NATIONAL PHARND BOARD INGDECTIO INSPECTION CODE INSPECTIONNATIONAL BOARD INSPECTION CODE 2021 EDITION DATE OF ISSUE — JULY 1, 2021 This code was developed under procedures accredited as meeting the criteria for American National Stan- dards, The Consensus Committee that approved the code was balanced to ensure that individuals from com petent and concemed interests had an opportunity to participate. The proposed code was made available for public review and comment, which provided an opportunity for additional public input from industry, academia, regulatory and Jurisdictional agencies, and the public-atarge. ‘The National Board does not “approve,” “rate,” or “endorse” any item, construction, proprietary device, or activity The National Board does not take any position with respect to the validity of any patent rights asserted in connection with any items mentioned in this document, and does not undertake to insure anyone utilizing a standard against labilty for infringement of any applicable Letters Patent, nor assume any such liability. Us~ ers of a code are expressly advised that determination of the validity of any such patent rights, and the risk of infringement of such rights, is entirely their own responsibilty Participation by federal agency representative(s) or person(s) affiliated with industry is not to be interpreted ‘as govemment or industry endorsement of this code. ‘The National Board accepts responsibility for only those interpretations issued in accordance with governing National Board procedures and policies that preclude the issuance of interpretations by individual committee % por 4 per wy NS (Ry Dl 7/0 ‘The above National Board symbols are registered with the US Patent Office “National Board" is the abbreviation for The National Board of Boiler and Pressure Vessel Inspectors. No part of this document may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher, All charts, graphs, tables, and other criteria that have been reprinted from the ASME Boiler and Pressure Vesse! Code, Sections |, IV, Vill, and X are used with the permission of the American Society of Mechanical Engineers. All Rights Reserved. Library of Congress Catalog Card No. 52-44738 Printed in the United States of America All Rights Reserved www.NBBLorg Copyright © 2021 by ‘THE NATIONAL BOARD OF BOILER & PRESSURE VESSEL INSPECTORS All rights reserved Printed in U.S.A.PART 2 — INSPECTION TABLE OF CONTENTS Introduction xi Foreword . . . von XVIL Personnel XIX Section 1 General Requirements for Inservice Inspection of Pressure-Retaining Items. 1 Ad Scope 1 12 ‘Administration 1 13 Reference to Other Codes and Standards... 4 14 Personnel Safety. 2 144 Personal Safety Requirements for Entering Gonfined Spaces. 3 142 Equipment Operation .. o “3 15 Inspection Activities a4 184 Inservice Inspection Activities 4 15.2 Pre-Inspection Activities 4 15.2.4 Inspection Planning... 4 153 Preparation for Internal Inspection 5 154 Post-Inspection Activities 6 16 Change of Service 6 Section 2 _ Detailed Requirements for Inservice Inspection of Pressure-Retaining Items 7 24 Scope 7 22 Boilers 7 224 Scope «.. 7 222 Service Conditions 7 223 Pre-inspection Activities . 7 2.24 Condition of Boiler Room or Boiler Location... aT 225 External Inspection 7 226 Internal Inspection 8 227 Evidence of Leakage 8 2.28 Boilor Corrosion Considerations ... 8 229 Waterside Deposits... 9 2.2.10 [pseeete Bones aia Eats. tid Acpuriannees 9 2.2.10.1 Boller Piping ..... 9 22.102 Flanged or Other Connections 9 22103 Miscellaneous 40 22104 Gages 40 2210.5 Pressure Relie! Devices .. 1 22.106 Controls .... : 1 22.11 Records Review 12 2.2.42 Description and Goncems of Specific Types of Boiler 12 2.2.42.1 —— Cast-lron BOllets «0 . . 12 22122 — Firelube Boilers 413 22123 — Watertube Boilers 15, 22124 Electric Boilers ..... 16 22.125 Fired Coil Water Heaters 16 22.126 Fired Storage Water Heaters - : a7 2.2.12.7 Thermal Fluid Heaters 7 22.128 Waste Heat Bollers «0 . oe 419 22.129 Kraft or Sulfate Black Liquor Recovery Boilers 20 23 Pressure Vessels 22 234 Scope .. 22 23.2 Service Conditions: 22 2.3.3 External inspection 22 234 Intemal Inspection .... . . 23 235 Inspection of Pressure Vessel Parts and Appurtenances... 242351 Gages 24 23.52 Safety Devices 25 23.53 Controls/Devices 25 2354 Records Review 25 236 (esc dt iia com pa Ee eee 28 2.3.6.1 DeaeratOrs enn 26 23.62 Compressed Air Vessels 28 2363 Expansion Tanks ar 23.64 Liquid Ammonia Vessels 28 23.6.5 Inspection of Pressure Vessols wih Quick-Acuating Closures 31 2368 Transport Tanks. 33 2367 Anhydrous Ammonia Nurse Tanks... 33 2.3.6.8 Inspection of Pressure Vessels for Human Occupancy (PVHO'S). 34 2369 Inspection of Static Vacuum Insulated Cryogenic Vessels. 38 2.3610 Inspection of Wire Wound Pressure Vessels, 39 24 Piping and Piping Systems. 44 2.4.1 Scope .. . ses at 24.2 Service Conditions | at 243 Assessment of Piping Design -_ rascal 244 External inspection of Piping at 245 Internal Inspection of Piping 42 248 Evidence of Leakage 42 247 Provisions for Expansion and Support 42 2.4.8 [ager al igs Say aimee ae ia 43 24.8.1 Gages .. : : 43 2482 Safety Devices 43 24.83 ‘Quick-Disconnect Coupling, 43 2.4.9 Covered Piping Systems. 43 25 Pressure Relief Devices .. 43 254 Scope 43 252 Pressure Relief Device Data ... 44 25.3 Inservice Inspection Requirements for Pressure Relief Device Conditions 44 254 Inservice Inspection Requirements for Pressure Relief Devices installation Condition 45 255 ‘Additional Inspection Requirements 45 2.5.5.1 Boilers... . 45 25.5.2 Hot Water Supply Boilers, and Potable Water Heaters. 45 2553 Pressure Vessels and Piping 46 25.5.4 Rupture Disks 46 256 Packaging, Shipping, and Transportation... remans AT 257 ‘Testing and Operational inspection of Pressure Relief Devices. 48 257.4 Corrective Action . 49 2572 Valve Adjustments. : 49 258 Recommended Inspection and Test Frequencies for Pressure Relief Devices 49 2581 Establishment of Inspection and Test Intervals 50 25.8.2 Establishment of Service Intervals .... 51 Section3 Corrosion and Fallure Mechanisms 52 34 Scope .. sa 52 32 General 52 33 Corrosion... 52 33.4 Macroscopic Corrosion Environments 52 33.2 Microscopic Corrosion Environments .. 54 3.3.3 Control of Corr O$iON errr 7) 3.3.3.4 Process Variables 54 3332 Protection 55 3.3.3.3 Material Selection 55, 3.3.34 Coatings: 55 33.3.5 Engineering Design 56 3336 Conclusion’ 56 34 Failure Mechanisms ..... 5B TABLE OF CONTENTS | IIT344 Fatigue 342 Creep . 343 Temperature Effects 344 Hydrogen Embrittement 345 High Temperature Hydrogen Atak... 346 Hydrogen Damage .... : 347 Bulges and Blisters 348 Overheating 349 Cracks Section 4 Examinations, Test Methods, and Evaluations 44 SOP 42 Nondestructive Examination Methods (NDE). 424 Visual 422 Magnetis Particle 423 Liquid Penetrant 424 Ulrasoni€ nn 425 Radiography 426 Eddy Current 427 Metallographie 428 ‘Acoustic Emission 43 Testing Methods 431 Pressure Testing 43.1.4 AllPressure Testing 434.2 Liquid Pressure Testing... 431.3 Pneumatic Pressure Testing 44 Metods to Assess Damage Mechanisms en inspection Frequency for Pressure-Retaining Items, i 444 Scope... 442 General Requirements 443 Responsibilities 4a Remaining Service Life Assessment Methodology 445 Data Requirements for Remaining Service Life Assessments 446 Identification of Damage Mechanisms 447 Determining Inspection Intervals 447.1 Method for Estimating Inspection intervais for Pressure-Reetaining Items Subject to Erosion or Corrosion. 4.47.2 Method for Estimating Inspection intervals for Exposure to Corrosion .. 447.3 Estimating Inspection Intervals for Prossure-Rotaining Items Where Corrosion is Not a Factor... 448 Evaluating Inspection Intervals of Pressure-Retaining items Exposed to Inservice Failure Mechanisms. 44.8.1 Exposure to Elevated Temperature (Creep). 4482 Exposure to Brittle Fracture. 44.8.3 Evaluating Conditions That Cause Bulges/Blisters/Laminations..... 44.84 Evaluating CrackcLike Indications in Pressure Retaining items... 448.5 Evaluating Exposure of a Pressure-Retaining Item to Fire Damage. 44.8.6 Evaluating Exposure of Pressure-Retaining items to Cyclic Fatigue 448.7 Evaluating Pressure-Retaining tems Containing Local Thin Areas 45 Risk-Basod Inspection Assessment Programs. 454 Scope 452 Definitions 453 General 454 Considerations - 455 Key Elements of an RBI Assessment Program 458 RBI Assessment 45.8.1 Probabilly of Failure. 456.2 Consequence of Failure... 4583 Risk Evaluation SLKRRFRL RBSBRBRLVS223SsS Bes ae4564 Risk Management 78 457 Jurisdictional Relationships... = r 79 46 Quantitative Engineering Assessments including Finite Element Analysis (FEA) 79 46.1 Calculations, . 73 46.2 Engineer Experience. 73 46.3 Finite Element Analysis (FEA) Engineer Experience 79 Section 5 Stamping, Documentation, and Forms. 80 5A Scope 80 52 Replacement of Stamping or Nameplate ... vs BO 524 indistinct Stamping or Nameplate is Lost, legible, or Detached on 80 5.2.2 Reporting... 80 5.2.3 Replacement of Duplicate Nameplates. . . se 81 53 National Board Inspection Forms. 81 53.1 Scope. 81 5.3.2 Forms 81 5.33 Instructions for Completing the Form NB-136, Replacement of Stamped Data FOM wnneeeuuB1 534 Guide for Completing Fitness for Service Assessment Reports. 82 Section 6 Supplements. 95 ‘Supplement 1 Steam Locomotive Firetube Boiler Inspection and Storage 95 Sit Scope 95 S12 Special Jurisdictional Requirements eorteme 96 813 Fodoral Railroad Administration (FRA) ai si is OB S14 Locomotive Firetube Boller Inspection 96 S144 Inspection Methods 96 81.4.2 Inspection Zones. 97 $1421 Riveted Seams and Rivet Heads 97 $1422 Welded and Riveted Repairs 98, 814.23 Boiler Shell Course. i 99 $14.24 Dome and Dome Lid 99 $1425 Mudring 99 81426 Flue Sheets... 100 $14.27 Flanged Sheets 100 $1428 Stayed Sheets. 100 $14281 — Bulged Stayed Sheets 101 814.29 Staybolts...n 401 $142.10 Floxible Staybolts and Sieoves. 102 $142.11 Girder Stay and Crown Bars 103 814.212 — Sling Stays... 103 $142.18 Crown Stays and Expansion Stays rs z 104 $142.14 Diagonal and Gusset Braces. 4105 814215 Flues 105 $1.4.2.16 Supetheater Units and Header... 405 $1.4.2.17 Arch Tubes, Water Bar Tubes, and Circulators. 108 814.218 — Thermic Syphons 108 814.219 Firebox Refractory ...nnnn : i a arn OF 814.220 Dry Pipe. 107 $1.4.221 Throttle and Throttle Vaive 107 $14222 — Screw-Type Washout Plugs, Holes, and Sleeves: 107 81.4223 Handhole Washout Doors 108 814.224 Threaded and Welded Attachment Studs.. 108 814.225 — Fusible Plugs. . 109 81.4226 — Water Glass, Water Column, and Gage Gocks 109 814227 Steam Pressure Gage 109 $1.4.228 Boiler Fillings and Piping. 110 $1.4.228 Boiler Attachment Brackets... i . st 110 $14230 Fire Door 110 TABLE OF CONTENTS | VS14231 Gants and Grate Cperating Machen 814.232 Smokebox : $14.23 Smokebox Steam Pipes... 814.234 Ash Pan and Fire Pan 3143 Method of Checking Height of Water Gage Glass 1.4.3.1 Water Height Measurement Method... $1432 Flexible Spirit Level Method S815 Guidelines for Steam Locomotive Storage S151 Storage Methods $1.52 Wet Storage Method . 81.53 Dry Storage Method S154 Recommended General Preservation Procedures 381.55 Use of Compressed Air to Drain Locomotive Components S156 Return to Service S16 Safety Valves, S17 Tables and Figures. ‘Supplement 2 Historical Boilers. $2.1 Scope Introduction. Responsibilities General Inspection Requirements Pre-Inspection Requirements Post Inspection Activities Boiler Operators Examinations and Tests Nondestructive Examination Methods Testing Method... Specific Examination and Test Methods Specific Examination Methods Visual Examination... Preparation for Visual Inspection... Visual Examination Requirements Untrasonic Exarnination. Liquid Penetrant Examination Magnetic Particle Examination Specific Testing Methods Hydrostatic Pressure Testing. Ultrasonic Thickness Testing... Evaluation of Corrosion... Line and Crevice Corrosion. Randomly Scattered Pits. Locally Thinned Areas Generalized Thinned Areas Inspections... Inservice Inspections, inservice Inspection Documentation Inspection Intervals intial Inspection. Subsoquent Inspections Safety Devices — General Requirements Safety Valves. Gage Glass... Try-Cocks Fusible Plug. Pressure Gage ‘Appurtenances ~ Piping, Fitings, and Valvas. Piping, Fittings, and Valve Replacements. Maximum Allowable Working Pressure (MAWP} m1$210.1 Strength 133 $2102 Rivets and Rivet Heads. 433 S2.102.1 Rivot Head Types 133 $21022 Inspection of Corraded Rivets. 134 $2103 Cylindrical Components... 135 82.10.31 Cylindrical Components Under External panne secre 185 $2104 Stayed Surfaces 154 $2104.41 —_Staybolts, 154 $21042 Bulging 154 $210.6 Construction Cods. 163 $210.6 Nomenclature: 163 $210.7 Limitations 164 $210.8 Boiler Insulation and Jacketing - ss 164 S211 Boller Inspection Guideline. 184 8212 Initial Boiler Certification Report Form 169 $213 Guidelines for Historical Boiler Storage. 169 $213.4 Storage Methods. - 169 $213.11. Wet Storage Method 170 S2.13.1.2 Dry Storage Method... = en saescent7D 82.132 Recommended General Preservation Procedures a7 $2133 Use of Compressed Air to Drain Historical Boiler Components 173 $2134 Return to Service. 173 82.14 Safety Procedures, 174 $214.1 Experience... 474 $2.142 Stopping Engine in an Emorgency a . nen TS $2143 Water Glass Breakage 175 $2144 Runaway Engine and Governor Over Speed 178 82145 Killing a Fire... 178 $214.6 Injector Problems . 178 $214.7 Foaming or Priming Boiler. 178 $214.8 Handhole Gasket Blows Out 178 $214.9 TUD® BUTBt ven nn : a Fs 2 178 $214.10 Leaking Valves 173 $214.11 Broken Pipes 173 $214.12 Safely Valve Problems... 2 . si 173 $214.18 Safety Valve Opens But Will Not Close ve 179 $214.14 Leaking Pipe Plugs. 173 S214.15 Melted Grates.nom 179 82.14.16 Firing of Historical Boilors with Liquid or Gaseous Fuels. 180 $2.15 Tables and Figures 180 ‘Supplement 3 Inspection of Graphite Pressure Equipment = cs 185 $3.4 ‘Soope 185 $32 Application 185 $33 Operations .... 185 S34 Inservice Inspection 185 ‘Supplement 4 Inspection of Fiber-Reinforced Thermosetting Plastic Pressure Equipment ......0.0...187 S44 ‘Scope 187 842 Inservice Inspection 7 187 843 General 187 S44 Visual Examination 188 S45 Inspector Qualifications src st sn vo 189 S46 ‘Assessment of Installation 189 S461 Preperation 190 S462 Leakage 190 84.63 Tools 190 S47 External Inspection... sais a est asia 10D Sa74 Insulation or Other Coverings 190 TABLE OF CONTENTS | Vil84.7.2 Exposed Surfaces 84.7.3 Structural Attachments 848 Internal Inspection .... 84.8.1 General 84.8.2 Specific Areas of Concern ... 34.9 Inspection Frequency 84.9.1 Newly installed Equipment 8492 Previously Repaired or Altered Equipment 84.10 Photographs of Typical Conditions. 84.11 Tables and Figures ‘Supplement 5 Inspection of Yankee Dryers (Rotating Cast-Iron Pressure Vessels) with Finished Shell Outer Surfaces : sent $5.1 Scope $5.2 ‘Assessment of Installation $52.1 Determination of Allowable Operating Parameters 85.2.2 Adjusting the Maximum Allowable Operating Parameters of the Yankee Dryer Due to ‘a Reduction in Shell Thickness from Grinding or Machining $5.23 Documentation of Shell Thickness and Adjusted Maximum Allowable Operating Parameters. $5.3 Causes of Deterioration and Damage 85.3.1 Local Thinning 8532 Cracking $5.3.2.1 Through Joints and Bolted Connection: $53.22 Through-Wall Leakage... 85.323 Impact From Objects Passing Through the Yankee/Pressure Roll Nip. 85.324 Stress Magnification Around Drilled Holes $5.32.5 Thermal Stress and/or Micro-Structural Change From Excessive Local Heating and Cooling. $53.26 Joint Interface Corrosion 85.327 —Stress-Corrosion Cracking of Structural Bolts. $5.33 Corrosion " 854 Inspections 35.5 Nondestructive Examination $5.6 Pressure Testing. 85.7 Tables and Figures aan otnniesitebnimteninhe imelitivntdiice: seeimliode 86.1 ‘Scope : $6.2 Terminology $6.3 Administration $6.4 Inspection $84.1 Scope 86.42 General Requirements for Inspectors 86.4.3 Registration of Inspectors... 36.4.4 Qualifications of Inspectors... 86.45 Codes of Construction. $6.46 Inspector Duties for Continued Service Inspections. '$6.4.6.1 __ Inspector Duties for Continued Service Inspection of Cargo Tanks $6.4.6.2 Inspector Duties for Continued Service Inspection of Portable Tanks. $646.3 _ Inspector Duties for Continued Service Inspections of Ton Tanks 86.4.7 (eatin, orien oredr ac 00) (ideo cia Soaps 6.4.7.1 Administration... 864.72 Inspection and Test Required Frequencies $647.3 External Visual and Pressure Tests. 86.4.7.4 Leak Tightness Testing of Transport Tanks $6.4.7.4.1 Cargo Tanks 86.47.42 Portable Tanks 864743 Ton Tanks. 190 191 19 191 192 192 192 193 194 210 210 210 212 213 213 213 214 214 DAS 215 215 215 216 216 216 216 216 217 217 218 219 219 219 219 219 219 219 220 220 221 221 221 202 222 222 222 223 223 203 223 223