NR 13 - Boilers and Pressure Vessels (safety regulation of MTE) Inspection and Maintenance Engineer Static Equipment Deyson Marcelo

Rothen Speaker Mechanical Technician (CEFET-PR, 1993) Refinery Pres. Getúlio Vargas (Petrobras) Industrial Engineering Mechanics (CEFET-PR, 1998) Laboratory for Concurrent Engineering (Siemens) Kværner Pulping Kværner Oilfield Products Companhia Siderurgica de Tubarão (since 1999) 21/03/2005 NR 13 - Boilers and Pressure Vessels 2 Topics 21/03/2005 Legislation History Purpose Responsibility legal requirements of care Domain Man agement Services own inspection technology management trends in CST Doubts / que stions NR 13 - Boilers and Pressure Vessels 3 1 - Legislation Legal Structure Legislative CF (CLT) Executive (Ordinances) ABNT, corporate standards (technical standards) "Regulation prevails over technical standard" 21/03/2005 NR 13 - Boilers and Pressure Vessels 5 ILO Conventions ILO 155 Occupational Safety and Health Workers (1981) 21/03/2005 Article 4 1. Each Member shall, in consultation with the most representative o rganizations of employers and workers concerned, taking into account national co nditions and practice, formulate, implement and periodically review a coherent n ational policy on safety and health of workers and the environment work. 2. Th is policy shall aim to prevent accidents and damage to health that are a consequ ence of the work, relate to the work activity or supervene at work by minimizing , as far as is reasonably practicable, the causes of hazards inherent in the wor

k environment. 6 NR 13 - Boilers and Pressure Vessels ILO Conventions ILO 155 Occupational Safety and Health Workers (1981)

21/03/2005 Article 8 Each Member shall adopt, by law or regulation or any other method co nsistent with national conditions and practice, and in consultation with represe ntative organizations of employers and workers concerned, the necessary measures to give effect to Article 4 of this Agreement. Article 9 1. The enforcement o f laws and regulations concerning safety, hygiene and working environment should be ensured by a system of inspection is appropriate and sufficient. 2. The co ntrol system should provide for appropriate penalties for violations of the laws or regulations. 7 NR 13 - Boilers and Pressure Vessels Legal Grounds Federal Constitution (1988) Article 21. It is for the Union: XXIV - organize, maintain and carry out inspection of work;

Article 22. It is incumbent on the Union to legislate: I - civil, commercial, penal, procedural, electoral, agrarian, maritime, aeronau tical, space and labor;

Law 6514/77: Amendment to Chapter 5 of the CLT 8 21/03/2005 NR 13 - Boilers and Pressure Vessels Legal Grounds Decree-Law 5452 (May 1, 1943) Chapter V THE SAFETY AND OCCUPATIONAL HEALTH Article 200 - The Ministry of Labor to establish additional provisions to the standards mentioned in this chapter, bearing in mind the peculiarities of each activity or sector of employment, part icularly regarding:

I - measures to prevent accidents and personal protective equipment in construct ion, demolition or repairs; 21/03/2005 NR 13 - Boilers and Pressure Vessels 9 Legal Grounds Ordinance 3214/78 Publication of Regulatory Standards Drafted by Working Groups tripartite (govern ment, employers, workers) NR 13: no participation by manufacturers 21/03/2005 NR 13 - Boilers and Pressure Vessels 10 Supervision

It is for the Regional Labor Office to make inspection of compliance to the Regu latory Standards WRD / ES: Del. Tarciso Celso Vieira de Vargas DRT / SP: mean of 4 assessments per day (assuming all NR's) Annual visit: risk and risk 4 3 Every two years: risk 2 Every 3 years: a risk NR 13 - Boilers and Pressure Vessels 21/03/2005 11 2 - History Worldwide Nineteenth century: steam as an energy source Accident boilers: God's work! Crea tion of ASME: 1880 protests in 1905 (50 000 casualties per year) U.S. Legislatio n: 1908 ASME Code: 1914 National Board Inspection Code: 1919 13 21/03/2005 NR 13 - Boilers and Pressure Vessels In Brazil

First version: 1978 First review: 1984 (operators and the definition of serious and imminent) Second Revision: 1994 (after an accident on Refinery) ABNT NB-55 ( safety inspection of boilers stationary) ⇒ NBR 12 177 Order 16 (2001) Inmetro: S PIE NR 13 - Boilers and Pressure Vessels 21/03/2005 14 Major industrial accidents 1976 - Sevezo - 500 dead 1984 - Bhopal - 2500 deaths in 1998 - Nigeria - 700 dea d 1986 - Chernobyl - 500,000 deaths in 1972 - REDUC - 37 dead 1984 - Cubatão - 5 08 dead 21/03/2005 NR 13 - Boilers and Pressure Vessels 15 ILO Convention 174 (1993) Prevention of major industrial accidents (accidents Extended): beyond the limits of the company Brazil is a signatory since 2001 Example: pole Camaçari cu rrent Accidents: pipes and ducts (range over large areas populated) 21/03/2005 NR 13 - Boilers and Pressure Vessels 16 21/03/2005 Rio Iguaçu (Paraná) Source: Report on the Internet NR 13 - Boilers and Pressure Vessels 17 21/03/2005 Refinery in Algeria (Africa), boiler accident (5 photos) Source: Report on the I nternet NR 13 - Boilers and Pressure Vessels 18 21/03/2005 NR 13 - Boilers and Pressure Vessels

19 21/03/2005 NR 13 - Boilers and Pressure Vessels 20 21/03/2005 NR 13 - Boilers and Pressure Vessels 21 21/03/2005 NR 13 - Boilers and Pressure Vessels 22 3 - Purpose Goal NR 13

Control over the state of equipment, trying to protect the physical integrity of employees (CLT) as a function of potential energy accumulated Definition of cri minal liability in the event of noncompliance and / or accidents 21/03/2005 NR 13 - Boilers and Pressure Vessels 24 Equipment covered Boilers 20000 in Brazil, 200 in large enterprises (10 in CST) 5 million in Brazil and 70 ,000 in large enterprises (900 in ~ CST) shall comply with NR 13 (contractual) a udits (co-responsibility) 25

Pressure Vessels

Units outsourced (lending): 21/03/2005

NR 13 - Boilers and Pressure Vessels NR's related NR 1: General Provisions (RGI) NR 3: Embargo or prohibition NR 8: Buildings (ins ide buildings) NR 15: Activities unhealthy (fluid) NR 20: Fuels and flammable NR 23: 26 NR Fire Protection: Safety signs NR 28: Penalties NR 13 - Boilers and Pressure Vessels 21/03/2005 26 4 - Liability Staff involved The NR's down mainly involve the personal security and Occupational Medicine

NR 4: Services specializing in Safety Engineering and Occupational Medicine 5 NR : CIPA (Internal Commission) NR 6: PPE (Personal Protective Equipment) NR 7: Con trol of occupational health physician NR 9: PPRA (Environmental Risks) 28 21/03/2005 NR 13 - Boilers and Pressure Vessels Staff involved NR 10: Facilities and Services in Electricity It involves the technical staff of Electrical involves mainly mechanical inspect ion and maintenance, and operation, engineering and other specialties

NR 13: Boilers and Pressure Vessels 21/03/2005 NR 13 - Boilers and Pressure Vessels 29 Qualified professional

Signing legal documents Mechanical Engineer with registration in CREA (assignmen ts of Law 5194/66) has responsibility for the acts pertaining to Legislation (ch arged or not) is the technical manager of the company 21/03/2005 NR 13 - Boilers and Pressure Vessels 30 13.1.2 For purposes of this NR, it is considered "Qualified Professional" who ha s legal competence to practice the profession of engineer in activities relating to project construction, operation and maintenance of monitoring, inspection an d supervision of inspection of boilers and vessels pressure in accordance with p rofessional regulations in force in the country 21/03/2005 NR 13 - Boilers and Pressure Vessels 31 Violation and penalties Auto Offense: fine the company As NR 28 Depends on number of employees and the degree of the violation (1 to 4) varies between 630 and 6304 UFIR

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

Dual seen

If it is serious and imminent risk Consequence: embargo or ban Feature preventive (not punitive) 21/03/2005 NR 13 - Boilers and Pressure Vessels 32 Responsibility (accident) Social Security should be refunded MPT (Federal): Intra-muros MPT> Prosecutor> labor justice MPE> prosecutor> common justice Prosecution Not dependent on the civil suit Search punishment (freedom) against the professi onal NR 13 - Boilers and Pressure Vessels

MPE (State): Environmental and individual

Civil lawsuit Prove the guilt (omission, negligence or recklessness) The company pays damages Search 21/03/2005 33 5 - Legal requirements Organization Installation General Maintenance Operation Inspection 21/03/2005 NR 13 - Boilers and Pressure Vessels 35 General Requirements Definition of Boilers and Pressure Vessels Boilers Categorization and Pressure V essel imminent and serious risk of identification cards and banners Documentatio n 21/03/2005 NR 13 - Boilers and Pressure Vessels 36 13.1.1 Steam boilers are devices intended to produce and accumulate vapor pressu re above atmospheric, using any energy source, except for the reboilers and simi lar equipment used in process units. 13.6.1 Pressure Vessels are devices that co ntain fluids under pressure internally or externally. 21/03/2005 NR 13 - Boilers and Pressure Vessels 37 1 - The NR should be applied to the following equipment: a) any vessel whose pro duct "PV" higher than 8 (eight) where P is the maximum operating pressure in kPa and "V" its internal geometrical volume in m3 including: - heat exchangers, eva porators and the like - pressure vessels and parts subject to direct flame that are not within the scope of other NR's, or the item 13.1 of NR - Pressure Vessel jacketed, including reboilers and reactors; - autoclaves and boilers, thermal f luid that does not vaporize. b) vessels containing fluid class "A", specified in Annex IV, irrespective of size and product "PV." 21/03/2005 NR 13 - Boilers and Pressure Vessels 38 2 - NR This does not apply to the following equipment: a) transportable cylinder s, vessels for the transport of goods, portable tanks of compressed fluid and fi re extinguishers; b) intended for human occupancy, c) the combustion chamber or

vessel forming part of rotating machinery or alternatives such as pumps, compres sors, turbines, generators, motors, pneumatic and hydraulic cylinders and which can not be characterized as independent devices, d) ducts and pipes for conducti ng fluid, e) heat exchange coils f) tanks and storage containers and storage of fluids not included in design codes and standards relating to pressure vessels; 21/03/2005 NR 13 - Boilers and Pressure Vessels 39 13.1.9 For purposes of this NR, boilers are classified into three categories as follows: a) boiler category "A" are those whose working pressure is less than 19 60kPa (19.98 kgf/cm2), b) boilers category "C" are those whose working pressure is less than or equal to 588 kPa (5.99 kgf/cm2) and the internal volume is equal to or less than 100 liters c) boilers category "B" are all the boilers are not fall into the above categories. 21/03/2005 NR 13 - Boilers and Pressure Vessels 40 21/03/2005 NR 13 - Boilers and Pressure Vessels 41 21/03/2005 NR 13 - Boilers and Pressure Vessels 42 Documentation Medical record Registry Security Installation Project Inspection Reports Project s Alteration or Repair Available for consultation and monitoring 21/03/2005 NR 13 - Boilers and Pressure Vessels 43 Documentation Data Handbook:

Project code and year of publication of materials Specification Procedures manuf acturing drawings and data for monitoring shelf life (inspection plan) Functiona l characteristics of safety devices Data Year Manufacturing Equipment Categoriza

tion NR 13 - Boilers and Pressure Vessels 21/03/2005 44 21/03/2005 NR 13 - Boilers and Pressure Vessels 45 21/03/2005 NR 13 - Boilers and Pressure Vessels 46 Installation Requirements

The "Project of Installation" Boilers and pressure vessels categories I, II and III, with regard to the attendance of NR, is the responsibility of "Qualified Pr ofessional", as mentioned in subclause 13.1.2 and shall comply with those aspect s safety, health and environment provided in the Regulatory Standards, conventio ns and applicable legal provisions. 13.7.7 "Project Setup" must contain at least the floor plan of the establishment, with the positioning and category of each vessel and facility security. Internal standard to 47 suppliers 21/03/2005 NR 13 - Boilers and Pressure Vessels Operating Requirements 13.3.1 Each boiler must have "Operation Manual" updated in English in place of e asy access to operators, containing at least: a) procedures for starting and stopping, b) Procedures and operating parameters of routine c) procedures for emergency situations, d) general safety procedures, health and environmental preservation. 21/03/2005 NR 13 - Boilers and Pressure Vessels 48 Operating Requirements

Pressure vessels categories I and II also must have the operation manual (same r equirements) Schooling minimal (grade 1) specific training (minimum curriculum i n Annex I) Stage supervised practical standard for internal operational areas NR 13 - Boilers and Pressure Vessels 21/03/2005 49 Requirements for Inspection Safety Check: Initial Before the entry into operation at the place of operation Exam internal an d external hydrostatic test Test accumulation boiler criteria defined by PH 21/03/2005 NR 13 - Boilers and Pressure Vessels 50 Requirements for Inspection Safety Check: Periodic Investigations Internal and external hydrostatic test PH respecting the deadlines set 21/03/2005 NR 13 - Boilers and Pressure Vessels 51 Caldeira A, B or CA, B or C (Alkali) A (with annual test of the SV) Special Term 12 months 12 months 24 months 40 months 21/03/2005 NR 13 - Boilers and Pressure Vessels 52 Requirements for Inspection Safety Check: Extraordinary

Criteria defined by

Accident or occurrence affecting the safety or repair major change nactivity Change location Criteria defined by PH 21/03/2005 NR 13 - Boilers and Pressure Vessels 53 Requirements for Inspection Safety Check: Internal and external examinations

After i

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

Hydrostatic Test

Upon PH reports 21/03/2005 NR 13 - Boilers and Pressure Vessels 54 21/03/2005 NR 13 - Boilers and Pressure Vessels 55 21/03/2005 NR 13 - Boilers and Pressure Vessels 56 Requirements for Inspection Inspection of safety valves: Boilers A and B Calibration in the same period of regular monthly Manually operated when there i s a change (reform, operational parameter, MAWP, pipe) Calibration in the same p

eriod of internal examination NR 13 - Boilers and Pressure Vessels Boiler B and C Test accumulation (boilers)

Pressure Vessels 21/03/2005 57 Requirements for Inspection Inspection Report

Data Equipment Inspection Period Description of inspection and testing results f ound ratio of NR's items that are not being met Conclusions 58 21/03/2005 NR 13 - Boilers and Pressure Vessels Requirements for Inspection Inspection Report

Recommendations Inspection Date for Signing of the new inspection PH (CREA) and the inspectors who performed services in the registry Note Security Filing Amend ment right of plate (if necessary) NR 13 - Boilers and Pressure Vessels 21/03/2005 59 Maintenance Requirements Repairs or alterations must follow the code of design alteration or repair proje cts: Prepared preliminary design or approved by PH Determine materials, procedures, q uality control and qualification of

21/03/2005 NR 13 - Boilers and Pressure Vessels 60 6 - Management of care Key controls Computerized management, contemplated in the Asset Management System (Asset Mana gement) Registration Issue equipment Automatic Service Order Control deadlines All speci alties

Guard documentation (and access control) controlled internal standards Audit Doc uments NR 13 - Boilers and Pressure Vessels 21/03/2005 62 Register with Management Special 21/03/2005 NR 13 - Boilers and Pressure Vessels 63 Certification ISO / OHSAS 18001 - Safety Management System and Occupational Health Requires compliance with legal requirements creates a managing risks in the work place 27 firms already certified

SPIE 21/03/2005 NR 13 - Boilers and Pressure Vessels 64 7 - Domain technological Test

Qualified professional in SNQC or ASNT Acceptance criteria for Visual defects, n on-destructive inspection of welded joints Maps (scales) to treat discontinuitie s 21/03/2005 NR 13 - Boilers and Pressure Vessels 66 Non-destructive testing Conventional LP, MP, ME, U.S. eddy current, acoustic emission Phased-array, ACFM, TOFD, Iris Climbing industrial

Unconventional

Advanced 21/03/2005 NR 13 - Boilers and Pressure Vessels 67 21/03/2005 NR 13 - Boilers and Pressure Vessels 68 Inspection Equipment

Directed by inspector of equipment (team of technicians and engineers) as the Pl an of Inspection Notes service to technical and legal requirements Raises the In spection Report and Recommendation Inspection 21/03/2005 NR 13 - Boilers and Pressure Vessels 69

Integrity Evaluation Analysis conducted by engineer specialist multi-disciplinary Global (equipment s tatus) Determines the remaining factor of resistance (to reach the failure criterion) e g boilers with 25 years API RP 579, BS 7920, Fracture Mechanics Eg found broken on the inspection NR 13 - Boilers and Pressure Vessels

Located (fitness for use) 21/03/2005 70 Integrity Evaluation Tension Fracture (avoided by inspection) Defect Tenacity 21/03/2005 NR 13 - Boilers and Pressure Vessels 71 Interesting links Abend (www.abende.org.br) Qualification and certification of inspectors providing certification courses in NDT (ISO 17020) Certification COTEQ SPIE Courses Courses NR 13 - Boilers and Pressure Vessels

IBP (www.ibp.org.br)

ABM (www.abmbrasil.com.br) 21/03/2005 72 8 - Inspection Service itself SPIE

Service's own inspection equipment certified by INMETRO through product certific ation body (IBP) Creates staff training, work patterns and effective minimum acc eptable Advantages: Increase in technology terms NR 13 - Boilers and Pressure Vessels 21/03/2005 74 21/03/2005 NR 13 - Boilers and Pressure Vessels 75 21/03/2005 NR 13 - Boilers and Pressure Vessels 76 9 - Trends Current trends Topics under discussion

Regulations for pipelines Less state interference Elimination of initial inspect ion (for companies certified ISO) Time as Risk Reduction in the use of hydrostat ic test Emphasis on training for operators 78 21/03/2005 NR 13 - Boilers and Pressure Vessels Risk based inspection According to API RP 581 Relative risk (probability x consequence) Sorts the equipment for inspection ( pareto) Prioritize the performance charts Requires knowledge of damage mecha nisms for each component Limited by NR 13 (term) 21/03/2005 NR 13 - Boilers and Pressure Vessels

79 10 - Management in CST Own team Engineering and Maintenance Activities sections: Management Contract Drafting Standards Support with PPC Management Assessment Re port Equipment

Participation of staff of the Operation and Process Control (Electrical and Inst rumentation) NR 13 - Boilers and Pressure Vessels 21/03/2005 81 Team hired Local structure and external engineering Activities: Management of meeting legal requirements Performing inspections and evaluations of maintenance procedures and documentation Definition of extra features 21/03/2005 NR 13 - Boilers and Pressure Vessels 82 Outsourced Services Hiring activities, no responsibilities (co-responsible) internal standards are m andatory (safety, property, health and medicine) Should be transferred and trained quality management NBR ISO 17020 (service prov iders END) SNQC (Abend): certification of NDT Inspectors NR 13 - Boilers and Pressure Vessels

Quality: 21/03/2005 83 Companies providing

Brazil ISQ - Welding and Quality Institute www.isqbrasil.com.br www.sofles.com.br www.proenge.com.br www.mksservices.com.br www.german-engenharia.com.br www.pasa.com.br NR 13 - Boilers and Pressure Vessels

Sofla Engineering

Proenge Engineering

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

German Engineering

PASA 21/03/2005 84 11 - Doubts / questions Contact dmrothen@ebrnet.com.br (27) 3315 8927 (27) 9958 7696 dmrothen@cst.com.br (27) 33 48 2041 21/03/2005 NR 13 - Boilers and Pressure Vessels 86