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NR 13 - Boilers and Pressure Vessels (safety regulation of MTE)

Inspection and Maintenance Engineer Static Equipment Deyson Marcelo Rothen


Speaker

Mechanical Technician (CEFET-PR, 1993)

Refinery Pres. Getúlio Vargas (Petrobras)


Industrial Engineering Mechanics (CEFET-PR, 1998)

Laboratory for Concurrent Engineering (Siemens) Kværner Pulping Kværner Oilfield


Products Companhia Siderurgica de Tubarão (since 1999)
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Topics
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Legislation History Purpose Responsibility legal requirements of care Domain Man
agement Services own inspection technology management trends in CST Doubts / que
stions
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1 - Legislation
Legal Structure
Legislative CF (CLT) Executive (Ordinances) ABNT, corporate standards (technical
standards)
"Regulation prevails over technical standard"
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ILO Conventions

ILO 155 Occupational Safety and Health Workers (1981)

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Article 4 1. Each Member shall, in consultation with the most representative o
rganizations of employers and workers concerned, taking into account national co
nditions and practice, formulate, implement and periodically review a coherent n
ational policy on safety and health of workers and the environment work. 2. Th
is policy shall aim to prevent accidents and damage to health that are a consequ
ence of the work, relate to the work activity or supervene at work by minimizing
, as far as is reasonably practicable, the causes of hazards inherent in the wor
k environment. 6 NR 13 - Boilers and Pressure Vessels
ILO Conventions

ILO 155 Occupational Safety and Health Workers (1981)

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Article 8 Each Member shall adopt, by law or regulation or any other method co
nsistent with national conditions and practice, and in consultation with represe
ntative organizations of employers and workers concerned, the necessary measures
to give effect to Article 4 of this Agreement. Article 9 1. The enforcement o
f laws and regulations concerning safety, hygiene and working environment should
be ensured by a system of inspection is appropriate and sufficient. 2. The co
ntrol system should provide for appropriate penalties for violations of the laws
or regulations. 7 NR 13 - Boilers and Pressure Vessels
Legal Grounds

Federal Constitution (1988)

Article 21. It is for the Union:

XXIV - organize, maintain and carry out inspection of work;

Article 22. It is incumbent on the Union to legislate:

I - civil, commercial, penal, procedural, electoral, agrarian, maritime, aeronau


tical, space and labor;

Law 6514/77: Amendment to Chapter 5 of the CLT


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Legal Grounds

Decree-Law 5452 (May 1, 1943)

Chapter V THE SAFETY AND OCCUPATIONAL HEALTH Article 200 - The Ministry of Labor
to establish additional provisions to the standards mentioned in this chapter,
bearing in mind the peculiarities of each activity or sector of employment, part
icularly regarding:
I - measures to prevent accidents and personal protective equipment in construct
ion, demolition or repairs;
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Legal Grounds

Ordinance 3214/78

Publication of Regulatory Standards Drafted by Working Groups tripartite (govern


ment, employers, workers) NR 13: no participation by manufacturers
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Supervision

It is for the Regional Labor Office to make inspection of compliance to the Regu
latory Standards WRD / ES: Del. Tarciso Celso Vieira de Vargas DRT / SP: mean of
4 assessments per day (assuming all NR's)

Annual visit: risk and risk 4 3 Every two years: risk 2 Every 3 years: a risk
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2 - History
Worldwide

Nineteenth century: steam as an energy source Accident boilers: God's work! Crea
tion of ASME: 1880 protests in 1905 (50 000 casualties per year) U.S. Legislatio
n: 1908 ASME Code: 1914 National Board Inspection Code: 1919
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In Brazil
First version: 1978 First review: 1984 (operators and the definition of serious
and imminent) Second Revision: 1994 (after an accident on Refinery) ABNT NB-55 (
safety inspection of boilers stationary) ⇒ NBR 12 177 Order 16 (2001) Inmetro: S
PIE
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Major industrial accidents

1976 - Sevezo - 500 dead 1984 - Bhopal - 2500 deaths in 1998 - Nigeria - 700 dea
d 1986 - Chernobyl - 500,000 deaths in 1972 - REDUC - 37 dead 1984 - Cubatão - 5
08 dead
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ILO Convention 174 (1993)
Prevention of major industrial accidents (accidents Extended): beyond the limits
of the company Brazil is a signatory since 2001 Example: pole Camaçari cu
rrent Accidents: pipes and ducts (range over large areas populated)

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Rio Iguaçu (Paraná) Source: Report on the Internet
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Refinery in Algeria (Africa), boiler accident (5 photos) Source: Report on the I
nternet
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3 - Purpose
Goal NR 13

Control over the state of equipment, trying to protect the physical integrity of
employees (CLT) as a function of potential energy accumulated Definition of cri
minal liability in the event of noncompliance and / or accidents
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Equipment covered

Boilers

20000 in Brazil, 200 in large enterprises (10 in CST) 5 million in Brazil and 70
,000 in large enterprises (900 in ~ CST) shall comply with NR 13 (contractual) a
udits (co-responsibility)
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Pressure Vessels

Units outsourced (lending):

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NR's related

NR 1: General Provisions (RGI) NR 3: Embargo or prohibition NR 8: Buildings (ins


ide buildings) NR 15: Activities unhealthy (fluid) NR 20: Fuels and flammable NR
23: 26 NR Fire Protection: Safety signs NR 28: Penalties
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4 - Liability
Staff involved

The NR's down mainly involve the personal security and Occupational Medicine

NR 4: Services specializing in Safety Engineering and Occupational Medicine 5 NR


: CIPA (Internal Commission) NR 6: PPE (Personal Protective Equipment) NR 7: Con
trol of occupational health physician NR 9: PPRA (Environmental Risks)
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Staff involved

NR 10: Facilities and Services in Electricity

It involves the technical staff of Electrical involves mainly mechanical inspect


ion and maintenance, and operation, engineering and other specialties

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Qualified professional
Signing legal documents Mechanical Engineer with registration in CREA (assignmen
ts of Law 5194/66) has responsibility for the acts pertaining to Legislation (ch
arged or not) is the technical manager of the company
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13.1.2 For purposes of this NR, it is considered "Qualified Professional" who ha
s legal competence to practice the profession of engineer in activities relating
to project construction, operation and maintenance of monitoring, inspection an
d supervision of inspection of boilers and vessels pressure in accordance with p
rofessional regulations in force in the country
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Violation and penalties

Auto Offense: fine the company


As NR 28 Depends on number of employees and the degree of the violation (1 to
4) varies between 630 and 6304 UFIR

Expiration notification
Deadlines: 60d, 120d and> 120d Dual seen

If it is serious and imminent risk


Consequence: embargo or ban Feature preventive (not punitive)

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Responsibility (accident)

Social Security should be refunded MPT (Federal): Intra-muros

MPT> Prosecutor> labor justice MPE> prosecutor> common justice


Prosecution
Not dependent on the civil suit Search punishment (freedom) against the professi
onal
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MPE (State): Environmental and individual


Civil lawsuit
Prove the guilt (omission, negligence or recklessness) The company pays damages
Search
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5 - Legal requirements
Organization
Installation
General Maintenance Operation
Inspection
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General Requirements

Definition of Boilers and Pressure Vessels Boilers Categorization and Pressure V


essel imminent and serious risk of identification cards and banners Documentatio
n
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13.1.1 Steam boilers are devices intended to produce and accumulate vapor pressu
re above atmospheric, using any energy source, except for the reboilers and simi
lar equipment used in process units. 13.6.1 Pressure Vessels are devices that co
ntain fluids under pressure internally or externally.
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1 - The NR should be applied to the following equipment: a) any vessel whose pro
duct "PV" higher than 8 (eight) where P is the maximum operating pressure in kPa
and "V" its internal geometrical volume in m3 including: - heat exchangers, eva
porators and the like - pressure vessels and parts subject to direct flame that
are not within the scope of other NR's, or the item 13.1 of NR - Pressure Vessel
jacketed, including reboilers and reactors; - autoclaves and boilers, thermal f
luid that does not vaporize. b) vessels containing fluid class "A", specified in
Annex IV, irrespective of size and product "PV."
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2 - NR This does not apply to the following equipment: a) transportable cylinder
s, vessels for the transport of goods, portable tanks of compressed fluid and fi
re extinguishers; b) intended for human occupancy, c) the combustion chamber or
vessel forming part of rotating machinery or alternatives such as pumps, compres
sors, turbines, generators, motors, pneumatic and hydraulic cylinders and which
can not be characterized as independent devices, d) ducts and pipes for conducti
ng fluid, e) heat exchange coils f) tanks and storage containers and storage of
fluids not included in design codes and standards relating to pressure vessels;
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13.1.9 For purposes of this NR, boilers are classified into three categories as
follows: a) boiler category "A" are those whose working pressure is less than 19
60kPa (19.98 kgf/cm2), b) boilers category "C" are those whose working pressure
is less than or equal to 588 kPa (5.99 kgf/cm2) and the internal volume is equal
to or less than 100 liters c) boilers category "B" are all the boilers are not
fall into the above categories.
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Documentation

Medical record Registry Security Installation Project Inspection Reports Project


s Alteration or Repair

Available for consultation and monitoring


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Documentation

Data Handbook:

Project code and year of publication of materials Specification Procedures manuf


acturing drawings and data for monitoring shelf life (inspection plan) Functiona
l characteristics of safety devices Data Year Manufacturing Equipment Categoriza
tion
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Installation Requirements

The "Project of Installation" Boilers and pressure vessels categories I, II and


III, with regard to the attendance of NR, is the responsibility of "Qualified Pr
ofessional", as mentioned in subclause 13.1.2 and shall comply with those aspect
s safety, health and environment provided in the Regulatory Standards, conventio
ns and applicable legal provisions. 13.7.7 "Project Setup" must contain at least
the floor plan of the establishment, with the positioning and category of each
vessel and facility security. Internal standard to 47 suppliers
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Operating Requirements

13.3.1 Each boiler must have "Operation Manual" updated in English in place of e
asy access to operators, containing at least:
a) procedures for starting and stopping, b) Procedures and operating parameters
of routine c) procedures for emergency situations, d) general safety procedures,
health and environmental preservation.
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Operating Requirements
Pressure vessels categories I and II also must have the operation manual (same r
equirements) Schooling minimal (grade 1) specific training (minimum curriculum i
n Annex I) Stage supervised practical standard for internal operational areas
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Requirements for Inspection

Safety Check:

Initial
Before the entry into operation at the place of operation Exam internal an
d external hydrostatic test Test accumulation boiler criteria defined by PH

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Requirements for Inspection

Safety Check:

Periodic
Investigations Internal and external hydrostatic test Criteria defined by
PH respecting the deadlines set

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Caldeira A, B or CA, B or C (Alkali) A (with annual test of the SV) Special
Term 12 months 12 months 24 months 40 months
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Requirements for Inspection

Safety Check:

Extraordinary
Accident or occurrence affecting the safety or repair major change After i
nactivity Change location Criteria defined by PH

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Requirements for Inspection

Safety Check:

Internal and external examinations

When viable, may be replaced by the hydrostatic test when feasible, may be repla
ced by equivalent END safely

Hydrostatic Test

Upon PH reports
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Requirements for Inspection

Inspection of safety valves:

Boilers A and B

Calibration in the same period of regular monthly Manually operated when there i
s a change (reform, operational parameter, MAWP, pipe) Calibration in the same p
eriod of internal examination
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Boiler B and C

Test accumulation (boilers)

Pressure Vessels

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Requirements for Inspection

Inspection Report

Data Equipment Inspection Period Description of inspection and testing results f


ound ratio of NR's items that are not being met Conclusions
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Requirements for Inspection

Inspection Report

Recommendations Inspection Date for Signing of the new inspection PH (CREA) and
the inspectors who performed services in the registry Note Security Filing Amend
ment right of plate (if necessary)
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Maintenance Requirements

Repairs or alterations must follow the code of design alteration or repair proje
cts:

Prepared preliminary design or approved by PH Determine materials, procedures, q


uality control and qualification of
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6 - Management of care
Key controls

Computerized management, contemplated in the Asset Management System (Asset Mana


gement)

Registration Issue equipment Automatic Service Order Control deadlines All speci
alties

Guard documentation (and access control) controlled internal standards Audit Doc
uments
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Register with Management Special
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Certification

ISO / OHSAS 18001 - Safety Management System and Occupational Health

Requires compliance with legal requirements creates a managing risks in the work
place 27 firms already certified

SPIE

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7 - Domain technological
Test
Qualified professional in SNQC or ASNT Acceptance criteria for Visual defects, n
on-destructive inspection of welded joints Maps (scales) to treat discontinuitie
s
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Non-destructive testing

Conventional

LP, MP, ME, U.S. eddy current, acoustic emission Phased-array, ACFM, TOFD, Iris
Climbing industrial

Unconventional

Advanced

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Inspection Equipment

Directed by inspector of equipment (team of technicians and engineers) as the Pl


an of Inspection Notes service to technical and legal requirements Raises the In
spection Report and Recommendation Inspection
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Integrity Evaluation

Analysis conducted by engineer specialist multi-disciplinary Global (equipment s


tatus)

Determines the remaining factor of resistance (to reach the failure criterion) e
g boilers with 25 years API RP 579, BS 7920, Fracture Mechanics Eg found broken
on the inspection
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Located (fitness for use)

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Integrity Evaluation
Tension
Fracture (avoided by inspection) Defect Tenacity
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Interesting links

Abend (www.abende.org.br)

Qualification and certification of inspectors providing certification courses in


NDT (ISO 17020) Certification COTEQ SPIE Courses Courses
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IBP (www.ibp.org.br)

ABM (www.abmbrasil.com.br)

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8 - Inspection Service itself
SPIE
Service's own inspection equipment certified by INMETRO through product certific
ation body (IBP) Creates staff training, work patterns and effective minimum acc
eptable Advantages:

Increase in technology terms


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9 - Trends
Current trends

Topics under discussion

Regulations for pipelines Less state interference Elimination of initial inspect


ion (for companies certified ISO) Time as Risk Reduction in the use of hydrostat
ic test Emphasis on training for operators
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Risk based inspection

According to API RP 581


Relative risk (probability x consequence) Sorts the equipment for inspection (
pareto) Prioritize the performance charts Requires knowledge of damage mecha
nisms for each component Limited by NR 13 (term)

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10 - Management in CST
Own team

Engineering and Maintenance Activities sections:

Management Contract Drafting Standards Support with PPC Management Assessment Re


port Equipment

Participation of staff of the Operation and Process Control (Electrical and Inst
rumentation)
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Team hired

Local structure and external engineering Activities:

Management of meeting legal requirements Performing inspections and evaluations


of maintenance procedures and documentation Definition of extra features
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Outsourced Services

Hiring activities, no responsibilities (co-responsible) internal standards are m


andatory (safety, property, health and medicine)

Should be transferred and trained quality management NBR ISO 17020 (service prov
iders END) SNQC (Abend): certification of NDT Inspectors
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Quality:

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Companies providing
Brazil ISQ - Welding and Quality Institute

www.isqbrasil.com.br www.sofles.com.br www.proenge.com.br www.mksservices.com.br


www.german-engenharia.com.br www.pasa.com.br
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Sofla Engineering

Proenge Engineering

MKS

Just for example, there are others on the market. Companies mentioned have engin
eering and inspection with NDT.

German Engineering

PASA

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11 - Doubts / questions
Contact

dmrothen@ebrnet.com.br (27) 3315 8927 (27) 9958 7696 dmrothen@cst.com.br (27) 33


48 2041
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