EN_NR-13-Caldeiras-Vasos-de-Pressao-Tubulacoes-e-Tanques-Metalicos-de-Armazenamento.pptx.pdf

Transcript

1. NR 13 - Boilers, Pressure Vessels, Piping, and Metal Storage Tanks This presentation outlines the minimum requirements set forth by Regulatory Standard 13 for the management of structural integrity concerning boilers, pressure vessels, piping, and metal storage tanks. It emphasizes installation, inspection, operation, and maintenance aspects, with the objective of safeguarding the safety and health of workers.
2. Objective of NR 13 Establish Fundamental Criteria NR 13 sets forth minimum standards for the management of the structural integrity of boilers, pressure vessels, pipelines, and metal storage tanks. Emphasize Security It seeks to ensure the safety and health of workers concerning the installation, inspection, operation, and maintenance of this equipment. Employer's Liability The employer is accountable for implementing the measures outlined in this NR, which includes third-party equipment within the establishment.
3. Employer's Liability Primary Responsibility The employer is accountable for implementing the measures outlined in NR 13, thereby ensuring the safety of both equipment and personnel. Third-Party Equipment The employer's liability extends to equipment owned by third parties that is restricted to their premises. Collective Accountability The employer's liability does not absolve the equipment owner of the obligation to adhere to the relevant legal and regulatory requirements.
4. Proprietary Equipment Inspection Service (SPIE) Definition An establishment that possesses its own Equipment Inspection Service (SPIE) is regarded as one whose employer voluntarily acquires the certification outlined in Annex II of NR 13. Benefits Establishments with certified SPIE can prolong the interval between safety inspections, as stipulated in the standard, thereby optimizing resources while ensuring safety. Certification The SPIE certification is a voluntary process that showcases the company's dedication to upholding equipment integrity and ensuring worker safety.
5. Scope of Application of NR 13 Boilers With an operating pressure exceeding 60 kPa (0.61 kgf/cm²) Pressure Vessels For which product P.V exceeds 8, where P represents the maximum pressure in kPa and V denotes the volume in m³. Class A Fluid Containers Regardless of the product's P.V. Pipes Containing Class A or B fluids, linked to boilers or vessels governed by NR. Metal Containers With an external diameter exceeding 3 meters and a capacity surpassing 20,000 liters.
6. Equipment Excluded from NR 13 Coverage Portable Containers Vessels designed for the transportation of goods Portable compressed fluid containers Fire extinguishers Particular Vessels Designed for human habitation Members of the auxiliary systems for machine packages With an internal diameter of under 150mm Constructed from GRP (Glass Reinforced Plastic) Additional Equipment Pipelines and their constituents Heat exchangers, including furnaces and coils Non-code steam generators Instrumentation system tubes Boilers with a capacity of less than 100 liters
7. Inspection Accountability Equipment Excluded The exclusion of certain equipment from NR 13 does not absolve the employer of the responsibility to inspect and maintain it. Technical Accountability Inspections and maintenance should be overseen or conducted by a technical manager, in accordance with the manufacturer's guidelines. Codes and Standards The codes or standards relevant to the equipment must be adhered to, even if they are not explicitly addressed by NR 13.
8. Conditions of Significant and Immediate Threat 1 Operation Without Safety Devices Equipment operating without the safety devices specified in the relevant sub-items of the standard. 2 Inspection Postponement Delay in the periodic safety inspection of boilers, jeopardizing the assessment of their integrity. 3 Device Security Absence or obstruction of safety devices, lacking appropriate technical justification in accordance with codes or formal procedures. 4 Level Regulation Absence or operational unavailability of a water level control mechanism in the boiler. 5 Inadequate Operation Operation of equipment accompanied by an inspection report confirming its operational unsuitability or non- compliance with specified requirements.
9. Postponement of Evaluations Formal Justification Due to circumstances beyond control, with formal justification from the employer. Technical Analysis Accompanied by technical assessments and contingency plans Technical Accountability Prepared by a Licensed Legal Professional (PLH) Maximum Duration Postponement of the anticipated deadline by up to six months.
10. Communication to the Union 1 Mandatory The employer is required to notify the workers' union in the predominant category of the establishment regarding the formal justification for postponing the inspection. 2 Transparency This communication seeks to promote transparency in the postponement process, enabling workers' representatives to understand the technical rationale. 3 Documentation The communication should be formal and encompass all pertinent information required to comprehend the rationale behind the postponement and the contingency measures implemented.
11. Legally Qualified Practitioner (PLH) Definition Professional possessing the legal qualifications to engage in engineering activities pertaining to the equipment governed by NR 13. Voluntary Accreditation The PLH may voluntarily acquire certification of their professional competencies through a Personnel Certification Body (OPC). Responsibilities Technically accountable for the project, overseeing the operation, maintenance, inspection, and supervision of equipment evaluations.
12. Safety Assessment Technical Accountability Executed under the authority of PLH Assessments and Examinations Supported by particular examinations and assessments History Consider the equipment's history. Security Conducted under secure conditions for all participants.
13. Pneumatic or Hydropneumatic Assessments Responsibility The implementation of pneumatic or hydropneumatic tests, when necessary, must be conducted under the technical oversight of PLH. Preliminary authorization Prior approval of the procedures to be implemented is necessary, guaranteeing their safety and efficacy in assessing the equipment. Safety Standards These tests entail particular risks and must be conducted with all requisite safety precautions to safeguard the workers involved.
14. Safety Instruments and Systems Prohibition of Inhibition The inhibition of instruments, controls, and safety systems is strictly prohibited, except in designated circumstances. Documented Exceptions Provisional disqualification is allowed in formal proceedings or with documented justification. Technical Accountability Justification formulated by a technical manager, accompanied by a preceding risk analysis. Employer's Authorization The approval of the employer or appointed representative is necessary.
15. Instrument and System Upkeep Optimal Conditions The instruments, control systems, and safety mechanisms of the equipment governed by NR 13 must be kept in appropriate conditions for operation. Routine Examination They must undergo regular inspections and testing to ensure their proper functionality in emergency situations. Calibration Where applicable, instruments must be calibrated to guarantee measurement accuracy and the proper functioning of safety systems.
16. Equipment Maintenance and Modifications Materials They must adhere to the materials outlined in the building codes and the manufacturer's specifications. Enforcement Protocols Adhere rigorously to established protocols to maintain equipment integrity. Quality assurance Implement control procedures in compliance with relevant codes. Personnel Qualifications Employ qualified and certified personnel for repair operations.
17. Unidentified Building Code Respect for the Original Idea When the building code is unknown, the original design of the equipment must be adhered to, whether it pertains to a boiler, pressure vessel, piping, or metal tank. Control Procedures The control procedures mandated by the relevant codes for this equipment must be implemented to ensure its integrity and safety. Cutting-Edge Technologies At the technical discretion of the PLH, more sophisticated calculation technologies or methodologies may be employed, superseding those stipulated by building codes.
18. Modification or Restoration Initiatives Preliminary Conceptualization Alteration or repair projects must be planned in advance when design conditions are altered or when repairs could jeopardize safety. Project Specifications Projects must be designed or approved by PLH, which will determine materials, execution procedures, quality control, and personnel qualifications. Disclosure Projects must be communicated to the establishment's employees engaged with the equipment, ensuring their awareness of the changes.
19. Interventions Involving Boring or Welding Assessments and Examinations All interventions involving boring or welding on components operating under pressure must undergo examinations or tests for quality control. Specified Parameters The parameters for examinations and tests must be established by PLH, ensuring compliance with the requisite technical specifications. Applicable Regulations Examinations and assessments must adhere to relevant codes or standards, thereby ensuring the integrity of the equipment post-intervention.
20. Safety Inspection Reports 1 Preparation Deadline Safety inspection reports for equipment governed by NR 13 must be completed within 60 days or, in the event of a general maintenance shutdown, within 90 days. 2 Prompt Registration Immediately following the inspection, the operational and safety status of the equipment must be recorded in the safety log. 3 Execution of Recommendations Recommendations resulting from inspections must be documented and executed by the employer, with deadlines established and responsible parties identified.
21. Digital Documentation Digital Format Reports, projects, certificates, and other documents stipulated in NR 13 may be prepared and stored in computerized systems. Information Security Systems must ensure information security, with signatures authenticated by a Certification Authority (CA). Fundamental Prerequisites The requirements for authenticity, integrity, availability, traceability, and irrevocability of information must be guaranteed. Printed Editions In the case of printed safety inspection reports, pages must be numbered to maintain the document's integrity.
22. Access to Documentation Availability Documentation for equipment governed by NR 13 must remain accessible for consultation by various stakeholders within the establishment. Operators Maintenance staff Inspection staff Workers' Representation Access must also be ensured for the representatives of workers and employers on the Internal Accident Prevention Committee (CIPA). CIPA Membership Employee representatives Employer representatives Union Representation The employer is required to provide complete access to documentation for the union representation of the primary professional category within the establishment upon formal request. Upon official request Comprehensive access to documents Transparency in information
23. Incident Reporting 1 Mandatory The employer is required to notify the appropriate regional labor authority and the trade union regarding the predominant professional category involved in serious accidents. 2 Types of Events Leak, fire, or explosion involving equipment governed by NR 13 that leads to fatalities, hospitalization, or significant incidents. 3 Term The communication must be dispatched within the second business day following the incident, including all pertinent information regarding the accident. 4 Union Engagement The employer is required to formally inform the representatives of the workers' union to engage in the accident investigation.
24. Accident Report Components Identification The employer's corporate name, address, location, date, and time of the occurrence facilitate the accurate identification of the event. Description and Victims A comprehensive account of the incident, including the names and roles of the victim(s), offering a thorough overview of the accident. Procedures and Documentation Investigation procedures implemented, a copy of the most recent safety inspection report for the equipment involved, and a copy of the Work Accident Report (CAT).
25. Equipment Certification Mass Production Boilers and pressure vessels that are clearly produced in series must be certified under the Brazilian Conformity Assessment System, when applicable. This certification ensures that mass-produced equipment complies with the minimum safety standards set forth in technical regulations. Compulsory Identification The construction, import, sale, auction, rental, transfer under any title, exhibition, and use of boilers and pressure vessels is prohibited unless the corresponding construction code is indicated in the records and on the identification plate. This requirement seeks to guarantee the traceability and adherence of equipment to relevant safety standards.
26. Boiler Classification Category A Boilers These are classified as having an operating pressure equal to or exceeding 1,960 kPa (19.98 kgf/cm²). Such boilers pose a heightened potential risk and are consequently subject to more rigorous inspection and safety standards. Category B boilers These are classified as having an operating pressure exceeding 60 kPa (0.61 kgf/cm²) and less than 1,960 kPa (19.98 kgf/cm²). While they pose a lower risk than category A boilers, they still necessitate careful consideration concerning safety.
27. Boiler Safety Mechanisms Safety Valve With the opening pressure established at a value equal to or below the Maximum Allowable Working Pressure (PMTA), in compliance with the stipulations of the building code. Pressure Gauge An instrument that displays the accumulated steam pressure, facilitating continuous monitoring of operational conditions. Power Distribution Network Injector or water supply system separate from the primary one, in non-atomized solid fuel boilers or those utilizing suspension firing. Drainage System A dedicated system for the swift drainage of water in alkali recovery boilers, featuring automatic functions triggered by the operator's activation. Level Regulation Automatic water level control system featuring interlocking mechanisms that prevent overheating caused by inadequate power supply.
28. Boiler Identification Identification Plate Every boiler must possess a permanent identification plate affixed to its body in a location that is easily accessible and visible, containing essential information: Manufacturer Name Order number provided by the manufacturer Year of production Maximum permissible working pressure Supplementary Information Regarding the Plate Steam generation capacity Heating surface area Building code and year of issuance In addition to the identification plate, the boiler category along with its identification number or code must be prominently displayed, ensuring ease of identification and traceability.
29. Boiler Documentation Boiler Log Supplied by the manufacturer with technical specifications. Security Log Documentation of events and inspections Projects Installation, alteration, or repair Reports and Certifications Safety evaluation and examination of devices
30. Boiler Record Documentation Technical Specifications Building code and year of issuance Material specifications Procedures employed in manufacturing, assembly, and final inspection Methodology for the establishment of the PMTA Documentation of the execution of the manufacturing hydrostatic test Project Documentation Collection of drawings and additional data essential for monitoring service life Functional attributes Safety device information Year of production Boiler classification
31. Reconstruction of the Medical Record Responsibility In cases where the boiler record is non-existent or lost, it is the employer's responsibility to reconstruct it, with the technical accountability resting with the manufacturer or PLH. Fundamental Components It is imperative to reconstruct the functional characteristics, safety device data, and PMTA calculation memory. Transfer When the boiler is sold or transferred between establishments, the requisite documentation, modification plans, and inspection reports must be included.
32. Security Log Format The safety record must comprise a book with numbered pages, folders, or a computerized system in which significant occurrences will be documented. Significant Events All instances that may affect the safety conditions of the boiler must be documented, including modifications to inspection deadlines. Inspections Initial, periodic, and extraordinary safety inspections must be documented, indicating the operational status of the boiler. Signatures The record must include the clearly legible name and signature of the PLH and the boiler operator present during the inspection.
33. Closure of the Security Record Insufficient Boiler If the boiler is determined to be unsuitable for use, the safety record must clearly and explicitly include this information. Formal Conclusion The safety record must be formally closed, officially documenting that the equipment is no longer suitable for operation. Documentation This closure acts as essential documentation to avert the inadvertent reactivation of the equipment.
34. Boiler Installation Project Accountability The authorship of the boiler installation project rests with PLH, which must adhere to the safety, health, and environmental considerations outlined in the relevant standards. Particular Location The boilers of any establishment must be installed in a designated location known as a boiler house or boiler area. Installation Prerequisites Depending on whether the boiler is situated in an open or closed environment, specific requirements must be fulfilled to ensure safety.
35. Requirements for Open-Air Boilers Removal Maintain a distance of at least three meters from other facilities, fuel depots, third-party property boundaries, and public roads. Exits Ensure there are a minimum of two wide exits that remain permanently unobstructed, clearly signposted, and situated in different directions. Access Ensure convenient and secure access, essential for boiler operation and maintenance, accompanied by appropriate guardrails. Gas Capture Implement a system for the capture and release of gases and particulate matter from combustion outside the operational area. Lighting Ensure that lighting complies with current official standards and implement an emergency lighting system for nighttime operations.
36. Boiler House Specifications Construction and Site A standalone structure, built from fire-resistant materials. May have only one wall adjoining other installations. Other walls should be at least three meters away from adjacent installations. Elimination of fuel deposits, with the exception of departure tanks. Security and Access Control A minimum of two broad, unobstructed exits in distinct directions. Permanent ventilation featuring unobstructed air inlets Gas leak detection sensor (for gas- fired boilers) Exclusive use, no alternative purposes Infrastructure Convenient and secure access for operation and maintenance Gas and particulate matter capture and release mechanism Lighting in accordance with official standards Emergency lighting system
37. Alternative Installation Initiative Impossibility of Service When the establishment is unable to fulfill the requirements for installation in either an open or closed environment, an alternative installation project must be developed. Supplementary Measures The project must incorporate supplementary safety measures that facilitate risk mitigation, thereby ensuring worker safety even in suboptimal conditions. Previous Correspondence The employer is required to inform the union representation of the establishment's primary professional category in advance regarding the alternative project.
38. Control Room for Category A Boilers Instrument Cluster Boilers categorized as A must be equipped with an instrument panel located in a separate control room. Appropriate Construction The control room must be constructed in compliance with the relevant regulatory standards to ensure the safety of operators. Protection This requirement seeks to safeguard operators in the event of boiler accidents by facilitating remote monitoring and control.
39. Boiler Operating Manual Availability Every boiler must possess an updated operating manual in Portuguese, situated in a location readily accessible to operators. Minimum Content The manual must include start-up and shutdown procedures, routine operating protocols and parameters, emergency situation procedures, and general safety guidelines. Importance The manual is crucial for ensuring the safe operation of the boiler, offering clear guidance for both normal and emergency scenarios.
40. Water Quality Management Significance of Regulation Water quality must be monitored and treatments applied as necessary to ensure safe and efficient boiler operation. Insufficient water can lead to corrosion, scale accumulation, and various issues that undermine the integrity of the equipment and its energy efficiency. Compatibility The treatments are designed to align the physical-chemical properties of the water with the operating parameters of the boiler as specified by the manufacturer. Each type of boiler may have particular requirements concerning water quality that must be meticulously adhered to in order to ensure its longevity.
41. Boiler Technician Mandatory Every boiler must be operated and managed by a qualified boiler operator to ensure the safe functioning of the equipment. Qualification A boiler operator is defined as an individual who adheres to the stipulations outlined in item 1.1 of Annex I of NR 13, which delineates the training and qualification criteria. Responsibility The operator is tasked with continuously monitoring the boiler's operational conditions, detecting anomalies, and implementing corrective measures as needed.
42. Types of Boiler Safety Assessments Preliminary Assessment Conducted on new boilers prior to commissioning. 1 Periodic Examination Conducted at regular intervals based on boiler classification. Exceptional Examination Produced in particular circumstances, such as accidents or significant repairs.
43. Preliminary Safety Assessment Moment of Epiphany The preliminary safety inspection must be conducted on new boilers prior to their commissioning at the final installation location. Internal Assessment Includes an examination of the boiler's internal conditions and the identification of potential manufacturing or assembly defects. External Assessment Evaluates the external conditions of the equipment, encompassing connections, instruments, and safety devices. Pressure Assessment Evaluates the structural integrity of the boiler under pressure, confirming the absence of leaks or unacceptable deformations.
44. Hydrostatic Testing of Boilers Compulsory Production Boilers are required to undergo Hydrostatic Testing (TH) during the manufacturing phase, with verification provided by a report signed by PLH. Insufficient Evidence In the absence of documentary evidence, for boilers manufactured or imported after May 2, 2014, the TH must be conducted during the initial safety inspection. Aged Boilers For boilers that were operational prior to May 2, 2014, the implementation of the TH is at the technical discretion of the PLH and, if required, must be carried out before the subsequent internal periodic inspection.
45. Deadlines for Periodic Safety Evaluations 12 Months Maximum duration for boilers of categories A and B 18 Months For alkali recovery boilers of any classification 24 Months For category A boilers, valve testing is conducted every 12 months. 30 Months For category B boilers equipped with a combustion management system
46. Extended Deadlines for Entities with SPIE Boiler Classification Maximum Duration Alkali recovery boilers 24 months Category B boilers 24 months Category A boilers 30 months Category A boilers equipped with a Safety Instrumented System (SIS) 48 months
47. Integrity Evaluation at 25 Years Assessment Duration After a maximum of twenty-five years of use, boilers must undergo a more thorough integrity assessment during their subsequent inspection. Methodology The evaluation must be conducted in compliance with relevant codes or standards, employing sophisticated inspection and analysis methodologies. Aim Assess the remaining useful life of the boiler and set new maximum inspection deadlines, provided it remains in operational condition.
48. Safety Valve Examination 1 Standard Duration Boiler safety valves must be disassembled, inspected, and tested within a timeframe suitable for their maintenance, but not exceeding the duration stipulated for the periodic safety inspection of boilers. 2 Extraordinary Circumstances In exceptional circumstances, appropriately justified by PLH, safety valves may be tested in the field at a frequency consistent with the operational history. 3 Category B Boilers Safety valves installed in category B boilers must undergo periodic testing, at a minimum frequency of once a month for boilers lacking water treatment, or in accordance with the manufacturer's specifications for boilers utilizing treated water.
49. Accumulation Assessments Applicability In addition to routine testing, safety valves installed in boilers may undergo accumulation tests at the technical discretion of the PLH. Aim Accumulation tests confirm that the safety valves can effectively relieve pressure during instances of excessive accumulation, thereby safeguarding the boiler from overpressure. Importance These tests are crucial to guarantee that the safety valves operate effectively in critical situations, thereby averting serious accidents.
50. Exceptional Security Assessment 1 Accidental Damage Whenever the boiler is inadvertently damaged or subjected to any event that may jeopardize its safety, it necessitates immediate inspection. 2 Modifications or Restorations When the boiler experiences significant modifications or repairs that may affect its safety conditions, an evaluation is necessary before it can resume operation. 3 Extended Inactivity Before the boiler is returned to operation, following a period of inactivity exceeding six months, it is essential to inspect for any potential deterioration that may have occurred during this time. 4 Change of Venue When relocating the boiler installation, it is essential to ensure that the new setup complies with safety regulations.
51. Communication to the Union Regarding Inspections Information Deadline The employer is required to notify the union representation of the primary professional category of the establishment, upon formal request, within a maximum timeframe of 30 days following the completion of the periodic safety inspection regarding the operational status of the boiler. Report Submission Upon receiving a formal request, the employer is required to provide a copy of the inspection report to the union representative within a maximum of 10 days following its preparation. Standard Shipping The union representation may request that the employer provide, on a regular basis, a copy of the boiler safety inspection report within thirty days of its completion.
52. Inspection Report Components Identification Nameplate information, boiler classification and type, facilitating accurate identification. Inspection Conducted Type of inspection conducted, start and end dates, description of inspections, evaluations, and tests carried out. Records Photographic documentation of the internal inspection of the boiler, visually capturing the observed conditions. Outcomes and Suggestions Inspection results, recommendations, necessary actions, and a definitive assessment of integrity until the subsequent inspection. Responsibility Name, signature, and professional registration of the PLH and participating technicians, along with valve testing certificates.
53. Data Revision Modifications to Project Information Whenever the inspection results necessitate modifications to the design data, the identification plate and the documentation in the record must be revised. Significance of Revision The update guarantees that the information regarding the equipment accurately represents its current conditions, which is crucial for safe operation and maintenance. Responsibility The responsibility for the update lies with the employer, who will receive technical guidance from the PLH that conducted the inspection and identified the required modifications.
54. Pressure Vessel Classification Fluid Classification Risk Potential Collective Category A (Combustible, hazardous liquids, etc.) 1 (P.V > 100) I B (Flammable, hazardous liquids) 2 (P.V < 100 and P.V > 30) II C (Water vapor, asphyxiating gases) 3 (P.V < 30 and P.V > 2.5) III D (Additional fluids) 4 (P.V < 2.5 and P.V > 1) IV - 5 (P.V < 1) In
55. Fluid Classification Class A Combustible liquids Combustible liquids with a temperature of 200ºC or higher Toxic substances with a tolerance threshold of ≤ 20 ppm Hydrogen Acetylene Class B Combustible liquids with a temperature below 200ºC Toxic substances with a tolerance threshold exceeding 20 ppm Class C Water vapor Simple asphyxiants Compressed air Class D Other fluids not categorized in the preceding classifications Mixtures When addressing mixing processes, it is essential to consider the fluid that poses the highest risk to both workers and facilities.
56. Risk Potential Categories 1 Group One P.V > 100 2 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
57. Safety Mechanisms for Pressure Vessels Safety Valve Or another device with an opening pressure calibrated to a value equal to or lower than the PMTA, installed directly on the vessel or within the encompassing system. Vacuum Safeguard Vessels exposed to vacuum conditions must be fitted with safety devices or alternative measures specified in the design for this scenario. Blockage Prevention Strategies Measures to avert the unintentional blocking of security devices, encompassing administrative controls or Anti-Inadvertent Blocking Devices (DCBI). Pressure Gauge An instrument that measures the operating pressure, installed directly on the vessel or within the system it encompasses.
58. Intrinsically Safe Systems Definition These systems are designed and maintained in compliance with the relevant building code, incorporating protections that are intrinsic to their design. Device Distribution They may forgo safety valves or vacuum protection devices, contingent upon a technical assessment provided by PLH. Technical Assessment The exemption must be grounded in a thorough technical analysis demonstrating that the system possesses protections that are equivalent to or exceed those of conventional systems.
59. Pressure Vessel Designation Identification Plate Every pressure vessel must be equipped with a permanent identification plate affixed to its body in a location that is easily accessible and visible, containing essential information: Manufacturer Identification Number Year of production Technical Specifications Maximum permissible working pressure Building code and year of issuance In addition to the identification plate, the vessel's category and its identification number or code must be prominently displayed, enhancing its identification and traceability.
60. Pressure Vessel Documentation Medical documentation Provided by the manufacturer with comprehensive technical specifications. 1 Security Log Documentation of events and inspections conducted Projects Of modification or restoration when executed 3 Reports and Certifications Safety evaluation and examination of devices 4