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

3

COMMISSIONING

boiler and pressure vessel inspectors

through its Commission Examination

CERTIFICATION

Pressure relief device

capacity cert. program

EDUCATING

the general public and

government representatives

on the need for safety

Standards, and tracking

violations

REGISTERING

all manufactured boilers

and pressure vessels

TRAINING

boiler and pressure

vessel inspectors

ASSISTING

in the establishment of

manufacturing,

maintenance and repair

standards for boiler and

pressure vessels

INVESTIGATING

accidents involving boilers

and pressure vessels

The National boardis comprised of

Chief Boiler Inspectorsrepresenting government

Agencies from acrossthe United States & Canada.

National BoardActivities include:

National Board Inspection Code (NBIC) Updates

New format for all Administrative requirementsVR program rules to NB-514R stamp program to NB-415NR program to NB-417

2015 AdditionsPart 1: Installation requirements for Biomass boilers and thermal fluid heaters added

Part 2: Added supplement on Change of ServiceAdded 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

Steam System rebuilt

220 HP

natural gas

steam

generators,

900 psi,

6,000 PPH,

plus

preheater

New feedwatersystem 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 1st 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 TOprogram

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.orgWeb page: www.nationalboard.org