applicable manufacturer’s specifications or when specified by an applicable code.

(2)  Comply with the applicable codes and manufacturer’s specifications when conducting tests that involve pressurized air or gases.  A CP must develop the test procedures and submit them to the USACE supervisor for approval or to the KO or COR for acceptance. The CP is responsible for supervising the testing procedures.  All workers performing the testing must be knowledgeable of the procedures, hazards, and
    controls. Quality assurance and control measures must require strict enforcement of all requirements.

(3)  If interim or final acceptance testing is anticipated to occur two or more months after the initial pipe or system installation preparatory meeting, conduct a supplemental preparatory meeting prior to the testing to review the test procedures and AHA.