Chapter 10 — BOILERS AND PRESSURE VESSELS

(Matrix Adoption Tables are non-regulatory, intended only as an aid to the code user. See Chapter 1 for state agency authority and building applications.)

This state agency does not adopt sections identified with the following symbol: The Office of the State Fire Marshal’s adoption of this chapter or individual sections is applicable to structures regulated by other state agencies pursuant to Section 1.11.0.

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CHAPTER 10

BOILERS AND PRESSURE VESSELS

shall apply to the construction, installation, operation, repair, and alteration of boilers and pressure vessels. Low-pressure boilers shall comply with this chapter and Section 904.0.

Exceptions:

(1) Listed and approved potable water heaters with a nominal capacity not exceeding 120 gallons (454 L) and having a heat input not exceeding 200 000 British thermal units per hour (Btu/h) (58.6 kW) used for hot water supply at a pressure not exceeding 160 pounds-force per square inch (psi) (1103 kPa) and at temperatures not exceeding 210°F (99°C), in accordance with the plumbing code.

(2) Pressure vessels used for unheated water supply, including those containing air that serves as a cushion and is compressed by the introduction of water and tanks connected to sprinkler systems.

(3) Portable unfired pressure vessels and Interstate Commerce Commission (I.C.C.) containers.

(4) Containers for liquefied petroleum gases, bulk oxygen, and medical gas that are regulated by the fire code.

(5) Unfired pressure vessels in business, factory, hazardous, mercantile, residential, storage, and utility occupancies having a volume not exceeding 5 cubic feet (0.14 m [3] ) and operating at pressures not exceeding 250 psi (1724 kPa).

(6) Pressure vessels used in refrigeration systems shall comply with Chapter 11.

(7) Pressure tanks used in conjunction with coaxial cables, telephone cables, power cables, and other similar humidity control systems.

(8) A boiler or pressure vessel subject to regular inspection by federal inspectors or licensed by federal authorities.

(9) Pressure vessels used in specific appliances shall comply with Chapter 9.

enclosures shall comply with the California Building Code .

1001.2.1 [OSHPD 1, 1R, 2, 3, 4 & 5] In no case shall boiler room volume or clearances be reduced below those required by the conditions of the boiler listing. The boiler and the boiler room ventilation system, including fans, con- trols, and damper motors shall be on essential power when required by Section 321.0. The ventilation system shall either operate continuously, or, if interlocked with the boiler(s) it shall not interfere with the proper boiler oper- ation. Listed boilers shall be installed with clearances in accordance with the manufacturer’s instructions.

combustion and ventilation shall be provided in accordance with Chapter 7.

applications, the boiler room shall be equipped with a floor drain or other approved means for disposing of the accumulation of liquid wastes incident to cleaning, recharging, and routine maintenance. No steam pipe shall be directly connected to a part of a plumbing or drainage system, nor shall a water having a temperature above 140°F (60°C) be discharged under pressure directly into a part of a drainage system. Pipes from boilers shall discharge by means of indirect waste piping as determined by the Authority Having Jurisdiction or the boiler manufacturer’s instructions.

level base capable of supporting and distributing the weight contained thereon. Boilers, tanks, and equipment shall be securely anchored to the structure. Equipment requiring vibration isolation shall be installed as designed by a registered design professional and approved by the Authority Having Jurisdiction.

1001.5.1 Floors. Boilers shall be mounted on floors of noncombustible construction unless listed for mounting on combustible flooring.

a chimney or vent, as provided for other fuel-burning equipment in Chapter 8 of this code.

designed in accordance with the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII.1. Boilers shall be constructed, designed, and installed in accordance with one of the following: (1) ASME BPVC Section I (2) ASME BPVC Section IV (3) NFPA 85

comply with Section 1002.2.1 and Section 1002.2.2. 1002.2.1 Listing & Labeling. Oil-burning boilers shall be listed and labeled in accordance with UL 726.

1002.2.2 Installation. Tanks, piping, and valves for oil-burning boilers shall be installed in accordance with NFPA 31.

labeled in accordance with UL 834.

Solid-fuel-fired boilers shall comply with UL 2523 and shall be installed in accordance with the manufacturer’s installation instruc tions.

Water heaters utilized for combined space- and water-heating applications shall comply with the standards referenced in Table 1203.2, and shall be installed in accordance with the manufacturer’s

installation instructions.

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The construction of boilers and pressure vessels and the installation thereof shall be in accordance with minimum requirements for safety from structural and mechanical failure and excessive pressures as established by the Authority Having Jurisdiction in accordance with nationally recognized standards.

and operating controls shall carry the approval of an approved testing agency or be accepted by the Authority Having Jurisdiction. Electrical controls shall be of such design and construction as to be suitable for installation in the environment

in which they are located.

1003.2.1 Automatic Boilers. Automatic boilers shall

be equipped with controls and limit devices in accordance with ASME CSD-1 or Table 1003.2.1.

The Authority Having Jurisdiction shall have the authority to approve solid-fuel-fired boilers that comply with the safety requirements for automatic gas fired boilers or oil fired boilers.

pressure gauge and a water level glass. Water boilers shall be provided with a pressure gauge and a temperature gauge. Automatic boilers shall be equipped with the following gauges, as applicable :

(1) Oil temperature

(2) Oil suction pressure

(3) High and low gas pressure

(4) Stack temperature

(5) Windbox pressure

with oil or solid fuel shall not close off more than 80 percent of the stack area. Operative dampers shall not be placed within a stack, flue, or vent of a gas-fired boiler.

Exception: Automatic boilers with prepurge, automatic draft control, and interlock.

by certified welders in accordance with nationally recognized standards.

hot-water-heating system as a means for controlling increased pressure caused by thermal expansion. Expansion tanks shall be of the closed or open type and securely fastened to or supported by the structure. Tanks shall be rated for the pressure of the system. Supports shall be capable of carrying twice the weight of the tank filled with water without placing a strain on connecting piping.

Hot-water-heating systems incorporating hot water tanks or fluid relief columns shall be installed to prevent freezing under normal operating conditions.

Open type expansion tanks shall be located not less than 3 feet (914 mm) above the highest point of the system. Such tanks shall be sized based on the capacity of the system. An overflow with a diameter of not less than one-half the size of the supply or not less than 1 inch (25 mm) in diameter shall be installed at the top of the tank. The overflow shall discharge through an air gap into the drainage system.

have an airtight tank or other approved air cushion that will be consistent with the volume and capacity of the system, and shall be designed for a hydrostatic test pressure of two and one-half times the allowable working pressure of the system. Expansion tanks for systems designed to operate at more than 30 pounds-force per square inch (psi) (207 kPa) shall comply with ASME BPVC Section VIII.1. Provisions shall be made

for draining the tank without emptying the system.

minimum capacity for a gravity-type hot water system expansion tank shall be in accordance with Table 1004.4(1). The minimum capacity for a forced-type hot water system expansion tank shall be in accordance with Table 1004.4(2) or Equation 1004.4(1). The minimum capacity for a diaphragmtype hot water system expansion tank shall be in accordance with Table 1004.4(2) or Equation 1004.4(2).

[Equation 1004.4(1)]

Vt (forced-type) = [(0.00041] [t] [ - 0.0466) ] [V][s]

(

P P a a

Pf Po )

[Equation 1004.4(2)]

Vt (diaphragm-type) = [(0.00041] [t] [ - 0.0466) ] [V][s]

– [P][f]

[1]

( Po )

Where:

Vt = Minimum volume of expansion tank, gallons. Vs = Volume of system, not including expansion tank, gallons.

t = Average operating temperature, °F.

Pa = Atmospheric pressure, pounds per square inch. Pf = Fill pressure, pounds per square inch. Po = Maximum operating pressure, pounds per square inch.

For SI units: 1 gallon = 3.785 L

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TABLE 1004.4(1) EXPANSION TANK CAPACITIES FOR GRAVITY HOT WATER SYSTEMS [1]

For SI units: 1 gallon = 3.785 L, 1 square foot = 0.0929 m [2]

Notes: 1 Based on a two-pipe system with an average operating water temperature of 170°F (77°C), using cast-iron column radiation with a heat emission rate of 150 British thermal units per square foot hour [Btu/(ft [2] - h)] (473 W/m [2] ) equivalent direct radiation. 2 For systems that exceed 2400 square feet (222.9 m 2 ) of installed equivalent direct water radiation, the required capacity of the cushion tank shall be increased on the basis of 1 gallon (4 L) tank capacity per 33 square feet (3.1 m [2] ) of additional equivalent direct radiation.

TABLE 1004.4(2) EXPANSION TANK CAPACITIES FOR FORCED HOT WATER SYSTEMS [1]

For SI units: 1 gallon = 3.785 L

Notes: 1 Based on an average operating water temperature of 195°F (91°C), a fill pressure of 12 psig (83 kPa), and an operating pressure of not more than 30 psig (207 kPa). 2 Includes volume of water in boiler, radiation, and piping, not including expansion tank.

Pressurized vessels or boilers shall be provided with overpressure protection by means of a listed pressure relief valve installed in accordance with the manufacturer’s

installation instructions.

temperature relief valve, pressure relief valve, or combination of both shall have no valves, obstructions, or means of isolation and provided with the following:

(1) Not less than the size of the valve outlet and shall discharge full size to the flood level of the area receiving the discharge and pointing down.

(2) Materials shall be rated at not less than the operating temperature of the system and approved for such use or shall comply with ASME A112.4.1.

(3) Discharge pipe shall discharge independently by gravity through an air gap into the drainage system or outside of the building with the end of the pipe not exceeding 2 feet (610 mm) and not less than 6 inches (152 mm) above the ground and pointing downwards.

(4) Discharge in such a manner that does not cause personal injury or structural damage.

(5) No part of such discharge pipe shall be trapped or subject to freezing.

(6) The terminal end of the pipe shall not be threaded.

(7) Discharge from a relief valve into a water heater pan shall be prohibited.

(8) Discharge to a termination point that is readily visible.

exceeds 212°F (100°C), the discharge pipe shall be installed with a splash shield or centrifugal separator.

safety valves is capable of being hazardous, discharge of steam inside the boiler room, such discharge shall be discharged to the outside of the boiler room. Discharges from relief valves on industrial boilers shall be discharged to an approved location.

that are subjected to a vacuum while in operation or during shutdown shall be protected with a vacuum relief valve that complies with ANSI Z21.22/CSA 4.4. Where the piping configuration, equipment location, and valve outlets are located below the boiler elevation, the system shall be equipped with a vacuum relief valve at the highest point.

be installed upstream of all control devices on the main burner of a gas-fired boiler. The takeoff point for the gas supply to the pilot shall be upstream of the gas shutoff valve of the main burner and shall be valved separately. A union or other approved means of disconnect shall be provided immediately downstream of these shutoff valves.

be installed on gas-fired boilers where the gas supply pressure is exceeding that at which the main burner is designed to operate. A separate approved gas-pressure regulator shall be installed to regulate the gas pressure to the pilot or pilots.

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BOILERS AND PRESSURE VESSELS

be installed with a low-water cutoff. A coil-type boiler or a water-tube boiler that requires forced circulation to prevent overheating of the coils or tubes shall be installed with a flowsensing device in the outlet piping in lieu of the low-water cutoff. The low-water cutoff or the flow sensing device shall be installed so as to prevent damage to the boiler and to permit testing of the fuel-supply cutoff without draining the heating system. The low-water cutoff shall shut off the energy source at a water level setpoint that is in accordance with the boiler manufacturer’s instructions.

retroactive:

(1) Hot-water-heating boilers, other than manually fired, shall be equipped with two temperature combustion regulators in series. Steam-heating boilers, other than manually fired, shall be equipped with a pressure combustion regulator and a low-water cutoff. (See Section 1008.0)

(2) Boilers and pressure vessels shall be provided with the required number, size, and capacity of safety or relief valves to ensure positive relief of overpressure in accordance with nationally recognized standards, as applicable. Valves so employed shall be constructed, sealed, and installed in accordance with nationally recognized standards, as applicable.

clearance shall be provided to allow access for inspection, maintenance, and repair. Passageways around all sides of boilers shall have an unobstructed width of not less than 18 inches (457 mm). Clearance for repair and cleaning shall be permitted to be provided through a door or access panel into another area, provided the opening is of sufficient size.

Exception: Subject to the approval of the Authority Having Jurisdiction, boilers shall be permitted to be installed with a side clearance of less than 18 inches (457 mm), provided that the lesser clearance does not inhibit inspection, maintenance, or repair.

Power boilers having a steam-generating capacity in excess of 5000 pounds per hour (lb/h) (0.6299 kg/s) or having a heating surface in excess of 1000 square feet (92.9 m [2] ) or input in excess of 5 000 000 Btu/h (1464 kW) shall have a clearance of not less than 7 feet (2134 mm) from the top of the boiler to the ceiling.

Power Boilers. Steam-heating boilers and hot-water-heating boilers that exceed one of the following limits:

(1) 5 000 000 Btu/h input (1464 kW)

(2) 5000 pounds steam per hour (0.6299 kg/s) capacity

(3) 1000 square foot (92.9 m [2] ) heating surface

Power boilers that do not exceed one of the following limits:

(1) 5 000 000 Btu/h input (1464 kW)

(2) 5000 pounds steam per hour (0.6299 kg/s) capacity (3) 1000 square foot (92.9 m [2] ) heating surface

Boilers with manholes on top of the boiler, except those described in Section 1010.2 and Section 1010.4, shall have a clearance of not less than 3 feet (914 mm) from the top of the boiler to the ceiling.

Hot-Water-Heating Boilers. Package boilers, steam-heating boilers, and hot-water-heating boilers with no manhole on top of the shell and not exceeding one of the above limits shall have a clearance of not less than 2 feet (610 mm) from the ceiling.

single burner boilers, multiple burner boilers, stokers, and atmospheric fluidized-bed boilers with not less than a fuel input rating of 12.5 E+06 Btu/h (3.663 MW) to pulverized fuel systems, fired or unfired steam generators used to recover heat from combustion turbines and to other combustion turbine exhaust systems shall be in accordance with NFPA 85. That portion of the oil-burning system supplied on boilers and covered within the scope of NFPA 85 shall be installed in accordance with NFPA 85.

Hot water boiler installations, upon completion, shall have controls set, adjusted, and tested by the installing contractor. A complete control diagram of a permanent legible type, together with complete boiler operating instructions, shall be furnished by the installer for each installation.

required shall not be put into service until it has been inspected and approved by the Authority Having Jurisdiction.

It shall be the duty of the owner or his authorized representative to notify the Authority Having Jurisdiction that the installation is ready for inspection and test. It also shall be the duty of the owner or his authorized representative to post in a conspicuous position on the installation a notice in substantially the following form: “WARNING! THIS INSTALLATION HAS NOT BEEN INSPECTED AND APPROVED

BY THE AUTHORITY HAVING JURISDICTION AND

SHALL NOT BE COVERED OR CONCEALED UNTIL SO INSPECTED AND APPROVED,” and it shall be unlawful for anyone other than the Authority Having Jurisdiction to remove such notice. The Authority Having Jurisdiction shall require such tests as it deems necessary to determine that the installation is in accordance with the provision of this section. Such tests shall be made by the owner or his authorized representative in the presence of the Authority Having Jurisdiction.

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Exception: On installations designed and supervised by a registered design professional, the Authority Having Jurisdiction shall have the authority to permit inspection and testing by such registered design professional.

Where the owner or his authorized representative requests inspection of a boiler prior to its installation, the Authority Having Jurisdiction shall make such inspection.

boiler or pressure vessel without first obtaining a valid operating permit to do so from the Authority Having Jurisdiction. Such permit shall be displayed in a conspicuous place adjacent to the boiler or vessel. The operating permit shall not be issued until the equipment has been inspected and approved by the Authority Having Jurisdiction.

Exception: The operation of steam-heating boilers, low-pressure hot-water-heating boilers, hot water supply boilers, and pressure vessels in residential occupancies of less than six dwelling units and utility occupancies.

Jurisdiction shall inspect boilers and pressure vessels operated under a permit in accordance with ASHRAE/ACCA 180 at such intervals as deemed necessary, but not less frequently than in accordance with Section 1013.4 through Section 1013.7.

miniature boilers shall be inspected externally annually. Where construction and operating conditions permit, they shall be subject to inspection internally annually.

Steam-heating boilers and hot-water-heating boilers shall be inspected externally annually. Where construction and operating conditions permit, they shall also be subject to inspection internally annually.

steam-heating boilers shall be inspected externally biennially. Where construction and operating conditions permit, they shall be subject to inspection internally biennially.

shall be inspected externally biennially. Where subject to corrosion and construction permits, they shall be subject to inspection internally biennially.

Inspection of boilers and pressure vessels covered by insurance shall be permitted to be made by employees of the insuring company holding commissions from the National Board of Boiler and Pressure Vessel Inspectors, subject to approval of the Authority Having Jurisdiction. Approved insuring company inspectors shall make reports on prescribed forms on inspections authorized by the Authority Having Jurisdiction. The reports shall be filed in the Authority Having Jurisdiction office. Company inspectors shall notify the Authority Having Jurisdiction of suspension of insurance because of dangerous conditions, new insurance in effect, and discontinuance of insurance

coverage.

Pressure Vessels.

Boilers and pressure vessels shall be operated and maintained in accordance with requirements for pro

tection of the public established by the Authority Having Jurisdiction in accordance with nationally recognized standards.

The Authority Having Jurisdiction shall notify the owner or authorized representative of defects or deficiencies and properly corrected. Where such corrections are not made, or where the operation of the boiler or pressure vessel is deemed unsafe by the Authority Having Jurisdiction, they shall have the authority to revoke the permit to operate the boiler or pressure vessel. Where the operation of a boiler or pressure vessel is deemed by the Authority Having Jurisdiction to constitute an immediate danger, the pressure on such boiler or pressure vessel shall be permitted to be relieved at the owner’s cost and the boiler or pressure vessel shall not thereafter be operated without the approval of the Authority Having Jurisdiction.

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FOOTNOTES FOR TABLE 1003.2.1 (continued)

1 Fuel input shall be determined by one of the following:

The burner input shall not exceed the input shown on the burner nameplate or as otherwise identified by the manufacturer.

The nominal boiler rating, as determined by the building official, plus 25 percent.

2 Automatic boilers shall have one flame failure device on each burner, which shall prove the presence of an ignition source at the point where it will ignite

the main burner, except that boiler groups A, B, E, F, and G, which are equipped with direct electric ignition, shall monitor the main burner, and boiler

groups using interrupted pilots shall monitor the main burner after the prescribed limited trial and ignition periods. Boiler group A, equipped with continu ous pilot, shall accomplish 100 percent shutoff within 90 seconds upon pilot flame failure. The use of intermittent pilots in boiler group C is limited to

approved burner units.

3 In boiler groups B, C, and D a 90 second main burner flame failure limit shall be permitted to be applied where continuous pilots are provided on manufac turer assembled boiler-burner units that have been approved by an approved testing agency in accordance with nationally recognized standards approved by

the building official. Boiler groups F and G equipped to re-energize their ignition systems within 0.8 second after main burner flame failure will be permit ted 30 seconds for group F or 15 seconds for group G to re-establish their main burner flames.

4 Boiler groups C and D shall have controls interlocked to accomplish a non-recycling fuel shutoff upon high or low gas pressure, and boiler groups F, G, and

H using steam or air for fuel atomization shall have controls interlocked to accomplish a nonrecycling fuel shutoff upon low atomizing steam or air pressure.

Boiler groups F, G, and H equipped with a preheated oil system shall have controls interlocked to provide fuel shutoff upon low oil temperature.

5 Automatic boilers shall have controls interlocked to shut off the fuel supply in the event of draft failure where forced or induced draft fans are used or, in the

event of low combustion airflow, where a gas power burner is used. Where a single motor directly driving both the fan and the oil pump is used, a separate

control is not required.

6 Boiler groups C, D, and H, where firing in excess of 400 000 Btu/h (117 kW) per combustion chamber, shall be provided with low fire start of its main burner

system to permit smooth light-off. This will normally be a rate of one-third of its maximum firing rate.

7 Boiler groups C, D, and H shall not permit pilot or main burner trial for ignition operation before a purging operation of sufficient duration to permit not less

than four complete air changes through the furnace, including a combustion chamber and the boiler passes. Where this is not readily determinable, five com plete air changes of the furnace, including combustion chamber up to the first pass, will be considered equivalent. An atmospheric gas burner with no mechan ical means of creating air movement or an oil burner that obtains two-thirds or more of the air required for combustion without mechanical means of creating

air movement shall not require purge by means of four air changes, so long as its secondary air openings are not provided with means of closing. Where such

burners have means of closing secondary air openings, a time delay shall be provided that puts these closures in a normally open position for four minutes

before an attempt for ignition. An installation with a trapped combustion chamber shall, in every case, be provided with a mechanical means of creating air

movement for purging. 8 An automatic hot-water-heating boiler, low-pressure hot-water-heating boiler, and power hot water boiler shall be equipped with two high-temperature limit

controls with a manual reset on the control, with the higher setting interlocked to shut off the main fuel supply, except that manual reset on the high-tem perature limit control shall not be required on an automatic package boiler not exceeding 400 000 Btu/h (117 kW) input and that has been approved by an

approved testing agency. An automatic hot-water heating, power boiler, and package hot-water supply boiler shall be equipped with one low-water level limit

control with a manual reset interlocked to shut off the fuel supply, so installed as to prevent damage to the boiler and to permit testing of the control with out draining the heating system, except on boilers used in Group R Occupancies of less than six units and in Group U Occupancies and further, except that

the low-water level limit control is not required on package hot-water supply boilers approved by a nationally recognized testing agency. However, a low water flow limit control installed in the circulating water line shall be permitted to be used instead of the low-water level limit control for the same purpose

on coil-type boilers. 9 An automatic low-pressure steam-heating boiler, small power boiler, and power steam boiler shall be equipped with two high-steam pressure limit controls

interlocked to shut off the fuel supply to the main burner with manual reset on the control, with the higher setting and two low-water-level limit controls,

one of which shall be provided with a manual reset device and independent of the feed water controller. Coil-type flash steam boilers shall be permitted to

use two high-temperature limit controls, one of which shall be manually reset in the hot water coil section of the boiler instead of the low-water level limit

control.

10 Boiler groups C, D, and H shall use an approved automatic reset safety shutoff valve for the main burner fuel shutoff, which shall be interlocked to the pro gramming control devices required. On oil burners where the safety shutoff valve will be subjected to pressures in excess of 10 psi (69 kPa) where the burner

is not firing, a second safety shutoff valve shall be provided in series with the first. Boiler groups C and D using gas in excess of 1 psi (7 kPa) pressure or

having a trapped combustion chamber or employing horizontal fire tubes shall be equipped with two approved safety shutoff valves, one of which shall be

an automatic reset type, one of which shall be permitted to be used as an operating control, and both of which shall be interlocked to the limit-control devices

required. Boiler groups C and D using gas in excess of 1 psi (7 kPa) pressure shall be provided with a permanent and ready means for making periodic tight ness checks of the main fuel safety shutoff valves.

11 Control and limit device systems shall be grounded with operating voltage not to exceed 150 volts, except that, upon approval by the building official, exist ing control equipment to be reused in an altered boiler control system shall be permitted to use 220 volts single phase with one side grounded, provided such

voltage is used for all controls. Control and limit devices shall interrupt the ungrounded side of the circuit. A readily accessible means of manually discon necting the control circuit shall be provided with controls so arranged that where they are de-energized, the burner shall be inoperative.

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CALIFORNIA MECHANICAL CODE – MATRIX ADOPTION TABLE