National Board Update Presentation to the Valve Repair Council June 2, 2016 Prepared by: Joseph F. Ball, P.E.
National Board Update National Board activities Who we are and what we do National Board Inspection Code (NBIC) Updates National Board Test Lab updates New Certified Testing Organization (TO) program
National Board Activities CERTIFICATION Pressure relief device capacity cert. program COMMISSIONING boiler and pressure vessel inspectors through its Commission Examination TRAINING boiler and pressure vessel inspectors EDUCATING the general public and government representatives on the need for safety Standards, and tracking violations The National board is comprised of Chief Boiler Inspectors representing government Agencies from across the United States & Canada. National Board Activities include: ASSISTING in the establishment of manufacturing, maintenance and repair standards for boiler and pressure vessels REGISTERING all manufactured boilers and pressure vessels INVESTIGATING accidents involving boilers and pressure vessels 3
National Board Inspection Code (NBIC) Updates New format for all Administrative requirements VR program rules to NB-514 R stamp program to NB-415 NR program to NB-417 2015 Additions Part 1: Installation requirements for Biomass boilers and thermal fluid heaters added Part 2: Added supplement on Change of Service Added supplement on Inspection of high pressure vessels includes AE testing procedures
NBIC Updates (cont.) 2015 Additions Part 3 NR program updated repairs broken into three categories 1. Repairs prior to fuel loading 2. Systems under ASME Section XI (after fuel loading) 3. Items constructed to standards other than ASME Updated NBIC repair welding procedures Added Welding Method 6 for Grade 91 material
NBIC Ongoing Activities Preparation of NBIC Part 4 for Pressure Relief Devices Merges installation, inspection and repair requirements NBIC pressure relief initiatives Repair of tank vents Repair of pin devices Shelf life concerns for PRV s
Testing Laboratory Updates
Gas Supply Changed 6000 gallon liquid N2 storage vessel with pumps and vaporizer
Additional Gas storage with 6 new 4000 psig storage bottles approx. 70,000 SCFM additional capacity
1350 psig test system added (N2) in 3000 sq. ft. addition
High pressure air test system revised, rated at 2500 psi
220 HP natural gas steam generators, 900 psi, 6,000 PPH, plus preheater Steam System rebuilt
New feedwater system Feed water storage and D/A tank
Updated controls and DAQ system
NATIONAL BOARD TEST ORGANIZATION PROGRAM
Test Organization Program Authorized in Feb. 2016 by National Board Board of Trustees Implements certification program for organizations that only perform In-Service testing of pressure relief valves Structure similar to VR program
Test Organization Program Formal program for Test Only process Development Goals Act as aid to Jurisdictions (Ref. Part 3 Supplement S7.10) Elevate standards and improve practices for the PRV testing process
Scope Program scope: certifies testing organizations who perform testing of in-service PRV s Provides specific qualification to make adjustments per NBIC Part 2, paragraph 2.5.7(g)
NBIC Part 2, par. 2.5.7 g) If a pressure test indicates the valve does not open within the requirements of the original code of construction, but otherwise is in acceptable condition, minor adjustments (defined as no more than twice the permitted set pressure tolerance) shall be made by an organization accredited by the National Board to reset the valve to the correct opening pressure. All adjustments shall be resealed with a seal identifying the responsible organization and a tag shall be installed identifying the organization and the date of the adjustment.
Program Details Quality program manual for testing process required Quality program needs to address in-service inspection Valve in good condition No broken or damaged parts Not leaking Seal(s) intact Test equipment must meet NBIC requirements Test vessel REQUIRED
Program Details Inspection and test to be documented on test report Test report to have unique identifier (test no.) TO symbol marked nameplate to be applied to valve that passes test Nameplate includes: Company name Test date Test number TO symbol Set Pressure
Program Details Valves that fail inspection or test (including leakage, outside of adjustment tolerance, or broken or missing seal) shall be repaired by a VR holder or be replaced.
TO sample test report ABC Test Company Inspection and Test Checklist for Pressure Relief Valves 1. Test Number 2. Customer Name 3. Address 4. Valve Type 5. Manufacturer 6. Set pressure 7. Size/ connection x 8. Serial Number 9.Capacity/ units 10. ASME/ NB/ VR Stamps: V UV NB VR 11. Last repair/ Date by Job. No. 12. Last test/ Date by Test No. Received by: Date Inspection Acceptable/ Action Req d 1. Set pressure seal intact Yes No 2. Adjusting ring(s) seal intact Yes N/A No 3. Seals match mfg. /repair/ test nameplate Yes No 4. Inspection and test done with valve: Removed Installed 5. Valve Condition: Clean Dirty Missing or damaged parts 6. Evidence valve is leaking No Yes 7. Evidence of rust or corrosion No Yes 8. Body drain open Yes No 9. Test gag found No Yes 10. Bonnet vented for bellows Yes N/A No 11. Drain pipe open Yes No 12. Binding of inlet or outlet piping No Yes 13. Discharge pipe support OK Yes No Inspected by: Date Test Data 1. Set Pressure Definition: Pop Aud. Disch. Bubble 1 st Steady Str. 2. Test method: Pop test Lift assist device 3. Test Fluid: Steam Air Water 4. Test Stand ID No. 5. Measured set press.: 1 2 3 Tolerance:+/- Set pressure: Acceptable: Requires Adjustment Not acceptable 6. Final set press. after adjustment Tested by: 7. Seat leakage test method: API-527 Audible Visual Other 8. Seat Leakage result: Acceptable: Not acceptable 9. Seal applied/ identification: Yes ID No adj. made By 10: M&TE Serial Nos. 11: TO Nameplate applied: Yes No By: Date Remarks:
TO Sample Nameplate TO symbol is registered certification trademark TO organization can pre-apply mark to test plate Tested By: ABC Test Co. Test Date 7-15-16 Test No. A12345-1 Set Pressure 500 psig
Application process Application form submitted NB Representative conducts shop review Evaluates written description of Quality System (QC Manual) Verifies implementation of Quality System Observes tests of demonstration valves Demonstration valves submitted for verification testing of set pressure at NBBI-accepted lab
Comparison of TO to VR program VR program Can test and adjust valves Can change set pressure VR symbol applied only to valves that meet all repair requirements Can perform repair processes: machining, welding, NDE Can perform fluid changes or conversion TO program Can test and adjust valves Can restore original set pressure only TO symbol applied only to valves that pass test Cannot perform repairs Cannot perform fluid changes or conversion
Affect on VR Holders VR holder can get TO certification with application and QC manual update only (no application charge or additional test required) When needed, repairs must be done by VR holder Repairs cannot be performed under the TO program
Value of TO Certification? Benefits for test company User are confident of test organization s quality due to independent audit and comparison tests Differentiate company from non-certified organizations reduce user s need to perform audits Help with liability concerns by complying with National Standard
Value of TO Certification? Benefit to User organizations Provides confidence in the suppliers test data, lessens need for vendor audit Help document safety equipment in uniform fashion Help in meeting Jurisdictional/ Inspection Agency / Insurance carrier requirements
More Information NB-528 program document and application form to be added to National Board web page VR Course material being updated
Thank You for Having the National Board Here! Recognizing our shared objective: To promote safety through proper repair and rebuild Contact Info: Ph: 614-888-8320 E-mail: jball@nationalboard.org Web page: www.nationalboard.org