Boilers and Pressure Vessels

TECHNICAL MANUAL

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Technical Manual for Boilers And Pressure Vessels

Preparation This Technical Manual on Regulatory Standard n 13 (NR-13) Boilers and Pressure Vessels, approved by Ordinance n 23, of 04.26.95 was prepared by Tripartite Technical Group, comprised by the technicians listed below, invited by the Labor, Health and Safety Department SSST, under the Labor Ministry MTb Dr. Aldo Cordeiro Dutra CEPEI/IBP Dr. Almir Augusto Chaves SSST/MTb Dra. Fatima Leone Martins DINPQ/INMETRO Dr. Jos Augusto da Silva Filho Fora Sindical Labor Union Dr. Luiz A. Moschini de Souza ABIQUIM/IBP/Petroqumica Unio Dr. Marcelo Salles IBP/PETROBRAS-REDUC Dr. Nilton B.B. Freitas DIESAT/Chemists Labor Union/SP Dr. Roberto Odilon Horta SINDIPETRO-RJ/CUT Dr. Rui de Oliveira Magrini (Technical Coordinator) DRT/SP Dr. Welcio Cracel do Rego Monteiro SENAI/CNI Fundacentro - Labor Ministry So Paulo 1997

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SUMMARY

13.1 13.2 13.3 13.4 13.5

STEAM BOILERS MISCELLANEOUS STEAM BOILERS INSTALLATION BOILER OPERATION SAFETY BOILER MAINTENANCE SAFETY SAFETY INSPECTION ATTACHMENT I-A MINIMUM PROGRAM REQUIRED FOR BOILER OPERATION SAFETY OPERATION ATTACHMENT II CERTIFICATION REQUIREMENTS FOR OWN EQUIPMENT INSPECTION SERVICE

4 12 15 19 22

30

33 34 39 42 46 48

13.6 13.7 13.8 13.9

PRESSURE VESSELS MISCELLANEOUS PRESSURE VESSEL INSTALLATION PRESSURE VESSEL OPERATION SAFETY PRESSURE VESSEL MAINTENANCE SAFETY

13.10 PRESSURE VESSEL INSPECTION SAFETY ATTACHMENT I-B MINIMUM PROGRAM REQUIRED FOR PROCESSING UNIT OPERATION SAFETY TRAINING ATTACHMENT II CERTIFICATION REQUIREMENTS FOR OWN EQUIPMENT INSPECTION SERVICE ATTACHMENT III ATTACHMENT IV PRESSURE VESSEL CLASSIFICATION EXAMPLE OF PRESSURE VESSEL CLASSIFICATION

55

57 58

59

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13.1

STEAM BOILERS MISCELLANEOUS

13.1.1

Steam boilers are pieces of equipment designed to produce and accumulate steam under pressure above the atmospheric pressure, using any source of energy, except for Reboiler and similar equipment used in processing units. Steam can be used by the industry under several conditions, such as lo w pressure, high pressure, saturated, superheated, etc. Different types of equipment can also produce it, which include boilers. For the purpose of Regulatory Standard NR-13, it will be considered as boilers all equipment that simultaneously generate and accumulate water or other fluid steam. Units installed on vehicles such as trucks and ships are to comply with this regulatory standard as to the applicable items, and as to those not covered by a more specific standard or regulation. The following equipment shall not be deemed as boilers: 1) Reboiler type heat exchangers, Kettle, Reboiler, T.L.E., etc, whose constructio n project is governed by the criteria related to pressure vessels; 2) Equipment with coil subjected to direct flame or heated gas, which generate but do not accumulate steam, such as ove ns, forced circulation generators and others; 3) Oven or pressure vessel coils that use residual heat to generate or superheat steam. 4) Boilers that use thermal fluid and do not steam it. For illustration purposes, some pictures of the equipment previously mentioned are shown in Attachment III.

13.1.2

For the purpose of this regulation, a Qualified Professional is the person who is legally competent to work as a professional engineer in the activities regarding construction design, operation and maintenance follow-up, boilers and pressure vessels inspection and inspection supervision, in conformance with the professional regulation in force in Brazil . Regarding the items under regulation NR 13 that mention a Qualified Professional, it is taken at the time this document was prepared that:

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1) Federal Councils, such as Engineering, Architecture and Agronomy Federal Council (CONFEA) and Chemistry Federal Council (CFQ) are responsible, in their respective areas, for defining the competence and clarifying any doubts related to the professional regulation; 2) CONFEAs Resolution no. 218 of 06.29.73, CONFEAs Regulatory Decision no. 029/88 and CONFEAs Regulatory Decision no. 045/92 define Mechanic Engineers and Naval Engineers as certified, as well as Civil Engineers carrying out the duties under Article 28, Federal Decree 23569/33, who have taken courses in Thermodynamics and Its Application and Heat Transfer or equivalent under a different name, regardless of the number of years following their graduation; 3) The registration with the professional regional councils is the only necessary proof to be required from the Qualified Professional. 4) The proof of enrollment previously issued by the Labor Ministrys Regional Office (DRT/MTb ) for this purpose is no longer valid; 5) Other engineers not mentioned above shall request their respective regional council to analyze their boilers and pressure vessels inspection skills according to their school transcript, if personally interested. 6) Technical Reports and Opinions will only be legally valid when signed by a Qualified Professional; 7) As established by CONFEA/CREA, it is mandatory that service companies aiming at rendering the services described in this item are to be registered at their respective regional council, indicating their legally qualified Technical Person In Charge. 8) A Qualified Professional may can be a self-employed consultant, employee of a service company or employee of the company that owns the equipment; 9) Article 188 under the Consolidated Labor Laws - CLT was written when the professional councils were part of the Labor Ministrys structure. Presently they are independent entities.

13.1.3

Maximum Working Pressure Permitted PMTO, or Maximum Working Pressure Allowed MWPA (PMTA) is the highest-pressure value compatible with the project code, strength of the materials employed, equipment size and its operational parameters. This regulation does not include project rules and presumes the equipment is constructed in accordance with rules and codes acknowledged worldwide.
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The MWPA (PMTA) is calculated or determined by using the formulas and charts available in the boiler project code. These sources take the following into consideration: 1. Size and shape of each specific part of the boiler (e.g. diameter, thickness, etc). 2. Material strength (maximum stress value allowed depending on the temperature); 3. Other specific factors for each situation. It is important to emphasize the MWPA (PMTA) values may alter along the boilers life due to the decrease of the materials mechanical strength, thickness of different components, etc. The MWPA (PMTA) values update must be made in conformance with the written procedures on the boilers report chart. When a boilers MWPA (PMTA) value is altered, the necessary adjustment must be made on the identification tag and on other control elements that depend on this value, in regard to the safety valve opening pressure.

13.1.4

The absence of any of the following items poses a serious and imminent risk: a) Safety valve with its opening pressure adjusted to a value equal or lesser than the MWPA (PMTA); b) Instrument that indicates the accumulated steam pressure; c) Injector or other feedwater source, regardless of the main system, in solid fuel boilers; d) Quick water draining system, in alkali recovery boilers; e) Water level control indication system or other system that avoids overheating due to deficient feed.. Safety valves, even when adjusted to open at the MWPA (PMTA), must be: adequately designed adequately installed adequately maintained In cases where the se provisions are not complied with, the safety valve will be considered as non-existent. The quantity and place of installation of the safety valves must meet the applicable technical standards and codes. Any pressure increase allowed during the safety valve relief must be up to the maximum value recommended in the equipment design code.

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In the specific case of the ASME code, section I, boilers with heating surfaces greater than 47 m2 are to have two safety valves. In this case pressure increase during the relief is allowed, with the two valves open up to 6% of the ir MWPA (PMTA). The existence of at least one instrument indicating the accumulated steam pressure, deems it presumably correct as to specification, installation and maintenance. The pressure indicator readout may be analog or digital and installed on the boiler itself or in the control room. It is understood as a water level indicator system any device with a function equivalent to the water column gauge glasses. In case the water column cannot be read correctly due to a leak or blockage, the boiler shutdown procedures must be immediately activated.

13.1.5

All boilers must have an identification tag secured to their body in a place easily accessible and clearly seen, containing at least the following information: a) b) c) d) e) f) g) h) manufacturer; order number supplied by the boilers manufacturer; year of manufacturing; maximum working pressure allowed; hydrostatic test pressure; steam producing capacity; heating surface area; project code and date of issue

The tag may contain other information in addition to those mentioned in item 13.1.5 at the facilitys discretion. The identification tag is to be made of weatherproof material such as aluminum, bronze, stainless steel, etc. It shall be stenciled in indelible characters in Portuguese, and secured to the boiler shell with rivets, bolts, or welding. The identification tag is to be secured in a place easily accessible and conspicuous. Special care is to be taken so the tag is not secured to parts of the boiler that may be removed such as manhole covers, thermal insulation sheets, etc. According to the Decree- no. 18.621 of 05.03..78, Brazil endorses the International Units System. The following chart shows the conversion factors to be used for pressure units:
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Pressure Units Conversion Chart Bar Kgf/cm2 psi (lbf/pol2 ) 14,503 14,2233 1 19,368 1,42233 0,14503 MmHg mH20 KPa KN/ m2 100 98,0665 6,89475 133,322 9,80665 1

1 0,980665 0,068947 1,33322 0,09806 0,0100

1,019716 1 0,070307 1,3595 0,1000 0,01019

750,062 735,560 51,715 1000 73,556 7,50062

10,19716 10,00 0,70307 13,59 1 0,10197

In conformance with the International Units System. The official unit for pressure in International System is Pascal (Pa).

13.1.5.1

Besides the identification tag, the boiler category, as defined in item 13.1.9. under this regulation, and its identification number or code must also be informed in a conspicuous place. All boilers must feature their number or identification code and corresponding category, in addition to the identification plate. This information must be painted in a conspicuous place and large enough to be clearly identified. As an option to painting it directly on, the information may be stenc iled on a plate that can be equally visualized.

13.1.6

Every boiler shall have the following documentation duly updated, at the site of its installation. a) Data sheet containing the following information: - project code and year of issue; - material specification; - procedures used in the manufacturing, assembly, final inspection and MWPA (PMTA) assessment ; - set of drawings and other relevant data to control the boilers life; - function characteristic; - safety device data; - year of manufacturing;

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- boilers category. b) Safety Record, in conformance with item 13.1.7 c) Installation Project, in conformance with item 13.2 d) Repair or Alteration Projects, in conformance with items 13.4.2. and 13.4.3. e) Inspection Reports, in conformance with items 13.5.11, 13.5.12 and 13.5.13. In case the boiler is installed in an facility that has several textile f acilities distant one from other, the documentation must be available at the site the boiler is installed, for easy reference. Due to the characteristics of each company, it is not necessary to have all documentation filed in the same place. Nevertheless, it is recommended that all documents that comprise the boilers data sheet is The procedures for determining the MWPA (PMTA) must explain its guidelines step by step, including charts, abacus, etc, that may be consulted. It is understood as the boilers useful life the period of time elapsed between the date of manufacturing and the date it is considered inappropriate for use. The equipment documentation must be kept during life the entire equipment

13.1.6.1

If the Boilers Data Sheet is non-existent or lost the owner must remake it, and the technical responsibility therefor shall rely on the manufacturer or a Qualified Professional, mentioned in item 13.1.2. It is indispensable to reconstitute its function characteristics, the safety devices data and the procedures for determining the MWPA (PMTA). The boilers manufacturer shall provide the majority of the required documentation, as detailed as possible, specially the part encompassed in the Boilers Data Sheet. If the facility does not have this documentation, a part thereof shall be remade. When the reconstitution of some items, such as procedures used in the manufacturing and assembly , material specifications, etc., is not possible, the boilers basic working characteristics shall be reconstituted as a minimum, as well as the safety devices data and the procedures for determining the MWPA (PMTA). The boilers owner shall be responsible for remaking the documentation at all times. For this purpose, the boilers manufacturers services may be used, or in case it is undetermined or no longer exists, the services of a Qualified Professional or a specialized company may be utilized.

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It is important to reconstitute the boilers documentation not only for determining its operational parameters, but also essential for preparing and performing the inspection and maintenance of this equipment. Therefore, in case the said documentation is non-existent, all efforts shall be made to reconstitute the data sheet.

13.1.6.2

When the boiler is sold or transferred to another facility, the documents that mentioned in lines a, d and e under item 13.1.6 shall accompany it. The Safety Records may also accompany the boiler at the discretion of the facility where it had been installed. The Installation Project does not have to accompany the boiler since a new project should be prepared to meet the characteristics of the new installation.

13.1.6.3

The boilers owner should present the documentation mentioned in item 13.1.6, whenever requested by the competent authority with the Labor Ministry Regional Office. The competent authority of the Labor Ministrys Regional Office ( Regional Labor Office DRT) is the Regional Labor Officer for your jurisdiction.

13.1.7

The Safety Record should be a dedicated book with numbered pages or other equivalent system where the following information will be noted: a) all important events capable of altering the boilers safety condition; b) periodical and exceptional safety inspections, showing the legible name and signature of the Qualified Professional mentioned in item 13.1.2 and the boilers operator, present at the time of the inspection. The Safety Record shall be a book with numbered pages, exclusive for each boiler. The company may use another system (e.g. a computerized system), as long as it is in fact equally safe against fraud , allows it to be signed at the said occasions and is easily accessed. It is important to register in this book only the events related to the boiler that may have a positive or negative effect on the physical integrity of human beings.

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It is a common practice in industrial units to fill out the Shift Log or Service Overlap Log or a similar book, which may be accepted as a Safety Record as long as it complies with item 13.1.7. Typical example s of important events are: explosion, fire, leaking, rupture of boiler components, operation under conditions not predicted by the project, emergency shutdown, boiler and the safety devices testing, etc. When inspecting the boiler the Qualified Professional hired by the facility to perform the inspection or its own Qualified Professional for inspection services shall report on the Safety Record the date and type of the boiler safety inspection being performed. The Qualified Professional is to request the boiler operator or, in his absence, another operator to sign the said Safety Record. The purpose of the signature is to prove the boiler is being inspected and does not imply any responsibility on the operators part in the inspection activity. The log completio n and its respective signature shall be obtained during the time the boiler is being inspected..

13.1.7.1

In case the boiler is considered unfit for use, the Safety Record must contain such information and be formally closed. In case the boiler is considered unfit for future use, the corresponding Safety Record will clearly show the reason for such a decision. The Safety Record shall be formally closed by a Qualified Professional, and informed to the Labor Union representative for the Predominant Professional Class at the Facility, by means of an Exceptional Safety Inspection Report, according to the provision in item 13.5.12, and also to the MTb (Labor Ministrys) Regional Office, in case the boilers documentation has been previously demanded thereby, as anticipated in item 13.1.6.3. In such cases, it is advisable to the boiler out of commission before junking it, to avoid future use.

13.1.8

The documentation referred to in item 13.1.6 is to be ready for consultation by operators, maintenance personnel, inspectors and workers and employers representatives in the CIPA Internal Commission for Accident Prevention at all times. The owner shall assure the easy access to such documentation.

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The documentation referred to in item 13.1.6 is to be available at the facility at all times. Whenever it is necessary to remove the documentation from the facility, a second copy must be provided.

13.1.9

For the purpose of this regulation, there are three category of boilers, as follows: a) Category A boilers are those whose operational pressure is greater than 1960 kPa (19,98 kgf/cm2); b) Category C boilers are those whose operational pressure is lesser than 588 kPa (5,99 kgf/cm2) and volume equal or lesser liters; c) Category B boilers are all the others not included in the types. equal or equal or than 100 previous

The criterion adopted by this regulation for classifying boilers takes into consideration their operational pressure and internal volume. This concept, which is also adopted by other international regulations, represents the energy available in a boiler. Therefore, the higher the pressure, the higher the risk involved. The boilers steam producing capacity (t/h, kg/h) is not an indication of the risk, since it does not take into consideration the pressure of the produced steam or the volume of stored steam. The division into three different categories makes it easier to adopt different criteria to determine the risk presented by each boiler. The following chart represents the fields utilized to define each category of boiler. Pressure (kPa) Category A 1960 588 Category B

Category C

100 Volume (liters)

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13.2

STEAM BOILERSINSTALLATION

13.2.1

A Qualified Professional is the person responsible for the steam boilers Installation Project, in regard to this regulation, as mentioned in item 13.1.2, and it shall comply with the safety, health and environment aspects established in the applicable Regulatory Standards, , conventions and legal provisions. A Qualified Professional is responsible for the boiler installation project preparation. Whenever a Qualified Professional requests the assistance of specialists or legally qualified personnel during the project preparation, they will be considered responsible for the part of their concern, and clearly mentioned as authors of the parts they have done. The installation project is to contain all documents, plans, drawings, calculation, professional opinions, reports, analysis, standards and specifications related to the project, duly signed by legally qualified professionals.

13.2.2

The boilers of any establishments will be installed in the Boiler Room or in a specific place for such purpose, called the Boiler Area. It should be understood as the Boiler Room any dedicated place in the premises, surrounded by walls or partitions and adequately covered, where the boilers are installed. It should be considered as the Boiler Area any place, whether or not exposed to weather, without walls or partitions, intended for the boiler installation.. The option for installing the boiler in a Boiler Room or Boiler Area will be defined during the project phase, regardless of the boiler size or operational parameters.

13.2.3

When the boiler is installed in an open space, the Boiler Area must comply with the following requirements: a) 3 meters minimum clearance from: - other facilities in the premises; - fuel storage, exception made for fuel containers used to start the boiler up to 2,000 (two thousand) liter capacity; - third-party property lines

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b) c) d)

e) f)

- public roads. at least 2 (two) ample exits, permanently clear and set in opposite directions. easy and safe access, needed for operating and maintaining the boiler. The cage openings have to be sized as to prevent people from falling. a system to intake the gases and particles resulting from combustion and discharge them outside the operation area, according to the environmental laws in force. lighting according to the official standards in force. emergency lights for nighttime operation.

Up to the revision date of this technical manual, the regulatory standard NR 17, item 17.5.3.3 establishes that the minimum required lighting levels for a working area are the brightness values established in NBR 5413. It should be understood as an emergency lighting system every system capable of keeping the strategic points necessary for the boiler operation adequately lit in case of power failure. Examples of this system are bulbs connected to batteries that recharge automatically during normal power supply, steam generator or combustion engines, etc.

13.2.4

When the boiler is installed in a confined area, the Boiler Room must comply with the following requirements: a) be located in a separate building, made of fireproof material, with only one wall contiguous to other installations in the premises. Nevertheless, all other walls will be at least 3 (three) meters away from other facilities, third-party property, public roads and fuel storage, exception made for fuel containers used to start the boiler, up to 2,000 (two thousand) liter capacity; b) at least 2 (two) ample exits, permanently clear and set in opposite directions; c) permanent ventilation with air intakes that are obstruction-proof; d) gas leak sensor when the boiler uses gas fuel; e) not to be used for any other purpose; f) easy and safe access, required for operating and maintaining the boiler. The cage openings are to be sized as to prevent people from falling; g) a system to intake the gases and particles resulting from combustion and discharge them outside the operation area, according to the environmental laws in force. h) lighting according to the official standards in force and an emergency lighting system.

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13.2.5

The noncompliance with the following items poses a serious and imminent risk: a) lines b, d and f of item 13.2.3 of this regulation, for all boilers installed in an open area; b) lines a, b, c, d, e, g and h of item 13.2.4 of this regulation, for all category A boilers installed in a confined area; c) lines b, c, d, e, g and h of item 13.2.4 of this regulation , for all categories B and C boilers, installed in a confined area.

13.2.6

When the facility is not able to comply with the provisions under items 13.2.3 and 13.2.4, an Alternative Installation Project should be prepared with additional safety measures to reduce the risks. If the facility is not able to comply with the provisions under items 13.2.3 and 13.2.4, or with the safety, health and environment aspects established in the Regulatory Standards, conventions or legal provisions, an Alternative Project shall be prepared with sound measures to reduce risks. This requirement applies to current and new installations. The additional measures mentioned in this item refer to the prevention of eventual explosions and not to their consequence. Therefore, the Alternative Project should give priority to implementing measures that improve the reliability of the boiler operation. Some examples of sound measures to reduce risks are: - performing more frequently and strict inspections, regarding the application of non-destructive testing; - improvement of the control systems; - complying with more accurate quality and water treatment requirements, regardless of the pressure; - reducing the operational pressure whenever possible; - using a better qua lity fuel.

13.2.6.1

The boiler owner should present the Alternative Installation Project in order to obtain an agreement from the labor union for the main professional categories in the facility.

13.2.6.2

If no agreement is reached, the intervention of the regional Labor Ministry office (MTb) may be requested by any of the parties as established in item 13.2.6.1. Should an impasse prevail, the decision shall be settled by that office.

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13.2.7

The boilers classified as category A should have a n instrument panel installed in the control room, designed as established by the applicable Regulatory Standards. All boilers classified as category A should have an instrument panel or digital system console installed in the control room. Facilities that have more than one boiler may have all the panels installed in the same control room. The control room design and construction shall comply with the requirements defined by the Regulatory Standards (NR).

13.3

BOILER OPERATION SAFETY

13.3.1

Every boiler should have an updated Operations Manual, in Portuguese, easily accessible by the operators, containing at least: a) b) c) d) starting and stopping procedures ; routine operational procedures and parameters; procedures in case of emergency; general safety, health and environment procedures.

The boiler (or boilers) Operation Manual should be available for easy consultation by the operators in a place near their workstation. The manuals should be updated periodically and all changes to the operational procedures or in the boilers characteristics should be fully informed to the operators and immediately added to the respective manuals.

13.3.2

The boiler instruments and controls must be kept calibrated and in good operational condition. It is a severe and imminent risk to employ any makeshift to neutralize the boilers control and safety systems. All instruments and controls tha t interfere with the boilers safety must be calibrated periodically and maintained appropriately. The use of resorts such us jumps to neutralize the control and safety systems poses a severe and imminent risk and may lead to the boilers interdiction Transitory jumps in situations where there is a redundancy or preventive maintenance is under way , will not be considered as a resort to neutralize the boilers control and safety systems.

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In such cases it is necessary to calculate the risks involved and observe this operation closely, regarding all sectors that may be affected by it. The maintenance frequency and definition of the instruments and controls necessary for the boilers safety should be established by a specialized and legally qualified professional .

13.3.3

The water quality must be monitored and a treatment system implemented, whenever necessary, to render the physical-chemical properties of the water compatible with the boilers operational parameters. The water quality is a determining factor for the boilers life. It is not part of the scope of this regulation (NR) to establish parameters for quality water , as it applies to various types of boiler with different pressures and temperatures, installed in distinct locations. Whenever physical-chemical analysis and inspection results indicate problems such as excessive deposit, corrosion and other kinds of water deterioration, special attention shall be paid to the water quality , verifying if its characteristics are in agreement with the boilers requirements. As rule of thumb, the higher the operation pressure, and the more specific the water treatment requirements.

13.3.4

It is mandatory that every steam boiler is operated and controlled by the boiler operator. Non-compliance with this requirement characterizes severe and imminent risk condition. The facility owner is responsible for well- trained boiler operators. A boiler may be under the simultaneous control of several operators and one operator may be controlling more than one boiler simultaneously. It is not part of this regulations objective to establish a numerical limits for this matter. Nevertheless, it is understood as boilers under the operator control those where there is at least 1 (one) operator capable of acting promptly to correct any abnormal situation that may arise.

13.3.5

For this regulations purpose, it shall be considered as a boiler operator that who meets at least one of the following conditions: a) A Boiler Operation Safety Training certificate and proof of practical training according to item 13.3.9;

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b) A Boiler Operation Safety Training certificate, Boiler Operation Safety Training as established by NR 13 and approved by Edict 02/84 of 08.05.84; c) Proof of a minimum of 3 (three) years experience in this activity, up to 08.05.84. In cases where it is necessary to prove boiler operation experience, the following should be taken in consideration: - record on the work book; or - record or duties provided by the facility; or - witnesses. In the calculation for the 3 (three) years experience, any period of interruption should be disregarded. The boiler operators qualification established in line b and c is limited to the type of boiler he has been habitually operating that. In case he needs to operate other types of boiler, it is mandatory that he attends the practical training sessions defined in item 13.3.9.

13.3.6

The minimum requirement for attending the Boiler Operation Safety Training Safety Training course is an Elementary School degree.

13.3.7

The Boiler Operation Safety Training must: a) be under the technical supervision of a Qualified Professional as mentioned in item 13.1.2; b) be taught by professionals qualified for this purpose; c) observe, as a minimum the program proposed in Attachment I-A of this regulation. Other theoretical or practical subjects may be included in the training if it is considered relevant by the training technical supervisor.

13.3.8

In case of non-compliance with the provisions in item 13.3.7, the persons in charge of the Boiler Operation Safety Training are subject to being barred from conducting new courses as well as to other applicable legal penalties.

13.3.9

Every boiler operator should undergo practical training in the operation of the boiler he will operate. This training should be supervised, documented and last at least:

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a) Category A Boiler: 80 (eighty) hours b) Category B Boiler: 60 (sixty) hours c) Category C Boiler: 40 (forty) hours. The company or facility will file or gather all documents that prove the attendance of their operators in the training. If an operator trained in accordance with this regulation needs to operate another boiler, he must undergo practical training for the new boiler he will operate, even if the new boiler is of the same category as the previous one. In case of facilities where the operator has to work with different boilers, a practical training is required for each boiler. E.g.: In a facility featuring a category A Oil Boiler and a category C Electric Boiler, the operator will need 80 hours training for the first boiler and an additional 40 hour s training for the second boiler, making a total of 120 hours training. The training supervisor may be, for example: - Chief of Operations; - Chief Operator; - Engineer in charge of the plant; - A more experienced operator - A Qualified Professional

13.3.10

The facility where the supervised training takes place should inform the labor union representative for the main professional class at the facility beforehand: a) the training period; b) institution, company or professional responsible for the Boiler Operation Safety Training; c) list of participating trainees . See note in item 13.3.5

13.3.11

The operators should be kept permanently current, by means of continuous information about the physical and operational condition of the equipment, technical update, safety information, courses, presentations and pertinent events. The employer is responsible for setting the date and need for refresher courses.

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For certification purposes the type of activity, date and period, etc. should be attached to the file of each employee.

13.3.12

It is a severe and imminent risk to operate a boiler under conditions other than those originally determined in its design, without: a) a new design, taking in consideration all variables involved in the new operating condition; b) the implementation of all safety procedures related to the boilers new classification regarding its installation, operation, maintenance and inspection. Operating boilers under operating conditions other than those established in its design can be extremely dangerous. Examples of these conditions are: - pressures higher than the operating pressure; - overheating temperatures above the designed temperature; - using water or any other fluid other than what was considered in the design; - alteration to fuel or burners. Whenever a modification is made in the boiler design or on its operating condition, all necessary safety procedures should be adopted. All modifications made must be registered in the boilers documentation.

13.4

BOILER MAINTENANCE SAFETY

13.4.1

All repairs or alterations to the boiler should observe the corresponding construction design code and the manufacturers recommendations regarding: a) b) c) d) material; implementation procedures; quality control procedures; personnel qualification and certification.

The repair and alteration mentioned in this item are extensive to the boilers peripherals such as: flue, vents, instruments, etc. In the case of pipelines, this items coverage is limited to the section between the boiler and the weld or the nearest flange.

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It is considered as repair any operation aiming to correct a nonconformance with the original design. E.g., a welding repair to correct damaged areas, repair to refractory material and thermal insulation, replacement of corroded connections, etc. It is considered as alteration any operation that alters the original design, including the boilers operational parameters. For example, an alteration to the material specification, change of fuel, change in the configuration of heat exchange tubes, inclusion of connections, etc. The procedures provided by code ASME, section IX (Qualification for Welding and Brazing) and Section V (Non-Destructive Testing) is examples of personnel qualification and certification. .

13.4.1.1

When the construction design code is unknown, the original boiler concept should be respected, using the more rigorous control procedures defined in the pertinent codes. In case the boilers documentatio n is lost and to the manufacturer cannot be identified, any repair and alteration should respect the original boiler concept. At the times of such repairs and alterations, the Qualified Professional should suggest the testing, as well as the acceptance standards compatible with the most rigorous design codes acknowledged worldwide.

13.4.1.2

For categories A and B boilers, on a case by case basis and provided they are supported by the Qualified Professional mentioned in item 13.1.2, calculation procedures and technology not included in the design code may be used. Some examples of these procedures are mechanical fracture techniques that allow sub-critical discontinuities, alternate welding techniques that do not require stress relief, etc.

13.4.2

Alteration or Repair Projects should be previously prepared in the following cases: a) whenever the design condition is modified; b) whenever repairs are made that can jeopardize the safety. Before any repair or alteration that may jeopardize the boilers or the workers safety, an Alteration or Repair Project shall be prepared and filed in the boiler documentation. It is not necessary to submit this document to a department outside the company, such as DRT (Labor Ministrys Regional Office), labor union, etc.

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Some examples of Alteration and Repair Projects are alteration to material, piping arrangement, torch configuration, addition of connections, welding repair s, chemical cleaning, etc.

13.4.3

The Alteration or Repair Project should: a) be prepared or approved by a Qualified Professional, as mentioned in item 13.1.2; b) determine the material, implementation procedures, quality control and personnel qualification. A specialized company may prepare the Alteration and Repair Project, as long as it is registered with the Engineering and Architecture Regional Council CREA and has a technical legally qualified person in place.. Repairs and alterations that involve electricity, electronic or chemistry should be prepared and signed by a qualified professionals for each specific field. Regardless of this requirement, every Alteration or Repair Project should be signed by a Qualified Professional.

13.4.4

Any modification that demands mandrel work or welding on parts that operate under pressure should be followed by a hydrostatic test, according to the characteristics defined by the Qualified Professional, mentioned in item 13.1.2. If the hydrostatic test parameters are not defined in standards or codes, the Qualified Professional will be responsible for their definition, based on his experience and knowledge. These parameters should contain: - safety measures necessary to the protection of the personnel involved in the test; - fluid to be used for pressurization; - pressure increase rate and levels, when necessary; - final hydrostatic test pressure ; - period of time when the equipment will remain pressurized. The characteristics and results of the hydrostatic test should be recorded in the corresponding Safety Inspection Report that includes the test, whether initial, periodic or exceptional. Normally any modification of this nature justifies an Alteration or Repair Project, as defined in item 13.4.2, line b.

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13.4.5

The boilers control and safety systems should be submitted to Preventive or Predictive Maintenance. The definition of the instruments and control systems to be included in the Preventive/Predictive Maintenance plan, as well as its corresponding frequency should be defined by a legally qualified professional, competent to carry out this kind of activity. The Preventive Maintenance consists of performing pre-planned assistance tasks in specific points, in time to keep the functional capacity of the boilers safety and control system. When the maintenance date is determined by the evolution follow-up on the parameters connected to the system (e.g. temperature, vibration, oil viscosity) it is called Predictive Maintenance. When the maintenance date is determined by the useful life history of the components connected to the system, it is called Preventive Maintenance.

13.5

SAFETY INSPECTION

13.5.1

The boiler must be submitted to safety inspections in an initial, periodical and exceptional basis. The non-compliance with the terms that established by this regulation poses a severe and imminent risk.

13.5.2

The initial safety inspection should be carried out on new boilers, before put into service, at the operation site, and it should include internal and external inspection, hydrostatic and accumulation tests. Internal and external inspection and hydrostatic test performed at the owners facility are important and necessary, but they do not constitute an Initial Safety Inspection, since the boiler components may sustain damage during the transportation, storage and assembly at the final location. Therefore the Safety Inspection may only be performed when the boiler is already installed at the final location. The accumulation test should be performed in conformance with the technical standards in force, recommendations from the boiler and safety valve manufacturers, or yet in conformance with the procedures determined by a Qualified Professional.

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13.5.3

The Periodical Safety Inspection, comprised by internal and external inspection, should be performed at the most within the following terms: a) 12 (twelve) months for categories A, B and C boilers; b) 12 (twelve) months for alkali recovery boilers of any category; c) 24 (twenty four) months for category A boilers, once the safety valves opening pressure is tested at 12 (twelve) months; d) 40 (forty) months for special boilers as defined in item 13.5.5 A Qualified Professional taking into account the boilers record and the technical standards in force will define the Periodical Safety Inspection scope as well as the techniques used. The terms defined in this item should be considered as maximum limits. The real term should be established by the Qualified Professional in keeping with the previous experience available, which should be counted as of the last complete inspection on the boiler. This regulation does not intend to specify in detail the inspection methods or procedures. This should be done by a Qualified Professional, based on the codes and standards acknowledged worldwide. The terms established in lines a, b and c are applicable to companies that do not have their Own Equipment Inspection Service .

13.5.4

The facilities that have their Own Equipment Inspection Service, as established on Attachment II, may extend the periods between safety inspections observing the following maximum terms: a) 18 (eighteen) months for categories B and C boilers; b) 30 (thirty) months for category A boilers. The test to determine the opening pressure of safety valves may be performed with the boiler in operation, using appropriate hydraulic devices. The written procedure adopted in the test, the result obtained and the device calibration certificate should be attached to the boiler documentation. Extending the term for inspection of category A boilers to 30 (thirty) months does no exclude the performance of tests to determine the opening pressure of the safety valves every 12 (twelve) months.

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This item is also applicable to alkali recovery boilers installed in facilities that have their Own Service of Equipment Inspection. In a technical point of view, the performance of tests to determine the opening pressure of the safety valves every 12 (twelve) months should be maintained, even when the term for inspecting category A boilers is extended to 30 (thirty) months. The following chart summarizes the maximum terms established for boiler inspection.

Category A

Categories B and C

Special

12 months or Facility Without its Own Equipment Inspection Service

24 months, with safety valve tests every 12 months (except for Alkali recovery boiler)

12 months

Facility with its Own Equipment Inspection Service

30 months

18 months

40 months

13.5.5

Boilers that operate continuously and use gas or processing unit residue as main fuel for heat utilization or environment control purposes, may be considered special, when all the following conditions are observed: a) b) c) d) e) f) they are installed in a facilities that have their Own Equipment Inspection Service, mentioned on Attachment II; they have their interlocking system and the opening pressure of each safety valve tested every 12 (twelve) months; they do not present unexpected temperature variation in the gas and steam exhaust during the operation; there is a periodical control and analysis of the water quality; there is a deterioration control of the materials that make up the main parts of the boiler; the boiler is authorized as a special class boiler by:

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- agreement between the labor union representative for the main professional class working in the facility and the employer; - intervention of the MTb regional department, whenever requested by any of the parties when there is no agreement; - decision of the Labor Ministrys Regional Office when the impasse persists.

13.5.6

After 25 (twenty five) years of use, the boiler should be submitted to a rigorous integrity evaluation during its subsequent inspection, to determine the remaining life of the boiler and the new maximum terms for inspection, in case it is still in working condition. The evaluation of the residual life presumes that each basic component of the boiler is analyzed (e.g. tube, heat exchange tubes, mirrors, etc). The integrity and residual life evaluation may be performed by a Qualified Professional or by a specific company, registered with the Engineering and Architecture Regional Council - CREA that has at least a Qualified Professional in place. Boilers that are more than 25 (twenty- five) years old at the date of this regulations printing, and have not been inspected regarding their integrity, should be subject to this periodic safety inspection. In case a boiler has already been tested, inspected and analyzed to determine its residual life, and to evaluate its integrity, before the 25 (twenty five) years is up, this data may be considered sufficient to comply totally or partially with the requirements in this item, at the Qualified Professionals discretion. It is important to stress that inoperative boilers may sustain significant wear due to corrosion. Therefore, the periods that the boiler remained out of service should be analyzed in depth, during the 25 (twenty- five) years considered in this item.

13.5.6.1

For facilities that have their Own Equipment Inspection Service mentioned on Attachment II, the 25 (twenty five) - year limit may be altered in keeping with the follow-up on the boilers condition, made by the said department.

13.5.7

Safety valves installed in boilers must be periodically inspected as follows: a) for categories B and C boilers at least once a month, by actuating the lever manually during operation.

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b)

for categories A and B boilers, by disassembling, inspecting and testing the flanged valves on a workbench and the welded valves in the field, recalibrating them as often as compatible with their operational experience, but respecting the period for inspection established in item 13.5.3 or 13.5.4, if applicable, as the maximum limit.

Line a of this item determines the manual start of the lever, and therefore made the existence of a lever on safety valves installed in categories B and C boilers mandatory. The requirements under this item are technically based on the ASME code, Section I (Boilers) and in Standard ANSI/NB-23, National Board Inspection Code, acknowledged worldwide.

13.5.8

In addition to the tests recommended in item 13.5.7, the safety valves installed in boilers should be submitted to accumulation tests on the following occasions: a) at the boilers initial inspection ; b) when the boiler is modified or significantly remodeled; c) when the boilers operational parameters are modified or when there is variation in the MWPA (PMTA); d) when the intake or exhaust pipes are modified. In keeping with the risks involved during the performance of the accumulation tests, the facility should implement all necessary safety and environment preservation measures. Line b refers to the modification or repair s made in the boiler safety valves. Accumulation Test The accumulation test is performed in order to check if the safety valve or valves installed on the boiler are capable of expelling all the steam produced, at the maximum burning rate, without allowing the internal pressure to rise above the values considered in the design (in case of boilers designed according to ASME Section I, this value corresponds to 6% over the MWPA (PMTA). This test must be performed, based on the procedures established by the boilers manufacturer and/or the safety valve manufacturer. Since this test is performed with all steam exhaust closed, the lack of circulation may cause damage to boilers equipped with overeaters or to
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water heating boilers. Therefore it is not advisable to perform such test in boilers with this configuration.

13.5.9

The exceptional safety inspection should be performed on the following occasions: a) whenever the boiler is damaged accidentally or by other reason capable of jeopardizing its safety; b) when the boiler is submitted to a major alteration or repair capable of changing its safety condition; c) before the boiler is put to work, after being inactive for more than 6 (six) months; d) when the boiler is moved to another location. The exceptional safety inspection may cover the entire boiler or part thereof, according to the need and at the Qualified Professionals discretion. When the exceptional inspection covers the entire boiler, the term for the next periodical safety inspection may be defined as of the date the exceptional inspection is completed. In case a boiler stays out of service for a long period (more than 6 months), the exceptional inspection mentioned in line c should be performed before the boiler is put back in service, and not every 6 (six) months.

13.5.10

The safety inspection should be performed by a Qualified Professional, mentioned in item 13.1.2, or by its Own Equipment Inspection Service, mentioned on Attachment II. This item refers to all kinds of safety inspection - initial, periodical or exceptional. Inspectors and/or inspection experts may assist the Qualified Professional during the safety inspection. A specialized company may be used, provided it is registered with CREA and has a Qualified Professional in place.

13.5.11

An Inspection Report should be issued after the boiler is inspected, and be an integral part of its documentation.

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13.5.12

A copy of the Inspection Report should be sent by the Qualified Professional, mentioned in item 13.1.2, to the labor union representative for the main professional category at the facility, within 30 (thirty) days. This item mandate the Inspection Report is sent only to the labor union representative for the main professional category at the facility. It is understood that the end of the inspection is the date in which the boiler was cleared to operate. The technical report completion date is not considered as the inspection ending date.

13.5.13

The Inspection Report mentioned in item 13.5.11 should contain, as a minimum: a) b) c) d) e) f) g) h) i) j) k) l) the data recorded in the boilers identification plate; boiler category ; boiler type; type of inspection performed; date the inspection started and ended; description of inspection and tests performed; result of inspection and measures; list of items under this regulation or other legal requirements that are not being complied with; conclusion; recommendation and necessary measures; planned date for a new boiler inspection; legible name, signature and registration number of the qualified professional with the council, mentioned on item 13.1.2, and legible name and signature of the technicians that took part in the inspection.

It is understood as boiler type the information whether the boiler is waterpipe, flame-pipe or electric type, etc. Some examples of the items in line h are: - lack of manometers; - lack of safety valves; - incorrect distance between the boiler and the start container. An example of line i would be: In view of the inspections performed, the boiler may be put back in operation, respecting the operational parameters established by the design, and it should undergo a new periodic safety inspection on ___/___/___.

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Line j should list the recommendations to be followed after the inspection being performed, such as: - improve the water treatment; - test the safety valves in 3-months time.

13.5.14

Whenever the result of the inspection determines an alteration to the data on the identification plate, such plate should be updated.

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ATTACHMENT I A MINIMUM REQUIRED PROGRAM FOR BOILER OPERATION SAFETY TRAINING 1. NOTIONS OF PHYSICAL QUANTITIES AND UNITS Duration: 4 hours

1.1

Pressure 1.1.1 Atmospheric pressure 1.1.2 Internal pressure of a vessel 1.1.3 Gauge pressure, relative pressure and absolute pressure 1.1.4 Pressure units

1.2

Heat and Temperature 1.2.1 General concept: what is heat, what is temperature 1.2.2 Means of heat transfer 1.2.3 Specific heat and sensitive heat 1.2.4 Heat transfer at a constant temperature 1.2.5 Saturated steam and overheated steam 1.2.6 Saturated steam chart BOILERS GENERAL CONDITION Duration: 8 hours

2.1

Types of Boiler and their Purposes

2.2

Parts of a Boiler 2.2.1 Flame boiler 2.2.2 Water boiler 2.2.3 Electric boiler 2.2.4 Solid fuel boiler 2.2.5 Liquid fuel boiler 2.2.6 Gas boiler 2.2.7 Burners

2.3

Boilers Instruments and Control Devices 2.3.1 Feed device 2.3.2 Level glass 2.3.3 Level control system 2.3.4 Pressure gauges

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2.3.5 2.3.6 2.3.7 2.3.8

Safety devices Auxiliary devices Valves and tubes Smoke removal

BOILER OPERATION Duration: 12 hours

3.1

Starting and stopping

3.2

Regulation and control for 3.2.1 Temperature 3.2.2 Pressure 3.2.3 Energy supply 3.2.4 Water level 3.2.5 Pollutants

3.3

Operation failure, cause and measures

3.4

Guidelines for daily inspection

3.5

Operation of a multi-boiler system

3.6

Procedures in Emergency Situations

WATER TREATMENT AND BOILER MAINTENANCE Duration: 8 hours

4.1

Water impurity and its consequence

4.2

Water treatment

4.3

Boiler maintenance

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PREVENTION OF EXPLOSION AND OTHER RISKS Duration: 4 hours

5.1

General risks of accident and health hazards

5.2

Risks of explosion

LEGISLATION AND STANDARDIZATION Duration: 4 hours

6.1

Regulatory Standards

6.2

Regulation Standard 13 (NR 13) The program presented is the minimum and other subjects may be added, or the duration of the classes may be extended in keeping with the specifications of each facility. The proposed program is applicable to the training of operators as of the year of 1995. The graduation courses for operators held in the company that include all the subjects and class hours established in this attachment may be considered equivalent to the Boiler Operation Safety Training, provided a the certificate established in item 13.3.5, line a is issued.

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ATTACHMENT II CERTIFICATION REQUIREMENTS FOR OWN EQUIPMENT INSPECTION SERVICE Before putting the inspection periods established in items 13.5.4 and 13.10.3 of this regulation in practice, the companys Own Equipment Inspection Service, organized by sector, section, department, division or equivalent, should be directly certified by the National Department of Metrology, Standardization and Industrial Quality INMETRO, or by a Certification Institution accepted by INMETRO, which should verify the compliance with following minimum requirements, listed in lines a to g. This certification may be cancelled any time in case one of these requirements are not fulfilled: a) the company where the boiler or pressure vessel is installed must have its own personnel, dedicated exclusively to the inspection, integrity evaluation and residual life activities, with degrees, qualification and training compatible with proposed safety maintenance activity; b) the personnel hired for non-destructive testing shall be certified according to the regulation in force, and for other eventual services, screened and evaluated according the criteria that is similar to the guidelines applied to its own personnel. the proposed equipment inspection services must have a person in charge of their management, formally assigned to this duty; c) there shall be at least one Qualified Professional, as defined in item 13.1.2; d) conditions shall be in place to maintain an updated technical file, required for the compliance with this regulation, as well as means of distributing information whenever necessary; e) there shall be written procedures for the main activities carried out; f) there shall be equipment suitable for the performance of the proposed activity. This matter is subject to additional documentation issued by INMETRO. In the specific case of production and exploration platforms and ships, there Own Equipment Inspection Service may be installed onshore.

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13.6.

PRESSURE VESSEL MISCELLANEOUS

13.6.1

Pressure vessels are pieces of equipment containing fluid under external and internal pressure. Pressure vessels are always submitted simultaneously to internal and external pressure. Even those vessels that work in a vacuum are submitted to these pressures, as absolute vacuum does not exist. What is usually called vacuum is any pressure below atmospheric pressure. The vessel is sized in accordance to the resulting differential pressure acting on its walls, which can be higher externally or internally. There are cases in which the pressure vessel should be sized by most severe pressure conditions, as when the internal and external pressures are not acting simultaneously, for instance. Pressure vessels can be built of varied materials and geometrical shapes, determined by the type of application for which they are intended. Therefore, there are spherical, cylindrical, conical, etc. pressure vessels, made from carbon-steel, aluminum, stainless steel, fiberglass and other materials. The pressure vessels can hold liquid, gas or a mixture of both. Some of the applications are final or intermediary storage, pulsation dampening, heat exchange, reaction restraint, filtering, distillation, fluid separation, cryogen, etc. Regulation NR 13 is applicable to pressure vessels installed in industrial units and other public or private facilities, such as hotels, hospitals, restaurants, etc. As it governs Law 6514 (77) of the Consolidated Labor Laws - CLT, this standard is also applicable to equipment installed in ships, exploration and production platforms, etc, provided there is no conflicting legislation.

13.6.1.1

This Regulations field of application, referring to pressure vessels, is defined in Attachment III. See comments in Attachment III

13.6.1.2

The pressure vessels included in this NR are classified in categories as per Attachment IV.

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See comments on Attachment IV

13.6.2

The lack of any of the following items poses a serious imminent risk: a) the valve or any other safety device with its opening pressure adjusted to a value equal or lesser than the Maximum Working Pressure Permitted - PMTA, installed directly on the vessel or in the system; a safety device against the valves accidental blockage, when it is not installed directly on the vessel; an instrument indicating the operational pressure.

b) c)

It is understood as other safety device, a device that is intended to prevent the vessels internal pressure from reaching values may that endanger its structural integrity. Some examples of other devices of disk rupture, broken valves, vacuum drop, plugs, fuses, etc. Pilot operated safety valves can be considered as other device, provided they keep their operating capacity under any abnormal operational condition. The safety device is a component that evaluates the vessels pressure, independent of the causes that brought on the overpressure. Therefore, pressure switches, pressures stabilizers, instrumentation control network, etc, and should not be considered safety devices. The safety device against accidental blockage is applicable to: pressure vessels with 2 (two) or more safety devices; vessels joined togethe r and protected by only one safety valve. Vessels with 2 (two) or more safety valves, with independent blockages are used when easy handling is required - one of the safety valves may be removed for repair or inspection, and the others kept in operation. In this case, the remaining safety valves in a set, or by themselves, should be designed with sufficient capacity to relieve the vessels pressure. The device that prevents an accidental blockage of the safety device is applicable to pressure valves with two or more safety devices. Examples of these devices are the valves with two or more byways, gate valves without a handle or with a padlocked handle, etc. When the pressure vessel has only one safety valve, there are standards Internationally Accepted, that consider the existence of a blockage between the safety valve and the pressure vessel inadequate.

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The instruments for indicating pressure, such as pressure gauges, may have an analog or digital display and be installed on the vessel itself or in an appropriate control room.

13.6.3

All pressure vessels must have an identification tag secured to their body in a place easily accessible and clearly seen, containing at least the following information: a) b) c) d) e) f) manufacturer; identification number; year of manufacture; maximum permitted work pressure; pressure of hydrostatic test; design code and year of edition.

In accordance to decree 63.233 of 12/09/68, Brazil is the signatory for the International System of Units. The table on page 17 shows the conversion factors that sho uld be used for converting pressure units. The identification number is an alphanumerical identification, known as tag, item, order number, etc. assignedby the designer or facility to the pressure vessel. For the purpose of complying with line f, in case the code year of edition is unknown, the Qualified Professional should verify if the equipment under analysis meets the requirements of the last edition published in the year preceding the vessels manufacturing. If the original design code or year of manufacture is unknown, the vessel should be inspected in accordance with one of the existing codes for pressure vessels, that are internationally accepted, such as: ASME, DIN, JIS, etc. The identification plates already installed should meet the requirements of this Regulation.

13.6.3.1

In addition to the identification plate, the vessels category, according to Annex IV, and its identification number or code shall be marked in a conspicuous place. The information referring to the vessel identification and its respective category are to be painted in a place where they may be easily noticed.

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As an option to painting, the information may be inserted on a plate that can be equally visualized.

13.6.4

All pressure vessels should have the following update documentation in the area is installed. a) b) c) d) e) Pressure Vessel Data Sheet supplied by the Manufacturer containing the following information: design code and year of edition; material description; procedures used during manufacturing, assembly, final inspection and PMTA determination; set of drawings and whatever data necessary to monitor the vessels service life; functional features; data on safety devices; year of Manufacture; category of vessel; Safety Register in accordance with item 13.6.5. Installation design, in accordance with item 13.7. Alteration or Repair Project, in accordance with sub- items 13.9.2 and 13.9.3. Inspection Reports, in accordance with sub-item 13.10.8.

If the company where the pressure vessels are installed has various units, the document should be handy at the unit where they have been installed so they can be promptly consulted. This requirement is also applicable to exploration and production platforms and ships. It is not necessary to file all the documentation in a single location at the unit. However, it is recommendable that all the data sheet documentation be kept together.
The procedures for determining the MWPA (PMTA) must explain its guidelines step by step, including charts, abacus, etc, that may be consulted. If the facility agrees, the design pressure may be adopted as the MWPA for

the pressure vessel. The vessels useful life consists of the period of time between manufacture and the time when the vessel is considered unfit for utilization. The documentation should be kept during the pressure vessels entire life.

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13.6.4.1

If the Pressure Vessels Data Sheet is non-existent or lost the owner must remake it, and the technical responsibility therefor shall rely on the manufacturer or a Qualified Professional, mentioned in item 13.1.2. It is indispensable to reconstitute its function characteristics, the safety devices data and the procedures for determining the MWPA (PMTA). The Pressure Vessels manufacturer shall provide the majority of the required documentation, as detailed as possible, specially the part encompassed in the Pressure Vessels Data Sheet. If the facility does not have this documentation, a part thereof should be remade, as determined in this item. The pressure vessels owner shall be responsible for remaking the documentation at all times. For this purpose, the pressure vessels manufacturers services may be used, or in case it is undetermined or no longer exists, the services of a Qualified Professional or a specialized company may be utilized. Internationally acknowledged technical standards State the MWPA calculation should take into consideration, other required stresses in addition to the pressure, encompassing all parts of the equipment such as connections, flange connection neck, buttress, supporting brackets, seats, etc.

13.6.4.2

The pressure vessels owner should show, when required by the authorities from the Ministry of Labors Regional Department, the documentation mentioned in item 13.6.4. The competent authority of the Labor Ministrys Regional Office ( Regional Labor Office DRT) is the Regional Labor Officer for your jurisdiction.

13.6.5

The Safety Record should consist of a book with numbered pages, files, or a computerized or non-computerized system, equally reliable, where the following information will be noted: a) b) all important occurrences capable of having an effect on the vessels safety conditions; safety inspection .

The Safety Record may consist of a book with numbered pages for each pressure vessel or a book with numbered pages for several pressure vessels.

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It is possible for the Company to use another system (e.g. computerized), but they must feature the same safety against frauds and should require an electronic signature. It is important to register in the book only occurrences that may affect a persons physical integrity. Typical examples of these occurrences: explosions, fires, leakage, rupture of the components, operations that were not anticipated, overdue inspection deadlines, irregular performances of the safety valves, etc. It is a common practice in industrial units to fill out the Shift Log or Service Overlap Log or a similar book, which may be accepted as a Safety Record as long as it complies with item 13.6.5.

13.6.6

The documentation referred to in item 13.6.4 is to be ready for consultation by operators, maintenance personnel, inspectors and workers and employers representatives in the CIPA Internal Commission for Accident Prevention at all times. The owner shall assure the easy access to such documentation, including to the labor union representative for the predominant professional category at the facility, whenever formally requested. The documentation referred to in this item should be available for consultation and inspection at all times. Whenever it is necessary to remove the documentation from the establishment, a second copy must be provided.

13.7

PRESSURE VESSEL INSTALLATION

13.7.1

All pressure vessels should be installed in such a way that drains, air vents, entrance nozzles and level indicators, pressure and temperature, when present, are easily reached. The accessories described in this item, may require the presence of a worker to perform inspection and maintenance operations; they have to be easily and safely accessible by stairs, platforms and other ways in accordance to the NRs.

13.7.2

When the pressure vessels are installed in confined spaces, the installation should be according to the following requirements:

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a) b)

c) d) e)

at least two ample exits, permanently clear and set in opposite directions. Be of easy and safe access for maintenance, operations and inspection activities. The guard rails should have measurements that will avoid a person falling through. Permanent ventilation with air intakes that are obstruction-proof. Lighting according to the official standards in force. Emergency lighting system.

The lines under this item refer to the place where the pressure vessel is installed. In this manner, line a prescribes the procedure area or place where the pressure vessel is installed should have 2 (two) exits set in opposite directions. It should be understood as an emergency lighting system every system capable of keeping the strategic points necessary for the pressure vessel operation adequately lit in case of power failure. Examples of this system are bulbs connected to batteries that recharge automatically during normal power supply, steam generator or combustion engines, etc.

13.7.3

When the pressure vessel is installed in an open area, the installation should be in accordance with lines a, b, d and e under item 13.7.2.

13.7.4

The noncompliance with the following lines under item 13.7.2 poses a serious and imminent risk: a, c, e for vessels installed in confined spaces; a for vessels installed in open areas; e for vessels installed in open areas that operate during the

night.

13.7.5

When the establishment is not able to comply with the provisions under item 13.7.2 an Alternative Installation Project should be developed with additional safety that measures to reduce the risks. When the establishment cannot comply with item 13.7.2 or follow the safety, health and environmental aspects established in the Regulatory Standards, conventions or other legal provisions, an Alternative Installation Project shall be prepared with sound measures to reduce risks. This requirement is applicable to current and new installations.

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13.7.5.1

The pressure vessel owner should present the Alternative Installation Project in order to obtain an agreement from the labor union for the main professional category in the establishment.

13.7.5.2

When there is no agreement, as foreseen in subitem13.7.5.1, mediation by the MTb Regional Office can be requested by any one of the parties and if an impasse persists, this department will take the decision.

13.7.6

The authorship of the Installation Project for pressure vessels established in categories I, II and III, per Attachment IV, concerning the compliance with this Regulation, is the responsibility of a Qualified Professional, as stated in item 13.1.2, and should observe all safety, health and environmental aspects established in the Regulatory Standards, conventions and applicable legal provisions. The authorship of the Installation Project for pressure valves is a responsibility of the Qualified Professional. If during the creation of the project, the Qualified Professional should request the participation of specialized and legally qualified professionals, they will be held liable for their share and should be explicitly mentioned as authors of their part of the project.

13.7.7

The Installation Project should have at least a blueprint of the facility with the location and type of each vessel and the safety installations. The Installation Project should have a blueprint of the facility with the location and type of each pressure vessel installed. The blueprint should also show the position of the safety installations, such a fire extinguishers, sprinkler systems, water cannons, foam chambers, hydrants, etc. Legally qualified professionals should duly sign all documents that constitute the Installation Project. When an existing installation does not possess the blueprints or the above mentioned documents, or when the identification of the legally qualified professionals is not very clear, a Qualified Professional should redo the Installation Project.

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13.8

PRESSURE VESSEL OPERATION SAFETY

13.8.1

Every pressure vessel included in categories I and II should have its own operational manual or operational instructions in the manual belonging to the unit where it is installed, in Portuguese and easily accessible to the operators, with at least: a) b) c) d) start and stop procedures; operational parameters and routine procedures; emergency situation procedures; general safety, health and environmental preservation procedures.

The operation manual belonging to units with categories I and II pressure vessels should always be available to operators close to their work station. The manual should always be updated and all alterations to operational procedures or equipment features should be made widely known to the operators and readily incorporated in the respective manuals. This requirement is also applicable to exploration and production platforms.

13.8.2

The instruments and controls for pressure vessels should be kept calibrated and in good operating conditions. All instruments and controls that may interfere with the pressure vessels safety should periodically be calibrated and kept in satisfactory conditions. The use of resorts such us jumps to neut ralize the control and safety systems poses a severe and imminent risk and may lead to the equipments interdiction. The frequency of the maintenance and the definition of which instruments and controls of the pressure vessels should be included in this item are responsibility of the legally qualified professionals for each specialty.

13.8.2.1

The use of resorts that neutralize the vessels safety and control systems poses a serious and imminent risk.. Transitory jumps in situations where there is a redundancy or preventive maintenance is under way, will not be considered as a resort to neutralize the control systems or instruments. In such cases it is necessary to calculate the risks involved and observe this operation closely, regarding all sectors that may be affected by it.

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13.8.3

The operation of units with pressure vessels belonging to I or II categories should be performed by professional trained on Unit Operation Safety Procedures. The noncompliance with this requirement characterizes a serious and imminent risk. The establishments owner or his legal representative holds the responsibility for having well trained operators in the operating units. It should be realized that due to the units complexity an operator may operate several pressure vessels simultaneously or one single pressure vessel may be controlled by various operators. The operator responsible for the units operation should be capable of acting promptly to correct abnormal situations that may arise. When a computerized remote controlled system is installed, a staff to act in emergency situations should be considered.

13.8.4

For purpose of this Regulation, a Professional will be considered as trained on Professional the Processing Unit Operation Safety only if he meets one of the following conditions: a) b) Processing Unit Operation Safety Certificates issued by a competent training institution. Proof of experience in operating categories I or II pressure vessels for at least 2 (two) years before this Regulation was effected.

In cases where it is necessary to prove Processing Unit operation experience, the following should be taken in consideration: records in the work book or documents or duties supplied by the establishment or witnesses

To calculate the 2 (two) years of experience, the time with interruption should be disregarded.

13.8.5

The minimum requirement for attending, as a pupil, the Processing Unit Safety Training is the conclusion of Elementary School.

13.8.6

It is mandatory that the Safety Training in Operating the Procedure Units should be:

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a) technically supervised by a Qualified Professional as mentioned in item 13.1.2; b) the teachers should be proficient in this subject; c) observe, as a minimum requirement, the program proposed in Attachment 1-B of this Regulation. Other theoretical or practical subjects may be included in the training if it is considered relevant by the technical supervisor of the training.

13.8.7

In case of the non-compliance with the provisions of item 13.8.6, the persons in charge of the Processing Unit Operation Safety Training Processing Unit Operation Safety Training are subject to be precluded from conducting new courses as well as other legal penalties.

13.8.8

All professional trained in Processing Unit Operation Safety should undergo a supervised practical training period on pressure vessel operations with the following duration as a minimum: a) 300 (three hundred) hours for categories I and II vessels. b) 100 (one hundred) hours for categories III, IV or V vessels. The company or establishment will file all documents that prove the attendance of their operators in above mentioned practical training periods. In cases where the unit does not have categories I and II pressure vessels it is not necessary to have professionals trained in Processing Unit Operation Safety. However it is necessary to comply with the 100 hour practical training period. The supervisor of the training period may be: Chief of operations. A chief operator. An engineer in charge of processing. A Qualified Professional. A more experience operator.

13.8.9

The establishment where the supervised training takes place should inform the labor union representative for the main professional class of the establishment beforehand: a) the training period;

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b) institution, company or professional responsible for the Processing Unit Operation Safety Training; c) list of participating trainees.

13.8.10

The operators should be kept permanently current, by means of continuous information about the physical and operational condition of the equipment, technical update, safety information, courses, presentations and pertinent events. The employer will be responsible for setting the date and the need for refresher courses. For certification purposes, the type of activity, date and period, etc should be attached to each employees file.

13.8.11

It is a serious and imminent risk to operate any pressure vessel in conditions other than those established in the original project, without: a) A new design, taking into consideration all the variables involved in the new operating condition. b) The implementation of all safety procedures related to the vessels new classification, regarding its installation, operation, maintenance and inspection. Operating pressure vessels under operating conditions other than those established in its design can be extremely dangerous. Examples of these conditions are: higher pressure than the operational. higher temperature than determined in the project. using different fluids than those originally planned. alterations of the shape, thickness, type of material, etc. Whenever a modification is made in the pressure vessels design or in its operational conditions, all necessary safety procedures should be adopted. All modifications made must always be registered in the pressure vessels documentation.

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13.9

PRESSURE VESSEL MAINTENANCE SAFETY

13.9.1

All repairs or alterations made to the pressure vessels should observe the corresponding construction design code and the manufacturers recommendations regarding: a) b) c) d) materials; implementation procedures; quality control procedures; personnel qualification and certification.

In the case of pipelines, this items coverage is limited to the section between the vessels body and the weld or nearest flange. It is considered as a repair any operation aiming to correct a nonconformance with the original design. For example, a welding repair to correct damaged areas, taking off imperfections from the welded connections or from the metal base, substituting inserts or corroded connections, etc. It is considered as alteration any operation that alters the original design, including the vessels operational parameters. For example: alterations in the material specification, change of the inserts or connections, changes in shape, etc. Examples of personnel qualification and certification are the procedures provided by code ASME, Section IX (Qualification for Welding and Brazing) and Section V (Non-Destructive Testing).

13.9.1.1

When the construction design code is unknown, the original vessels concept should be respected, using the more rigorous control procedures defined in the pertinent codes. In case the vessels documentation is lost and the manufacturer cannot be identified, any repair and alteration should respect the original boiler concept. At the times of such repairs and alterations the Qualified Professional should suggest the testing, as well as the acceptance standards compatible with the most rigorous design codes acknowledged worldwide.

13.9.1.2

At the Qualified Professionals discretion, as mentioned in item 13.1.2, modern methods of calculation or more advanced procedures can be used to replace the ones established by the project code.

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In special cases, and as long as a Qualified Professional approves it, calculation procedures and technology not included in the design code may be used. Some examples of these procedures are mechanical fracture techniques that allow subcritical discontinuities, alternate welding techniques that do not require stress relief, finite element molding, etc.

13.9.2

Alteration or Repair Projects should be previously conceived in the following cases: a) whenever the conditions of the project are modified; b) whenever repairs are made that can jeopardize safety. Before performing any repairs or alterations that may jeopardize the pressure vessels or workers safety, an Alteration or Repair Project should be devised and filed in the pressure vessels documentation. It is not necessary to submit this document to a department outside the company, such as: DRT (Labor Regional Office), labor union, etc. Examples of Alteration and Repair Projects are alterations in the specifications of the vessels or accessories material, inclusion or exclusion of connections, welding repairs, etc.

13.9.3

The Alteration or Repair Project should: c) be planned or approved by a Qualified Professional, as mentioned in item 13.1.2; d) determine the material, implementation procedures, quality control and personnel qualification. e) be made known to employees of the establishment that are involved in some way with the equipment. A specialized company can make the Alteration and Repair Project as long as it is registered with the Engineering and Architecture Regional Council CREA and has a technical person legally qualified in place. Repairs and alterations that involve specialization in electricity, electronic or chemistry qualification shall be planned and signed by a qualified professional for each specific field. Independently, every Alteration or Repair Project will be signed by a Qualified professional.

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13.9.4

Any modification that demands mandrel work or welding in parts that operate under pressure shall be followed by a hydrostatic test according to the characteristics defined by the Qualified Professional, mentioned in item 13.1.2, taking into account what is mentioned in item 13.10. If the hydrostatic test parameters are not defined in standards or codes, the Qualified Professional will be responsible for their definition, based on his experience and knowledge. These parameters should contain: - safety measures necessary to the protection of the personnel involved in the test; - fluid to be used for pressurization; - pressure increase rate and levels, when necessary; - final hydrostatic test pressure ; - period of time when the equipment will remain pressurized. The characteristics and results of the hydrostatic test should be recorded in the corresponding Safety Inspection Report that includes the test, whether initial, periodic or exceptional.

13.9.4.1

Small superficial interventions may make the hydrostatic test unnecessary, the Qualified Professional as mentioned in item 13.1.2 takes this decision.

13.9.5

The control and safety systems of the pressure vessel will be submitted to Preventive or Predictive Maintenance. The definition of instruments and control systems to be included in the Preventive/Predictive Maintenance plan, as well as its corresponding periodicity shall be defined by a legally qualified professional who is competent to perform this kind of activity.

13.10

PRESSURE VESSEL INSPECTION SAFETY

13.10.1

The pressure vessels should be submitted to an Initial, Periodic and Extraordinary Safety Inspection.

13.10.2

The initial safety inspection shall be made on new pressure vessels, before putting them to work, at the operation site, and it shall cover internal and external inspection, hydrostatic and accumulation tests, considering the limitations mentioned in item 13.10.3.5.

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Internal and external inspection and hydrostatic tests made at the owners facility are important and necessary but they do not constitute an Initial Safety Inspection since the components of the pressure vessel may suffer damage during the transportation, storage and assembly in their definitive site. The Initial Safety Inspection can only be made when the pressure vessel is already installed on its final location. Applicable for this item are the clauses made out when performing the hydrostatic tests appearing in items 13.10.3.4 and 13.10.3.5.

13.10.3

The periodical safety inspection, comprised of an external and internal inspection, and a hydrostatic test, should obey the following established deadlines: a) For establishments that do not have their own Equipment Inspection Service, as mentioned in Attachment II: EXTERNAL INSPECTION 1 YEAR 2 YEARS 3 YEARS 4 YEARS 5 YEARS INTERNAL INSPECTION 3 YEARS 4 YEARS 6 YEARS 8 YEARS 10 YEARS HYDROSTATIC TEST 6 YEAR 8 YEARS 12 YEARS 16 YEARS 20 YEARS

CATEGORY OF VESSEL I II III IV V b)

For establishments that have their own Equipment Inspection Service, as mentioned in Attachment II: EXTERNAL INSPECTION 3 YEARS 4 YEARS 5 YEARS 6 YEARS 7 YEARS INTERNAL INSPECTION 6 YEARS 8 YEARS 10 YEARS 12 YEARS freedom of choice HYDROSTATIC TEST 12 YEARS 16 YEARS freedom of choice freedom of choice freedom of choice

CATEGORY OF VESSEL I II III IV V

The Periodical Safety Inspections scope as well as the techniques used will be defined by a Qualified Professional taking into account the pressure vessels record and the technical rules in force. The deadlines defined in this item should be considered as maximum limits. The real term shall be established by the Qualified Professional, taking into account the available previous experience, being counted from the last complete inspection made on the pressure vessel.

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The deadlines established in line b is applicable to companies who have their own Equipment Inspection Service, certified in accordance to the recommendations in that Attachment II. This Regulation does not intend to specify in detail the inspection methods or procedures. A Qualified Professional based on internationally accepted codes and policies and engineering knowledge shall do this. Since some vessels, even when they are not in operation, can suffer extreme corrosive wear, should be given as an inspection deadline the date of the last complete safety inspection and not take into consideration the starting or restarting of operations with the vessel.

13.10.3.1

Pressure vessels that cannot be inspected internally and externally due to physical difficulty should be submitted alternatively to a hydrostatic test, taking into consideration the limitations anticipated in item 13.10.3.5. Examples of pressure vessel that do not permit an internal examination: vessels that do not have a manhole or opening for a person to get through; vessels with a hull diameter that does not allow a person to get through; heat exchangers with a mirror welded to the hull, etc. Examples of equipment that do not permit an external examination: Buried equipment.

13.10.3.2

Vessels with internal filling or with a catalyst can have the periodicity of their internal inspection or hydrostatic test extended, so that it coincides with the period in which filling and catalyzer, provided this extension of time does not surpass 20% of the established deadline in item 13.10.3 of this Regulation. Examples of internal pressure vessels filling are: clay; activa ted charcoal; steel shavings; Rashig rings; orientated fillings; Disassembled accessories, such as: trays; demister; distributors.

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13.10.3.3

Vessels with hygroscopic internal coating should be tested hydrostatically before the coating is applied, and the subsequent tests should be substituted to alternative techniques. A typical example of hygroscopic internal coating is refractory coating.

13.10.3.4

When technically unfeasible and duly recorded in The Safety Record by a Qualified Professional, mentioned in item 13.1.2, the hydrostatic test can be substituted by another non-conformance technique or inspection in which equivalent security may be obtained. The person responsible for defining the inspection techniques that will supply equivalent safety to hydrostatic test is a Qualified Professional. Examples of these techniques are: ultra-sound inspection. X-ray inspection. penetrating liquid inspection. magnetic particle inspection. flow checks inspection. Substituting the hydrostatic test for other techniques is a decision that should be part of the corresponding safety inspection report, duly signed by the Qualified Professional.

13.10.3.5

Technical reasons that make hydrostatic testing unfeasible are: a) structural resistance of the vessels foundation or support, incompatible with the weight of the water used in the hydrostatic test. b) damaging effects brought on by the test fluid to the vessels internal elements. c) impossibility of using cleaning and drying system techniques. d) Existence of internal coating. e) prejudicial influence of the test on sub-critical defects. The technical reasons, which make the hydrostatic test unfeasible, mentioned in this item, are the most frequent. There may be further reasons to make the hydrostatic test unfeasible other than those mentioned. Economical reasons should not be considered as restrictions for the hydrostatic test.

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Examples of internal coating that usually make the hydrostatic test unfeasible are: - glazed coating; - hygroscopic (refractory) coating. On the other hand, the existence of painted coating, lining, clad, etc. are not considered as technical reasons to make the hydrostatic tests unfeasible the. Vessels with a temperature below 0 C that operate in conditions where it is known through experience that there is no deterioration are free from periodical hydrostatic tests. However, it is necessary to perform an internal exam every 20 (twenty) years and an external exam every 2 (two) years. The pressure vessels operating with a temperature below 0 C, cryogenic vessels are rarely subject to serious deterioration. The frequent internal inspection and the hydrostatic tests can bring on phenomenon that may jeopardize the vessels service life. Therefore, the Regulation 13 does not foresee the performance of a mandatory hydrostatic test and establishes deadlines for internal inspection of up to 20 (twenty) years, a number that is compatible with other international laws. The details of internal and external exams should respect internationally accepted voluntary policies. The cryogenic pressure vessels should respect all of the items in the Regulation 13, with the exception of dispensation from hydrostatic and the deadlines for safety inspection.

13.10.3.6

13.10.3.7

When there is no other alternative, the pneumatic test can be performed, providing the Qualified Professional supervises it, mentioned in item 13.1.2, and with special care, as it is a very risky operation.

13.10.4

The pressure vessels safety valves should be disassembled, inspected and calibrated again at the time of the periodic internal inspection. The services established in this item can be done by removing the valve and taking it to a repair facility or performed at its place of installation. If the safety valves assembly components and the units allow it, a verification of the opening pressure, using hydraulic devices, while the pressure vessel is in operation.

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The established deadlines in this item for inspection and maintenance of the safety valves are final. Shorter deadlines can be established when the records of their operation show problems in shorter periods compared to those established for periodical internal inspection of the vessel. In this way, the inspection of safety valves can occur in dissimilar dates to those of the periodical internal inspection. In the same way, when the internal inspection deadlines are increased, as happens with the cryogenic vessels, shorter deadlines for safety valves inspection can be established.

13.10.5

The exceptional safety inspection shall be performed on the following occasions: a) whenever the vessel is damaged accidentally or by any other reason capable of jeopardizing its safety; b) whenever the vessel is submitted to major alterations or to repairs capable of changing its safety condition; c) before the vessel is put to work, after remaining inactive for more than 12 (twelve) months; d) whenever the vessel is moved to another location. The exceptional safety inspection may cover the whole vessel or only part of it, depending on the necessity or at the discretion of the Qualified Professional.

13.10.6

The Safety Inspection should be performed by a Qualified Professional, mentioned in item 13.1.2 or by the vessels own Equipment Inspection, as mentioned in Attachment II. This item refers to all types of safety inspection, initial, periodical or exceptional. Inspectors and/or inspection experts during the safety inspection may assist the Qualified Professional. Specialized companies can be used as long as they are registered with CREA and have Qualified Professionals.

13.10.7

An Inspection Report will be issued after the vessel is inspected, and will be part of its documentation.

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It is understood that the end of inspection takes place whe n the pressure vessel is released for operation. The date the technical report is concluded will not be considered as the inspection ending date.

13.10.8

The Inspection Report should have: a) b) c) d) e) f) g) h) i) j) k) pressure vessels identification; service fluids and category of pressure vessel; type of pressure vessel; date of start and end of inspection; type of inspection performed; description of inspection and tests performed; results of the inspections and measures taken; conclusions; necessary recommendations and measures; planned date for the next inspection; legible name, signature and registration number of the qualified professional in the council, mentioned in item 13.1.2 and legible name and signature of the technicians who took part in the inspection.

Examples of type pressure vessels: reactor, filter, distillation, storage sphere, etc. An example for line h would be: In view of the inspections and maintenance performed the pressure vessel can be put back into operation, and should be submitted to a new periodical inspection on the date: ___/___/___. An example for line i would be: During the pressure vessels next job, the following steps must be taken: improve the identification plates setting; substitute the earth cables connection; adapt the painting of pressurized air lines to the Regulation 26; alter the PMTAs value and make the necessary adjustments to safety devices.

13.10.9

Whenever the inspection reports determine there be alterations on the identification plates data, it should be updated.

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ATTACHMENT I-B MINIMUM PROCESSING UNIT OPERATION PROGRAM 1 NOTIONS OF PHYSICAL QUANTITIES AND UNITS Duration: 04 hours

1.1

Pressure 1.1.1 Atmospheric pressure 1.1.2 Internal vessel pressure 1.1.3 Manometer measured pressure, relative pressure and absolute pressure 1.1.4 Pressure units

1.2

Heat and Temperature 1.2.1 General conception: what is heat, what is temperature 1.2.2 Ways of transferring heat 1.2.3 Specific and sensitive heat 1.2.4 Heat transfer at constant temperatures 1.2.5 Saturated steam and overheated steam

PROCESSING EQUIPMENT Duration: established to conform to the complexity of the unit, keeping a minimum of 4 hours per item, when applicable.

2.1 2.2

Heat exchangers Tubing, valves and accessories

2.3

Pumps

2.4

Turbines and ejectors

2.5

Compressors

2.6

Towers, vessels, tanks and reactors

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2.7

Furnaces

2.8

Boilers

ELECTRICITY Duration: 04 hours

INSTRUMENTATION Duration: 08 hours

UNIT OPERATION Duration: established in conformity to the units complexity.

5.1

Description of procedure

5.2

Starting and stopping

5.3

Emergency procedures

5.4

Disposal of chemicals and environmental preservation

5.5

Estimating and controlling risks that are inherent to the procedure

5.6

Deterioration, explosion and other risks prevention

First Aid Duration: 08 hours

Legislation and normalization Duration: 04 hours

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The given curriculum is minimal, and other subjects can be added to it, or the duration of the subjects can be extended to suit each establishment. The curriculum is applicable for training operators from the procedure units that own categories I and II pressure vessels. The courses for operators existent in the companies and totally follow the Safety Training in Operating Procedure Units are regarded as equivalent, providing a certificate is issued as anticipated in item 13.8.4 line a. ATTACHMENT II REQUIREMENTS FOR CERTIFYING THE COMPANYS OWN EQUIPMENT INSPECTION Before putting into practice the special periods between inspections established in items 13.5.4 and 13.10.3 of this Regulation, the companys Own Services for Equipment Inspection organized by sector, section, department, division or equivalent, should be certified by The National Department of Metrology, Regulation and Industrial Quality - INMETRO, or by Certification Institutes with their credentials. They will verify the compliance with the following minimum requirements listed from, line a to g. This certification can be cancelled at any time it is verified that one of these requirements are not being followed: a) the company where the boiler or pressure vessel is installed must have its own personnel, dedicated exclusively to the inspection, integrity evaluation and residual life activities, with degrees, qualification and training compatible with proposed safety maintenance activity; the personnel hired for non-destructive testing shall be certified according to the regulation in force, and for other eventual services, screened and evaluated according the criteria that is similar to the guidelines applied to its own personnel. the proposed equipment inspection services must have a person in charge of their management, formally assigned to this duty; proposed equipment inspection service there shall be a person in charge of its management, formally assigned for this duty; there shall be at least one Qualified Professional, as defined in item 13.1.2; conditions shall be in place to maintain an updated technical file, required for the compliance with this regula tion, as well as means of distributing information whenever necessary; there shall be written procedures for the main activities carried out; there shall be equipment suitable for the performance of the proposed activity.

b)

c) d) e)

f) g)

This matter is subject to complementary documentation issued by INMETRO.

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For the specific case of production and exploration oilrigs and also ships, the Own Services for Equipment Inspection can be installed onshore.

ATTACHMENT III 1 THIS REGULATION SHOULD BE IMPLEMENTED FOR THE FOLLOWING EQUIPMENT: a) any vessel with a P.V product above 8 (eight) and where P is the maximum operating pressure in kPa and V is its internal geometrical volume in m, including: - heat transferors, evaporators and similar; - pressure vessels or parts subject to direct flame that are not in the other regulation scopes, neither in item 13.1 of this Regulation; - pressure vessels with sleeves, including re-boilers and reactors. - autoclaves and thermal fluid boilers that do not steam the vessel up; b) vessels containing type A fluid, specified in Attachment IV, independent of the dimensions and the P.V product. 2 THIS REGULATION IS APPLICABLE TO THE FOLLOWING EQUIPMENT: a) portable cylinders, vessels destined for product transportation, portable reservoirs for pressurized fluid and fire extinguishers; b) those intended for human dwelling; c) combustion chamber or vessels that integrate the rotary or alternative machinery, such as pumps, compressors, turbines, generators, motors, pneumatic and hydraulic cylinders that cannot be marked as independent equipment; d) ducts and piping for the conveyance of fluids; e) serpentines for thermal exchange; f) tanks and receptacles for the storing and stowing of fluids that are not encompassed in the policies and codes pressure vessels projects; g) vessels with an internal diameter lower than 150 mm (one hundred and fifty) for type B, C and D fluids, as specified in Attachment IV. Collectors such as a header, manifold, etc or other fluids that cast or receive PIG should not be considered pressure vessels. Heat transferors should establish their category in two different ways: 1st.) taking into consideration the most critical category between the hull and the head (spool); 2nd) Considering the hull to be a pressure vessel and the head to be another.

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This Regulation is not applicable to vessels closely linked to rotary or alternative equipment, as it is understood that to more than an effort of pressure, this equipment is subject to dynamic efforts that c an cause it fatigue, corrosion, etc. It is understood that such vessels have more severe and specific policies than those of NR 13.Examples of this situation: - combustion motors crank case; - pump volutes; - pump and compressor framework. Pressure vessels installed in packages with the sole objective of reducing physical space or making installation easier, are not considered as being integrated to the machinery and therefore are subject to the requirements in NR 13 where P.V> 8. Examples of this situation: - pressurized air lungs that can hold small alternative compressors; - heat transference to cool the water or oil in the rotary machinery; - pump and compressor pulsation dampers; - filters; - pressurized rotary cylinders. Cryogenic receptacles to store liquefied gases derivatives of the air, such as oxygen, nitrogen, carbon dioxide, etc, when manufactured is in accordance to the policies and codes of a specific project, not related to pressure vessels, they should be encompassed in Attachment III, item 2, line f of the NR 13.

ATTACHMENT IV PRESSURE VESSELS CLASSIFICATION 1 FOR THE PURPOSES OF THIS REGULATION, THE PRESSURE VESSELS ARE CLASSIFIED IN CATEGORIES ACCORDING TO THE TYPE OF FLUID AND RISK POTENTIAL

1.1.

The fluids in the pressure vessels are classified according to the following: Type A: - Inflammable fluids; - Combustible with a temperature higher or equal to 200C; - Toxic fluids whose tolerance limit is equal or lesser than 20 ppm; - Hydrogen; - Acetylene. - Combustion fluids with a temperature lower than 200 C; - Toxic fluids with their tolerance limit higher than 20 ppm; - Water steam, simple asphyxiating gases or pressurized air.
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Type B:

Type C

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Type D

- Water or other fluids not encompassed in types A, B or C, with a higher than 50C temperature.

1.1.1

When considering mixtures, for classification sake, one should consider the fluid that represents greater risk to the workers and installations, considering its toxic effects, inflammability and concentration.

1.2.

The pressure vessels are classified in potential risk groups due to the P.V product, where P is the maximum operating pressure in MPa and V is its geometrical internal volume in cubic meters, as follows: Group 1 - P.V 100 Group 2 - P.V < 100 and P.V 30 Group 3 - P.V < 30 and P.V 2,5 Group 4 - P.V < 2,5 and P.V 1 Group 5 - P.V < 1

1.2.1

Pressure Vessels that operate in vacuum conditions should be encompassed in the following categories: - Category I - for inflammable fluids; - Category V - for other fluids.

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1.3

The following table classifies the pressure vessels in categories according to potential risk groups and the types of fluid it contains.
TYPE OF FLUID 1 P.V 100 A - Inflammable fluids - Combustible with a temperature higher or equal to 200C; - Toxic fluids with tolerance limit 20 ppm; - Hydrogen; - Acetylene. B - Combustib les with temperature lower than 200 C; - toxic fluids with tolerance limit > than 20 ppm; C - Water steam - simple asphyxiating gases - pressurized air D - Water or other fluids not encompassed in types A, B or C, with a higher than 50C temperature POTENTIAL RISK GROUP
2 P.V<100 P.V30 3 P.V<30 P.V2,5 4 P.V<2,5 P.V1 5 P.V<1

CATEGORIES

II

III

III

II

III

IV

IV

II

III

IV

II

III

IV

Notes: a) Consider Volume in m3 and Pressure in MPa. b) Consider 1 MPa correspondent to 10,197 kgf/cm2 . The classification of fluids into inflammable and combustible should attend to what is defined in Regulation 20. The most critical condition should always be considered. Example, if a gas is asphyxiating simple (type C fluid) and inflammable (type A fluid) it should be considered inflammable. The temperature to be used for classification is the one from the pressure vessel in operation. The toxins of the fluids should attend the anticipated in the NRs; in case the tolerance limits for the fluid or mixture are not taken into account; internationally accepted numbers should be used.

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For classification purposes, when a pressure vessel has a mixture of fluids, one should use the fluid that presents more risk to the workers, installations and environment, then a fluid with a significant concentration mixture, at the establishments discretion. For classification purposes, the values for the maximum operational pressure can be obtained from data obtained at the process engineering department, from the pressure vessels manufactures recommendations, or from the vessels functional features. If these numbers are significant they can be subtracted from the pressure vessels internal geometrical volume occupied by non-porous elements. All pressure vessels with the P.V. product higher than 8 (eight) are encompassed in Regulation 13. The vessels whose P.V is higher than 8 (eight), but their fluid is not encompassed in the types defined in Attachment IV, should have there category attributed according to their past operational history and to the risks presented to the workers and installations, taking into consideration: toxins, inflammability and concentration. In the calculation of the product P.V the pressure must be in kPa. The maximum operating pressure to be used in the calculation of the P.V. product in table under Annex IV should be in Megapascal (MPa). Water below 50 C and other fluids that are not encompassed in the types listed in this Attachment should be encompassed as type D.

EXAMPLES OF THE CLASSIFICATION OF PRESSURE VESSELS 1st. case Equipment: Ethylene Cracker Operation Temperature : 30 C Geometrical Volume: 785m3 Operation Pressure : 20.4 kgf/cm3 Product : Ethanol a) To verify if the Vessel can be encompassed in the NR 13 Maximum Operational Pressure = 20.4 kgf/cm2

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To change into kPa 20.4 0.010197 = 2000.58 kPa P.V = 2000.58 (kPa) x 785 (m3 ) P.V = 1,570,461.90 P.V > 8, therefore the Vessel is encompassed in the NR 13 b) To determine the Vessels category: Ethylene product = inflammable fluid = type A fluid P.V = 2.00058 MPa x 785m3 = 1570.45 (therefore P.V 100) With P.V 100 and type A fluid, in the table of Attachment IV we find that the Vessel is Category I. 2nd. case Equipment: Lubricating Oil Filter Operation Temperature : 40 C Geometrical Volume: 290 liters Operation Pressure : 5.0 kgf/cm3 Product : Lubricating Oil a) To verify if the Vessel can be encompassed in NR 13 Maximum Operational Pressure = 5.0 kgf/cm2 To change into kPa 5.0 0.010197 = 490.34 kPa Maximum Operation Pressure: 490.34 kPa Geometric volume: 290 ltrs = 0.290m3 Product P.V = 490.34 (kPa) x 0.290m3 = 142.19 P.V > 8, therefore the Vessel is encompassed in NR 13 b) To determine the Vessels category: Product = Lubricating Oil = type B fluid

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P.V = 0.49034 MPa x 0.290m3 = 0.14245 (therefore potential group of risk = 5 and fluid type B) By referring to the table under Attachment IV we determined the Vessel is a Category IV.

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