UFC 3-430-07
24 July 2003
including Change 1, Jan 2004 and Change 2, March 2005
CHAPTER 7
OPERATIONAL TESTS
7-1
GUIDANCE. Following internal inspection, as part of the external
inspection, bring the boiler or unfired pressure vessel up to operating pressure and
temperature. Inspect, and cause to function under operating conditions, all
automatically and manually operated control devices provided for controlling the
operation and safety of the vessel, steam or water pressure, hot water temperature,
combustion, and boiler water level. Inspect under operating conditions all associated
valves and piping, pressure and temperature indicating devices, metering and recording
devices, and all boiler auxiliaries. Boilers firing oil or gas without fully automatic or
semiautomatic controls must have an EFD waiver to be certified. All combustion
controls attached to the boiler regardless of the fuel being fired must be in good working
order or the inspection certificate will be withheld. Inspections and tests of boilers may
be made with the main steam or hot water distribution valves closed or open, as
necessary, to fire the boiler and operate it under normal operating conditions. Testing
the function of automatically or manually controlled devices and apparatus that may
interfere with the distribution requirements should be done with the main steam or hot
water distribution valves closed, as applicable.
7-1.1
Purpose. These additional inspections and tests allow the inspector to
discover any inefficient or unsafe operation or maintenance of the vessel or of the boiler
or its auxiliaries that may be evidenced under operating conditions.
7-1.2
Conditions to be Reported. Report all deficiencies requiring adjustment,
repair, or replacement, and all conditions indicating excessive operating and
maintenance cost. Withhold certificates until the deficiencies are corrected.
7-2
FIRING EQUIPMENT. Inspect, for any deficiency that may be evidenced
under operating conditions, the operation of all firing equipment including oil burners,
gas burners, fuel injectors, fuel igniters, coal stokers, and feeders, burner safety
controls and other such equipment provided to introduce fuel into the boiler furnace and
to ignite the fuel. All fuel leaks must be repaired before the certificate is issued.
7-3
CONTROLS. Inspect the operation of all controls directly associated with
the operation and safety of the boiler for any defects preventing proper operation.
These controls include such items as unloading valves, high-pressure cutout devices,
high temperature cutout devices, low-pressure cut-in devices, and burner safety
controls. Inspect the operation of combustion controls, steam pressure controls, water
temperature controls, and feedwater controls. Make sure that the ability of the
combustion control and steam pressure control to maintain proper steam pressure (or
water temperature in high temperature water installations) and air-fuel ratio is
demonstrated throughout the capacity range of the boiler and the load swings
encountered in the operation of larger boilers. Air-fuel ratio will be checked by the
activity or the inspector by both CO2 and O2 measuring devices. CO will also be
checked. Check fully-automatic boiler controls for the proper programming sequence
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