HAR §12-222.1-15
HAR §12-222.1-15. Preventive maintenance
Cite as Haw. Code R. § 12-222.1-15
The owner or user of the pressure retaining item is responsible for ensuring that all equipment is maintained as listed in Exhibit 1, titled, "Recommended Preventative Maintenance Schedule", dated October 1, 2023; Exhibit 2, titled, "Table D-1-1 Periodic Testing Recommended Checklist", dated October 1, 2023; and Exhibit 4, titled, "Unattended Power Boiler Log", dated October 1, 2023. Exhibits 1, 2, and 4 are made part of this chapter and located at the end of this chapter. [Eff and comp 12/21/19; am and comp SEP - 8 2024 ] (Auth: HRS §397-4) (Imp: HRS §397-4)
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# EXHIBIT 1 October 1, 2023
# Recommended Preventive Maintenance Schedule
# D-1 INTRODUCTION
Operation and maintenance instructions in this Appendix are intended for general applications. Table D-1-1 presents a periodic checklist for these recommended preventive maintenance tasks. For specific operating and maintenance instructions, consult the equipment manufacturer.
# D-2 DAILY
(a) Check gages, monitors, and indicators.
(b) Check instrument and equipment settings.
(c) For high-pressure boilers, test all low-water fuel cutoff devices and alarms.
(d) Check burner flame.
# D-3 WEEKLY
(a) For low-pressure boilers, test all low-water fuel cutoff devices and alarms.
(b) Check igniter.
(c) Check flame signal strength.
(d) Check flame failure detection system.
(e) Check firing rate control.
(f) Make aural and visual check of pilot and main fuel valves.
# D-4 MONTHLY
(a) Check flue, vent, stack, or outlet dampers.
(b) Test low draft, fan air pressure, and damper position interlocks.
(c) Check low fire start interlock.
(d) Test high and low oil pressure and oil temperature interlocks.
(e) Test high and low gas-pressure interlocks.
# D-5 SEMIANNUALLY
(a) Recalibrate all indicating and recording gages.
(b) For steam boilers, perform a slow drain test of all the low-water fuel cutoff devices.
(c) Check flame failure detection system components.
(d) Check firing rate control.
(e) Check piping and wiring of all interlocks and shutoff valves.
(f) Inspect burner components.
# D-6 ANNUALLY
(a) Flame failure detection system, conduct pilot turn-down test.
(b) Flame failure detection system, test for hot refractory hold-in.
(c) Check dual fuel change over control.
(d) Test high-limit and operating temperature or steam pressure controls.
(e) Replace vacuum tubes, scanners, or flame rods in accordance with manufacturer's instructions.
(f) Conduct a combustion test.
(g) Check all coils and diaphragms; test other operating parts of all safety shutoff and control valves.
(h) Test safety shutoff valve proof-of-closure switch(es) in accordance with manufacturer's instructions.
(i) Perform leakage test on pilot and main gas and/or oil fuel valves and valve proving systems in accordance with manufacturer's instructions.
(j) Test purge air switch in accordance with manufacturer's instructions.
(k) Test air/steam interlock in accordance with manufacturer's instructions.
(l) Test burner position interlock in accordance with manufacturer's instructions.
(m) Test rotary cup interlock in accordance with manufacturer's instructions.
(n) Test low fire start interlock in accordance with manufacturer's instructions.
(o) Test for gas leakage on all threaded and flanged connections.
(p) Verify burner is operating within manufacturer's specifications.
# D-7 AS REQUIRED
(a) Recondition or replace low-water fuel cutoff device.
(b) For oil-fired burners, clean atomizers and oil strainers.
(c) For gas-fired burners, check sediment trap and gas strainers.
(d) Flame failure detection system, conduct pilot turn-down test.
(e) Flame failure detection system, test for hot refractory hold-in.
(f) Test safety/safety relief valves in accordance with ASME Boiler and Pressure Vessel Code, Sections VI and VII.
(g) For parallel positioning systems, verify actuator-to-fuel-valve couplings and actuator-to-damper couplings are properly connected.
(h) For combustion air fan variable frequency drive applications, test interlocks wired to the primary flame safety device including drive fault interlocks and improper speed control interlocks.
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EXHIBIT 2 October 1, 2023
Table D-1-1 Periodic Testing Recommended Checklist
| Frequency [Note (1)] | | | | | | Component/Item | Recommended Test | Accomplished By | |
| --- | --- | --- | --- | --- | --- | --- | --- | --- | --- |
| D | W | M | S/A | A | A/R | | | Boiler Operator | Service Technician |
| X | .. | .. | .. | .. | .. | Gages, monitors, and indicators | Make visual inspection and record readings in boiler log. | X | .. |
| .. | .. | .. | X | .. | .. | Gages, monitors, and indicators | Recalibrate all indicating and recording gages. | .. | X |
| X | .. | .. | .. | .. | .. | Instrument and equipment settings | Make visual check against factory-recommended specifications. | X | .. |
| X | .. | .. | .. | .. | .. | Low-water fuel cutoff devices (high-pressure boilers) | Test all low-water fuel cutoff devices according to manufacturer's instructions. | X | .. |
| .. | X | .. | .. | .. | .. | Low-water fuel cutoff devices (low-pressure boilers) | Test all low-water fuel cutoff devices according to manufacturer's instructions. | X | .. |
| .. | .. | .. | X | .. | .. | Low-water fuel cutoff devices (steam boilers) | For steam boilers, perform a slow drain test in accordance with ASME Boiler and Pressure Vessel Code, Section VI. | .. | X |
| .. | .. | .. | .. | .. | X | Low-water fuel cutoff devices | Recondition or replace each low-water fuel cutoff device. | .. | X |
| .. | .. | .. | .. | X | .. | Operating and/or limit controls | Test high-limit and operating temperature or steam pressure controls. | .. | X |
| .. | .. | .. | .. | .. | X | Safety/safety relief valves | Test safety/safety relief valves in accordance with ASME Boiler and Pressure Vessel Code, Sections VI and VII. | .. | X |
| .. | .. | X | .. | .. | .. | Flue, vent, stack, or outlet dampers | Make visual inspection of linkage and check for proper operation. | X | .. |
| X | .. | .. | .. | .. | .. | Burner flame | Make visual inspection of burner flame [Note (2)]. | X | .. |
| .. | X | .. | .. | .. | .. | Igniter | Make visual inspection, and check flame signal strength if meter-fitted. | X | .. |
| .. | X | .. | .. | .. | .. | Flame signal strength | If flame signal meter is installed, read and log. For both pilot and main flames, notify service organization if readings are very high, very low, or fluctuating (refer to manufacturer's instructions). | X | .. |
| .. | X | .. | .. | .. | .. | Flame failure detection system | Close manual fuel supply for (1) pilot, (2) main fuel cock, and/or (3) valve(s). Check safety shutdown timing and log. | X | .. |
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# EXHIBIT 2 Continued
| Frequency [Note (1)] | | | | | | Component/Item | Recommended Test | Accomplished By | |
| --- | --- | --- | --- | --- | --- | --- | --- | --- | --- |
| D | W | M | S/A | A | A/R | | | Boiler Operator | Service Technician |
| ... | ... | ... | X | ... | ... | Flame failure detection system | Check flame failure detection system components, such as vacuum tubes, amplifier, and relays. | ... | X |
| ... | ... | ... | ... | X | ... | Flame failure detection system | Replace vacuum tubes, scanners, or flame rods in accordance with manufacturer's instructions. | ... | X |
| ... | ... | ... | ... | X | X | Flame failure detection system (pilot turndown test) | Conduct pilot turndown test according to manufacturer's instructions. This test is required annually and after any adjustments to flame scanner mount or pilot burner. | ... | X |
| ... | ... | ... | ... | X | X | Flame failure detection system (hot refractory hold in test) | Test for hot refractory hold-in. This test is required annually and after any adjustments to the flame scanner mount or pilot burner. | ... | X |
| ... | X | ... | ... | ... | ... | Firing rate control | Check firing rate control, and verify factory settings (refer to manufacturer's instructions). | X | ... |
| ... | ... | ... | X | ... | ... | Firing rate control | Check firing rate control, and verify factory settings (refer to manufacturer's instructions). | ... | X |
| ... | ... | ... | ... | X | ... | Firing rate control | Conduct a combustion test, and verify settings are in accordance with manufacturer's instructions. | ... | X |
| ... | X | ... | ... | ... | ... | Pilot and/or main fuel valves | Open limit switch, and make aural and visual check. Check valve position indicators, and check fuel meters if so fitted. | X | ... |
| ... | ... | ... | ... | X | ... | Pilot and/or main fuel valves | Check all coils and diaphragms. Test other operating parts of all safety shutoff and control valves. | ... | X |
| ... | ... | ... | ... | X | ... | Pilot and/or main fuel valves | Test fuel valve interlock switch in accordance with manufacturer's instructions. | ... | X |
| ... | ... | ... | ... | X | ... | Pilot and/or main fuel valves | Perform leakage test on pilot and main gas and/or oil fuel valves, in accordance with manufacturer's instructions. | ... | X |
| ... | ... | X | ... | ... | ... | Low draft, fan, air pressure, and damper position interlocks | Test low draft, fan, air pressure, and damper position interlocks according to manufacturer's instructions. | X | ... |
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# EXHIBIT 2 Continued
| Frequency [Note (1)] | | | | | | Component/Item | Recommended Test | Accomplished By | |
| --- | --- | --- | --- | --- | --- | --- | --- | --- | --- |
| D | W | M | S/A | A | A/R | | | Boiler Operator | Service Technician |
| .. | .. | .. | .. | X | .. | Low draft, fan, air pressure, and damper position interlocks | Test purge switch in accordance with manufacturer's instructions. | .. | X |
| .. | .. | X | .. | .. | .. | Low fire start interlock | Check low fire start interlock according to manufacturer's instructions. | X | .. |
| .. | .. | .. | .. | X | .. | Low fire start interlock | Test low fire start interlock according to manufacturer's instructions. | .. | X |
| .. | .. | X | .. | .. | .. | Oil pressure and temperature interlocks | Test high and low oil pressure and temperature interlocks according to manufacturer's instructions. | X | .. |
| .. | .. | X | .. | .. | .. | Gas pressure interlocks | Test high and low gas-pressure interlocks according to manufacturer's instructions. | X | .. |
| .. | .. | .. | X | .. | .. | Interlocks and valves | Check piping and wiring of all interlocks and shutoff valves. | .. | X |
| .. | .. | .. | .. | X | .. | Atomizing air/steam interlock | Test air/steam interlock in accordance with manufacturer's instructions. | .. | X |
| .. | .. | .. | .. | X | .. | Burner position interlock | Test burner position interlock in accordance with manufacturer's instructions. | .. | X |
| .. | .. | .. | .. | X | .. | Rotary cup burner interlock | Test rotary cup interlock in accordance with manufacturer's instructions. | .. | X |
| .. | .. | .. | X | .. | .. | Burner components | Inspect burner components according to manufacturer's instructions. | .. | X |
| .. | .. | .. | .. | X | X | Burner components | Check dual fuel change over control. If automatically controlled by gas utility, perform test under the supervision of gas utility. | .. | X |
| .. | .. | .. | .. | .. | X | Burner components | For oil-fired burners, clean atomizers and oil strainers. | .. | X |
| .. | .. | .. | .. | .. | X | Burner components | For gas-fired burners, check sediment trap and gas strainer. | .. | X |
GENERAL NOTE: See manufacturer's instructions.
NOTES:
(1) D = daily, W = weekly, M = monthly, S/A = semiannually, A = annually, A/R = as-required.
(2) Caution should be used when viewing burner flame. Personal protective equipment, such as filtered eyeware, may be necessary.
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# EXHIBIT 3 October 1, 2023
# FORM I-1 REPORT OF BOILER INSTALLATION
in accordance with provisions of the National Board Inspection Code
INSTALLATION:
☐ New
☐ Reinstalled
☐ Second Hand
Date ____/____/____
| INSTALLER | OWNER-USER | OBJECT LOCATION |
| --- | --- | --- |
| Name | Name | Name |
| Street | Street, PO Box, RR | Street |
| City, State, ZIP | City, State, ZIP | City, State, ZIP |
| Jurisdiction No. | National Board No. | Manufacturer | | Mfg. Serial No. | Year Built | Boiler Type | Boiler Use |
| --- | --- | --- | --- | --- | --- | --- | --- |
| Fuel | Method of Firing | Btu/kW Input | Btu/kW output | Operating PSI | ASME Code Designator(s) ☐ A ☐ S ☐ U ☐ HOW ☐ M ☐ E ☐ H ☐ Other | | |
| Stamped MAWP | Heating Surface, Sq. Ft. | Cast Iron | Manhole | Specific On-Site Location, i.e., Utility Room | | | |
| Pressure Relief Valve Size | Pressure Relief Valve Set Pressure | Pressure Relief Valve Capacity ☐ Btu/hr ☐ Lb/hr | Manufacturer | Low-Water Fuel Cutoff Mfg. | | | |
| 1. ____ | 1. ____ | 1. ____ | 1. ____ | No. | | | |
| 2. ____ | 2. ____ | 2. ____ | 2. ____ | Probe Type | | | |
| 3. ____ | 3. ____ | 3. ____ | 3. ____ | Flow Switch | | | |
| 4. ____ | 4. ____ | 4. ____ | 4. ____ | Flout & Chamber | | | |
| | | | | Other (Specify) | | | |
| PRESSURE/ALTITUDE GAGE: Dial Graduation ____ Valve/Cock Size ____ MAWP ____ Pipe Connection Size ____ Siphon or Equivalent Device ☐ Yes ☐ No | EXPANSION TANK: ASME Constructed ☐ Yes ☐ No Other ____ MAWP ____ No Gallons ____ | VENTILATION AND COMBUSTION AIR: Unobstructed Opening (sq. in.) ____ Power Ventilator Fan (CFM) ____ |
| --- | --- | --- |
| WATER LEVEL INDICATORS: Number of Gage Glasses ____ Number of Remote Indicators ____ Size of Connection Piping ____ | | FEED WATER SUPPLY: Number of Feeding Means ____ Pipe Size ____ Stop Valve Size ____ MAWP ____ Check Valve Size ____ MAWP ____ |
| STOP VALVES: Number of Valves ____ Valve Size ____ | | EXTERNAL PIPING ASME CODE: ☐ Yes ☐ No ☐ Other ____ FUEL TRAIN: ☐ CSD-1 ☐ NFPA-85 ☐ Other ____ |
| BOTTOM BLOWDOWN CONNECTIONS: Number of Valves ____ Valve Size ____ MAWP ____ Piping Run Full Size ☐ Yes ☐ No | | POTABLE WATER HEATER UNIQUE REQUIREMENTS ☐ Yes ☐ No Inlet Stop Valve Size ____ MAWP ____ Outlet Stop Valve Size ____ MAWP ____ Drain Valve Size ____ Thermometer ☐ Yes |
| Manufacturer's Certification Attached: ☐ Yes ☐ No Does boiler replace existing one: ☐ Yes ☐ No | | Clearance from walls and floors: Side ____ Bottom ____ Top ____ |
| Additional recommendations and remarks by installer: | |
| --- | --- |
| Installer Name (PRINT) ____ Registration # ____ | I HEREBY CERTIFY THAT THE INSTALLATION COMPLIES WITH NBIC, Part 1 ____ Installer Signature ____ |
This form may be obtained from The National Board of Boiler and Pressure Vessel Inspectors - 1055 Cropper Avenue, Columbus, Ohio 43229-1183
Page 1 of 1
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EXHIBIT 3 Continued
# 1.4.5.1.1 GUIDE FOR COMPLETING NATIONAL BOARD BOILER INSTALLATION REPORT (21)
1) INSTALLATION: Indicate the type and date of installation — new, reinstalled, or second hand.
2) INSTALLER: Enter the installer's name and physical address.
3) OWNER-USER: Enter the name and mailing address of the owner-user of the boiler.
4) OBJECT LOCATION: Enter the name of the company or business and physical address where the installation was made.
5) JURISDICTION NO.: Enter the Jurisdiction number if assigned at the time of installation.
6) NATIONAL BOARD NO.: Enter the assigned National Board number. Note: Cast section boilers do not require National Board registration.
7) MANUFACTURER: Enter the boiler manufacturer's name.
8) MFG. SERIAL NO.: Enter the assigned boiler manufacturer's serial number.
9) YEAR BUILT: Enter the year the boiler was manufactured.
10) BOILER TYPE: Enter the type of boiler, e.g., watertube, firetube, cast, electric, etc.
11) BOILER USE: Enter the service for which or for how the boiler will be used, e.g., heating (steam or water), potable water, etc.
12) FUEL: Enter the type of fuel, e.g., natural gas, diesel, wood, etc. If more than one fuel type, enter the types for which the boiler is equipped.
13) METHOD OF FIRING: Enter the method of firing, e.g., automatic, hand, stoker, etc.
14) Btu/kW INPUT: Enter the Btu/hr or kW input of the boiler.
15) Btu/kW OUTPUT: Enter the Btu/hr or kW output of the boiler.
16) OPERATING PSI: Enter the allowed operating pressure.
17) ASME CODE DESIGNATORS: Check the ASME Code designator shown on the code nameplate or stamping of other certification mark (specify).
18) STAMPED MAWP: Enter the maximum allowable working pressure shown on the nameplate or stamping.
19) HEATING SURFACE SQ. FT.: Enter the boiler heating surface shown on the stamping or nameplate. Note: This entry is not required for electric boilers.
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# EXHIBIT 3 Continued
20) CAST BOILER: Enter the total number of sections for cast boilers.
Note:
Not all cast boilers are sectional. Mono-block cast boilers should be described as having one (1) section.
21) MANHOLE: Indicate whether the boiler has a manway.
22) SPECIFIC ON-SITE LOCATION: Enter the on-site location of the boiler in sufficient detail to allow location of that boiler.
23) PRESSURE RELIEF VALVE SIZE: Enter the inlet and outlet size of all installed boiler safety or safety relief valves.
24) PRESSURE RELIEF VALVE SET PRESSURE: Enter the set pressure of all installed boiler safety or safety relief valves.
25) PRESSURE RELIEF VALVE CAPACITY: Enter the capacity in either lbs. of steam per hour or Btu/hr for each installed boiler safety or safety relief valve.
26) MANUFACTURER: Enter the manufacturer of each installed boiler safety and safety relief valve.
27) LOW-WATER FUEL CUTOFF: Enter the manufacturer's name, type, number, and maximum allowable working pressure of all installed low-water fuel cutoff devices.
28) PRESSURE/ALTITUDE GAGE: Enter the dial range of the installed pressure or altitude gage, cutout valve or cock size, a maximum allowable working pressure, and gage pipe connection size. For steam boilers, indicate gage siphon or equivalent device installed.
29) EXPANSION TANK: Indicate code of construction of installed expansion tank, tank maximum allowable working pressure, and tank capacity in gallons.
30) VENTILATION AND COMBUSTION AIR: Indicate total square inches of unobstructed opening or total cubic feet per minute of power ventilator fan(s) available for ventilation and combustion air.
31) WATER LEVEL INDICATORS: Enter the number of gage glasses and/or remote indicators and connecting pipe size.
32) FEEDWATER SUPPLY: Enter the total number of feeding means, connecting pipe size, stop and check valve size, and maximum allowable working pressure.
33) STOP VALVE(S): Enter the number of stop valves installed, valve size, and maximum allowable working pressure.
34) POTABLE WATER HEATER UNIQUE REQUIREMENTS: Indicate if stop valves are installed and, if so, enter size and maximum allowable working pressure. Enter drain valve size and indicate installation of thermometer at or near boiler outlet.
35) MANUFACTURER'S CERTIFICATION ATTACHED: Indicate if manufacturer's certificate is attached (mandatory for new installations).
36) CLEARANCE REQUIREMENTS AND REPLACEMENT OF EXISTING BOILER: Indicate clearances and whether the installation replaced an existing boiler.
37) ADDITIONAL REMARKS: Enter any remarks or comments you deem appropriate.
38) INSTALLER'S NAME AND SIGNATURE: Print installer's name and registration number and sign completed report.
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# EXHIBIT 4 October 1, 2023
# Unattended Power Boiler Log
| Day | | 8am | | 7am | | 6am | | 5am | | 4am | | 3am | | Remarks (Including date & time) |
| --- | --- | --- | --- | --- | --- | --- | --- | --- | --- | --- | --- | --- | --- | --- |
| Sample | | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 | |
| 1 | | | | | | | | | | | | | | |
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| 31 | | | | | | | | | | | | | | |
CODE
Normal Operating Check (boiler in service)
Started Boiler & Tested Low Water Control
Tested LWC (required every 12 hours when the boiler
is in service) Test with the Burner Co. Test Must
Extinguish Burner and Ring Low Water Alarm
3 Added Chemicals
4 Blow-down
5 Tested Safety Valve (first working day of the month hand raie spindle)
6 Stopped Boiler
NOTE The completed log must be available to the boiler inspector for at least six (6) months
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