TITLE:

ES&H Manual

 

DOCUMENT ID:

6151 Pressure and Vacuum Systems

Safety Program

 

NOTICE:

This document is currently under review.  All requirements outlined within this document apply to current laboratory operations until new content is approved, released, and published.

 

1.0            Purpose

 

The pressure systems program at Jefferson Lab ensures pressure systems safety by establishing:

 

·         Requirements for the design, fabrication, testing, inspection, maintenance, repair and operation of pressure systems.

·         A Pressure Systems Committee

·         Formalized documentation for each pressure system.

·         A quality control system for the fabrication of pressure system components.

·         Training and qualification procedures for operators of pressure systems.

 

Pressure vessel requirements

For design, fabrication, testing, repair, modification and inspection are based on the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section VIII, Rules for Construction of Pressure Vessels. 

 

Piping system requirements

For design, fabrication, testing repair, modification and inspection are based on the ASME Code for Pressure Piping, B31.  ASME Code B31.3, Process Piping, shall be the primary code of reference for Jefferson Lab piping systems.  Other sections of B31 are applied as appropriate based on sound judgment of the Design Authority and proven practices in the respective field.

 

Examples of pressure systems used at Jefferson Lab include:

·         Cryomodules, which include both pressure and vacuum systems

·         Experimental equipment with vacuum chambers above 15 psi

·         Small experiment-target vessels and piping confining pressures above 15 psi

·         Superconducting magnets, which include both pressure and vacuum systems

·         Oil-removal and gas-storage systems integral to the cryogenic plants

·         Compressed-air and pressurized air reservoirs above 15 psi

·         Heating and cooling water systems throughout the site

 

Table 1: Required Safety Training by Job Classification

Training Course

Pressure or Vacuum System Operator/Repair

Design Authority

Operate or Repair Pressure or Vacuum Systems

SAF130A

X

 

Design Authority

SAF130B

 

X

 

2.0            Scope

 

This chapter and its technical appendices provide the specific requirements of the pressure system program at Jefferson Lab.  The scope of this chapter and its technical appendices cover any new construction of a pressure system or inspection, repair, or modification of an existing system.  A pressure system is defined as a connected set of piping, piping components and/or pressure vessel(s) used to either convey or contain a fluid under pressure above 0 psig.  Pressure sources, fittings, pressure relief devices and associated hardware such as gages and regulators are also integral parts of the pressure system.  A system may be considered a non-pressure system and not included in the scope of this ES&H Manual chapter if all of the following hold:

 

·         The system pressure is less than 15 psig

·         The fluids contained in the system are nonflammable, nontoxic, and not damaging to human tissue, as defined by ASME B31.3 Paragraph 300.2

·         The system design temperature is within the range -20°F and 366°F.

 

Vacuum systems which cannot be protected against pressurization exceeding 15 psig from all credible pressure sources are considered pressure systems and are therefore subject to the requirements of this chapter and the ASME codes or the equivalency measures listed above.  For vacuum systems that are protected against pressurization above 15 psig but do pose some personnel or economic risk, ES&H Manual Chapter 6151 Appendix T5 Requirements for Vacuum Systems provides requirements for the design and testing of vacuum systems that are not subject to the full rigor of design, fabrication, testing and documentation identified for pressure systems.

 

ES&H Manual Chapter 6150 Compressed Gases, ES&H Manual Chapter 6540 Oxygen Deficiency Hazard Control Program, and ES&H Manual Chapter 6550 Cryogenic Safety Program are to be referenced for additional requirements for specific uses.

 

Users/experimenters planning to incorporate pressure or vacuum systems in a physics experiment must also comply with ES&H Manual Chapter 3120 The CEBAF Experiment Review Process and its appendices or FEL users must comply with ES&H Manual Chapter 3130 FEL Experiment Safety Review Process and its appendices.  Although all the provisions of the present chapter apply, users/experimenters must address them within the larger context of the experiment review process.

 

Additionally, the following pressure systems are specifically excluded from this chapter:

 

·         Department of Transportation (DOT) regulated cylinders and dewars.

·         Roof and floor drains, plumbing, and sewers.

·         Piping for hydraulic or pneumatic hand tools and their components downstream of the first block or stop valve off the system distribution header.

·         Piping internal to instruments (not instrument piping).

·         Fire protection systems constructed in compliance with recognized fire protection engineering standards and adhering to the provisions set forth in ES&H Manual Chapter 6900 Fire Protection Program Summary.

 

3.0            Responsibilities

 

3.1              ESH&Q Division:

·         Shall perform a final system walk-through and verify that documentation of the pressure system is complete before operation of that pressure system.

·         Shall manage the site-wide Jefferson Lab Welding and Brazing Program included in ES&H Manual Welding and Brazing Program Supplement.

·         Shall support, oversee and/or supervise, as needed, the code inspector.

·         Shall provide inspection as required by ASME codes or by engineering requirements.

·         Monitor current requirements and certifications necessary for examination and inspection personnel.

·         Shall provide access to ES&H Manual, procedures and forms.

·         Shall provide periodic assessment of processes and documentation.

 

3.2              Division Head

·         Shall designate Design Authorities qualified per the requirements of this chapter.

·         Shall verify that all groups within their division have a program in accordance with ES&H Manual Welding and Brazing Program Supplement.

·         Shall verify that all recordkeeping requirements for pressure systems are in compliance with this chapter.

 

3.3              Design Authority

·         Shall ensure that pressure system design, fabrication and testing meets ASME code requirements according to the policy set forth in this chapter.  The Design Authority shall employ, as required, the expertise available through other Design Authorities, the ESH&Q-provided code inspector, the Jefferson Lab Welding Committee and the Pressure Systems Committee as well as the experience and lessons learned documented in the Pressure Systems project files database.

·         Where established codes cannot be directly applied because of pressure range, vessel geometry, use of special material, etc., measures to provide equivalent protection and ensure a level of safety greater than or equal to the level of protection afforded by the ASME codes shall be applied.

·         Shall follow standards and procedures for mechanical design, fabrication and testing of pressure systems using the Pressure System Design, Pressure System Pressure Testing, and Pressure System Project Implementation and Documentation Requirements Appendices as outlined in this chapter.

·         Shall follow standards and procedures for design, fabrication and examination of welds and brazes for pressure systems specified in ES&H Manual Welding and Brazing Program Supplement.

·         Shall initiate and maintain pressure system documentation in a project file consistent with the requirements specified in ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements.

3.4              Pressure System and Vacuum System Owner

·         Shall maintain required training.

·         Shall ensure that systems under their purview are maintained and operated by trained personnel. This training shall include understanding of procedures.

·         Shall ensure that pressure vessels, pressure systems and relief devices installed on systems under their purview are tested and inspected.

·         Shall ensure that systems under their purview continue to be maintained and operated in a safe manner. Standard work planning tools (i.e. THA, ATLis, TOSP, etc.) shall be employed that describe any required system configuration and preparation prior to and following maintenance activities. 

                                                 

3.5              Pressure System and Vacuum System Technician 

·         Shall maintain required training.

·         Shall fabricate, install, test, operated, maintain and modify pressure and vacuum systems at the direction of the system owner and/or Design Authority. 

 

3.6              Pressure Systems Committee Chair

·         Shall brief the Directors Safety Council (DSC) periodically on committee activities.

·         Shall ensure that the Pressure Systems Committee meets periodically to:

o   Recommend requirements, standards, and procedures for systems designed to use, confine, or distribute pressurized media.

o   Review written deviation requests to approve or decline approval of the proposed design.

o   Document decisions and variances considered by the committee.

o   Brief the Directors Safety Council (DSC) periodically on committee activities.

 

3.7              Manager, Facilities Management and Logistics

·         Shall maintain required inspection and report documentation for all pressure vessels.

 

3.8              Chief Information Officer

·         Shall maintain a centralized database for the collection of all pressure systems records to include, at a minimum, design documentation, fabrication documentation and pressure test standards and procedures.

·         Shall assist Design Authority and quality assurance, fabrication, purchasing and facilities personnel with implementation of documentation control for pressure systems.

 

3.9              Everyone at Jefferson Lab:

·         Shall refer pressure system matters to the responsible Design Authority or the Pressure Systems Committee.

·         Before adding, moving, or modifying pressure systems associated with the normal physical plant—such as HVAC equipment, boilers, etc., shall consult the Maintenance Services Manager.

·         Shall inform the appropriate Design Authority, Pressure Systems Committee, or Division Head if you know or suspect that:

o   a pressure system planned for use on site does not conform to the intent of the ASME codes, or

o   a vessel, piping system or associated equipment such as a pressure-relief device, is unsafe.

 

4.0            Qualifications

 

4.1              Design Authorities must demonstrate ability to design and construct pressure systems according to the applicable ASME codes.  The qualifications and experience required of the Design Authority shall depend on the complexity and criticality of the pressure system and the nature of the individual’s experience.  All Design Authorities shall be trained in the application of this policy/procedure (ES&H Manual Chapter 6151 and its Technical Appendices) and ES&H Manual Welding and Brazing Program Supplement.  Jefferson Lab’s Engineering Manager approval is required if the individual does not meet at least one of the following criteria:

·         Completion of an engineering or physics degree, requiring four or more years of full-time study, plus a minimum of five years experience in the design of related pressure vessels or piping.

·         Professional Engineering registration, recognized by the local jurisdiction, and experience in the design of related pressure vessels or piping.

 

4.2              Welders and Brazers must maintain qualifications for the types of fabrication associated with pressure system construction.  For Class A and B welds and brazes (see ES&H Manual Welding and Brazing Program Supplement for definitions) qualifications for pressure systems are given in Articles III and XIII of the ASME BPV Code, Section IX.  Similar rules given in American Welding Society (AWS) construction codes may also apply provided they are the same or stricter than the ASME requirements or where the ASME requirements are not applicable.  For piping systems, ASME B31 Codes provide modified requirements that take precedence over ASME BPV Code Section IX.

 

4.3              Inspectors must meet the following qualifications:

·         For pressure systems fabricated and used at Jefferson Lab, the Inspector shall be designated by Jefferson Lab and shall be an employee of Jefferson Lab, an employee of an engineering or scientific organization, or of a recognized insurance or inspection company acting as Jefferson Lab’s agent.  For Jefferson Lab pressure systems fabricated by others, the Inspector must be independent of the manufacturing function.

·         For pressure vessels built by Jefferson Lab but used elsewhere, this person must be an Authorized Inspector who must be regularly employed by an ASME accredited Authorized Inspection Agency, i.e., the inspection organization of the Commonwealth of Virginia, or an insurance company authorized to write boiler and pressure vessel insurance.

·         The Inspector shall have not less than 10 years experience in the design, fabrication, or inspection of industrial pressure systems.  Each 20% of satisfactorily completed work toward an engineering degree recognized by the Accreditation Board for Engineering and Technology shall be considered equivalent to one year of experience, up to five years total.

·         In delegating performance of inspection, the Inspector is responsible for determining that a person to whom an inspection function is delegated is qualified to perform that function.

 

4.4              Examiners must have training and experience commensurate with the needs of the specific examinations.  ASNT Recommended Practice No. SNT-TC-1A is a required ASME BPV guideline for qualifying and certifying NDE personnel.

 

4.5              Operators of pressure, vacuum, and process piping systems must have hazard awareness training that includes basic principles of pressure technology and pressure safety.  Operators shall also be given on-the-job training that is system specific, focusing on the expected performance of the system, direction for noticed deviations from expected performance, and clearly defined operating procedures for the system.

 

5.0            Expectations and Process Steps

 

Jefferson Lab has safety policies and procedures that ensure all pressure systems are designed, fabricated, tested, inspected, maintained, repaired, and operated by trained and qualified personnel in accordance with applicable and sound engineering principles. 

 

Jefferson Lab further verifies that all new pressure systems designed and fabricated following the effectivity date of the original revision of this chapter (2/28/08) shall conform to the applicable:

·         ASME BPV Code, Sections I through XII including applicable code cases;

·         ASME B31 Code for Pressure Piping; and

·         To the strictest applicable state and local codes.

 

For new pressure systems where these ASME codes cannot be directly applied because of pressure range, vessel geometry, use of special material, etc., Jefferson Lab shall implement measures to provide equivalent protection and ensure a level of safety greater than or equal to the level of protection afforded by the ASME codes.  Measures shall include:

·         Design drawings, sketches, and calculations must be reviewed and approved by a qualified independent design professional or a documented Peer Review.

·         Qualified personnel shall be used to perform examinations and inspections of materials, in-process fabrications, non-destructive tests, and acceptance test.

·         Documentation, traceability, and accountability shall be maintained for each unique pressure vessel or system, including descriptions of design, pressure conditions, testing, inspection, operation, repair, and maintenance.

 

Vacuum systems which cannot be protected against pressurization exceeding 15 psig from all credible pressure sources are considered pressure systems and are therefore subject to the requirements of this chapter and the ASME codes or the equivalency measures listed above.  For vacuum systems that are protected against pressurization above 15 psig but do pose some personnel or economic risk, ES&H Manual Chapter 6151 Appendix T5 Requirements for Vacuum Systems provides requirements for the design and testing of vacuum systems that are not subject to the full rigor of design, fabrication, testing and documentation identified for pressure systems.

 

For pressure vessels where ASME Codes can be directly applied: pressure vessels required for conventional purposes and pressure vessels required in support of physics experiments shall be procured from and stamped by a company authorized to use the ASME “U” or “UM” Stamp to construct ASME Section VIII Pressure Vessels.  Pressure vessels that cannot be stamped because of pressure range, vessel geometry, special material, etc that have not been considered by the ASME codes shall be fabricated at Jefferson Lab or off-site with measures ensuring equivalent protection afforded by the ASME codes.

 

The pressure systems of the normal physical plant, including unfired and fired pressure vessels such as HVAC equipment and boilers, are maintained under the supervision of the Facilities Management and Logistics Manager.  No addition, movement, or modification of any such vessel or piping system is to be made without consulting with the manager.

 

ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements provides requirements for design, fabrication and installation of a pressure system at Jefferson Lab.  Figure 1, Pressure Systems Project Flow Chart provides a pictorial representation of the suggested pressure system process flow and points the reader to the applicable Technical Appendix for each step of the process.

 

Figure 1. Pressure Systems Project Flow Chart

 

5.1              Identifying a Pressure System

 

Step 1:             Determine whether a proposed system of piping, vessels or combination of both fits the definition of pressure system provided in this chapter.  If the design is a pressure system then the requirements included in this chapter and its appendices apply.

 

If the proposed system is excluded by the definition, the specific requirements of this chapter and its appendices do not apply.  In this case, the Design Authority or responsible engineer/designer shall apply sound engineering practices which shall include the requirements in ES&H Manual Welding and Brazing Program Supplement.

 

If the proposed system is a vacuum system, use ES&H Manual Chapter 6151 Appendix T5 Requirements for Vacuum Systems to determine the category applicable to the vacuum system and the appropriate actions required.  Category III vacuum systems are designated as pressure systems and as such the requirements included in this chapter and its appendices apply.  Requirements for Category I and II vacuum systems are provided in ES&H Manual Chapter 6151 Appendix T5 Requirements for Vacuum Systems.

 

Step 2:             Initiate a project documentation folder, project identification number and a project checklist according to the requirements provided in ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements.

 

Step 3:             Identify the ASME codes that apply to the different components of the pressure system and whether those codes can be applied directly (i.e. stamped ASME BPV vessel or B31.X compliant) or whether equivalent measures apply.  ES&H Manual Chapter 6151 Appendix T2 Pressure Systems Design Program provides guidance in ASME code application.  A Peer Review is required at this point if equivalent measures are to be invoked.  Documentation of the applicable ASME codes/equivalent measures shall be included in the project folder.

 

5.2              Designing a Pressure System

Pressure systems must be designed using sound engineering practices to satisfy the needs of Jefferson Lab.  The design must be evaluated using the guidance provided in the ASME BPV and B31 Piping Codes.  ES&H Manual Chapter 6151 Appendix T2 Pressure Systems Design Program provides requirements and guidance in designing pressure systems.  Design Authorities planning or designing pressure systems must perform the following steps:

 

Step 1:             Complete design calculations, drawings and specifications per the applicable Codes.  The Design Authority shall determine weld/braze classifications (see ES&H Manual Welding and Brazing Program Supplement) and include those classifications on design drawings or sketches.  If ASME codes cannot be directly applied because of pressure range, vessel geometry, use of special material, etc., the Design Authority must ensure a level of safety greater than or equal to the level of protection afforded by the ASME codes.  Components of pressure systems such as thin windows call for additional controls to verify safety.  Special requirements for thin window design are given in ES&H Manual Chapter 6151 Appendix T3 Safety Requirements for Thin Window Design.

 

Step 2:             Conduct required Peer Reviews and, if appropriate, design reviews.

 

Step 3:             Include pressure system design documentation such as design criteria, applicable ASME codes, calculations, drawings, specifications, references, parts lists, etc. in the project folder.  Required design documentation is presented in ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements.

 

5.3              Acquiring an Off-Site Manufactured Pressure System

The Design Authority shall verify that off-site manufactured pressure systems and pressure components comply with the design documentation and meet applicable quality assurance requirements by following these steps:

 

Step 1:             Determine the quality assurance requirements and the applicable ASME code requirements prior to acquiring a manufactured pressure system or pressure system component.  Consult the Quality Assurance Representative for assistance.

 

Step 2:             Develop Statement of Work which includes applicable drawings, references technical specifications and identifies required documentation and inspection reports.

 

Step 3:             Follow the Jefferson Lab purchasing process.

 

Step 4:             Work with the manufacturer to ensure ASME codes or their equivalent (verified by Peer Review) are implemented throughout the design, fabrication and any initial pressure testing of the pressure system.

 

Step 5:             Verify ASME applicable pressure vessels are identified with the ASME certification “U” or “UM” stamp.  Fabrication, testing, and certification shall be performed by a manufacturer or assembler holding the appropriate certificate.  A copy of the Manufacturer Data Report, signed by the manufacturer’s representative and the National Board commissioned inspector shall be received and forwarded to the Facilities Management and Logistics Department.

 

Step 6:             Ensure correct nameplate information is applied to all pressure vessels as identified in ES&H Manual Chapter 6151 Appendix T4 Pressure Systems Pressure Testing Program.

 

Step 7:             Verify that pressure relief devices have the proper marking as required by the ASME BPV Code.

 

Step 8:             Verify receiving inspections are performed.  Examples of receipt inspection include but are not limited to inspection for shipping damage, correct visible nameplate data, evidence of compliance with design documentation, and received documentation.  Contact Purchasing and the Quality Assurance Representative for assistance.

 

Step 9:             Include documentation for off-site manufactured pressure systems in the project folder.  Examples of required documentation are provided in ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements.

 

5.4              Fabricating a Pressure System

Design Authorities shall verify that pressure systems fabricated at Jefferson Lab comply with the design documentation and meet applicable quality assurance requirements.  Documented Peer Review approval is required where ASME code fabrication requirements cannot be directly applied.

 

Receipt inspection of materials and components used in the fabrication of a pressure system must be performed.  Examples of receipt inspection include, but are not limited to, inspection for shipping damage, material certifications, correct visible nameplate data when required, evidence of compliance with design documentation, and received documentation.  Contact Purchasing and the Quality Assurance Representative for assistance.

 

Materials and components designated for pressure system fabrication must be clearly marked as such with appropriate documentation attached as applicable.

 

All welded and brazed pressure systems must be fabricated and examined in accordance with ES&H Manual Welding and Brazing Program Supplement.

 

For pressure systems fabricated at Jefferson Lab but used elsewhere, the Design Authority shall verify that inspections by Authorized Code Inspectors are performed as required.

 

5.5              Installing and Pressure Testing a Pressure System

Pressure systems must be installed and inspected to comply with design documentation, quality assurance and code requirements.  Except for unmodified pressure vessels properly stamped as required by the ASME code, all new and modified pressure systems at Jefferson Lab must be tested in accordance with ES&H Manual Chapter 6151 Appendix T4 Pressure Systems Pressure Testing Program.  For minor repairs or additions, the Design Authority may waive pressure testing provided precautionary measures have been implemented to assure sound construction.

 

The Design Authority and Quality Assurance personnel must follow these steps for all pressure systems installations requiring pressure testing:

 

Step 1:             Installation shall be performed by qualified personnel with training and experience in the specific type of installation.

 

Step 2:             After installation is complete and before normal operation is initiated, a pressure test must be conducted and documented.  Pressure testing includes hydrostatic and/or pneumatic testing per ES&H Manual Chapter 6151 Appendix T4 Pressure Systems Pressure Testing Program.

 

Step 3:             Forward all pressure testing and installation documentation to Design Authority for inclusion in the project folder.

 

Step 4:             Designated Quality Assurance personnel shall participate in a final safety walk through before operation.  All requirements of the QA Project Checklist including design documentation, required material and component identification, shall be met.  Documented results of this final inspection shall be provided to the Design Authority for retention in the project folder.

 

5.6              Operating and Maintaining a Pressure System

All pressure systems shall be maintained and operated in accordance with the approved design criteria:

·         Operators must be trained in the operational characteristics of the system, understand the operational procedures, checklists, and inherent hazards associated with the system and be knowledgeable in lockout/tagout and emergency procedures.

·         Documentation of operator training shall be maintained in the Jefferson Lab training database.

·         Operators must regularly check the pressure system considering the following items:

o   Check pressure relief valves, gages, rupture disks, system components and piping for leaks, degradation, corrosion and blockage.

o   Verify valve positions are correct prior to operation and after any system changes.

o   Monitor and maintain systems within operational parameters with installed instrumentation.

 

5.7              Inspecting a Pressure System after Initial Operation

ASME stamped pressure vessels shall be inspected at intervals set by the Virginia Safety and Health Code Board according to requirements of the Code of Virginia Title 40.1 Chapter 3.1 and the Virginia Safety and Health Code Board Boiler and Pressure Vessel Rules and Regulations 16VAC 25-50-10.  To the extent practicable, pressure vessels must be installed so that any inspection openings are accessible.  The Facilities Management and Logistics Department is responsible for conducting these inspections and maintaining inspection records with appropriate links to the Pressure System database within DocuShare.

 

All other pressure systems shall be subject to periodic surveillance at intervals defined in the pressure system project folder.  Documentation of surveillance shall also be stored within the pressure system project folder.  See ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements for specific information on the location of the folder.

 

 

5.8              Taking a Pressure System Out of Service

If a pressure system is required to be taken out of service, adequate measures must be provided to protect worker safety, environmental safety and equipment.  Contact the Facilities Management and Logistics Department for methods to control potential hazards from corrosive, toxic, flammable or explosive contents.

 

5.9              Repairing or Modifying a Pressure System

Repairs or modifications to pressure systems must be completed under the direction of a Design Authority.  See ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements for specific information.  Maintenance work not requiring welding operations may be completed by competent technical staff with appropriate material certifications and documentation filed to the pressure system project folder within DocuShare.

 

Repairs and modifications to piping systems shall comply with the original construction code of the pressure system.  Where such a Code is unknown, sound engineering principles shall be used.  Documentation for both repairs and modifications shall follow the requirements provided in ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements.

 

Repairs or modifications to ASME stamped pressure vessels shall be performed by an organization that is authorized to use the National Board R stamp.  Repairs or modifications to stamped pressure vessels shall be coordinated by the Facilities Management and Logistics Department.  Repairs or modifications to non-stamped pressure vessels that were constructed according to the ASME code, but were not stamped shall be pressure tested prior to being placed in service.  Repairs or modifications to pressure vessels where ASME codes cannot be directly applied shall be performed using measures equivalent to the protection afforded by the original construction requirements.  Documentation shall follow the requirements provided in ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements.

 

Changing the service of a pressure vessel or piping system is viewed as a modification.  Changing the service can mean any change in the application or change in the location of the vessel or piping if the structural support is affected.

 

6.0            References

 

·         ES&H Manual Chapter 6151 Appendix T1 Pressure Systems Project Implementation and Documentation Requirements

·         ES&H Manual Chapter 6151 Appendix T2 Pressure Systems Design Program

·         ES&H Manual Chapter 6151 Appendix T3 Safety Requirements for Thin Window Design

·         ES&H Manual Chapter 6151 Appendix T4 Pressure Systems Pressure Testing Program

·         ES&H Manual Chapter 6151 Appendix T5 Requirements for Vacuum Systems

·         ES&H Manual Chapter 6122 Hot Work (i.e. Welding, Cutting, Brazing, and Grinding) Safety Program

·         ES&H Manual Welding and Brazing Program Supplement

·         American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel (BPV) Code, Section VIII: Rules for Construction of Pressure Vessels, Division I & II

·         ASME Code for Pressure Piping B31, B31.3 Process Piping

·         Vacuum Systems Consensus Standard for Department of Energy Accelerator Laboratories, July 20, 2008 Draft.

 

Revised Definitions from ES&H Glossary:

 

Pressure System  A connected set of  piping, piping components and/or pressure vessel(s) used to either convey or contain a fluid under pressure above 0 psig.  Pressure sources, fittings, pressure relief devices and associated hardware such as gages and regulators are also integral parts of the pressure system.  A system may be considered a non-pressure system and not included in the scope of this ES&H Manual Chapter if all of the following hold

1.      The system pressure is less than 15 psig

2.      The fluids contained in the system are nonflammable, nontoxic, and not damaging to human tissue, as defined by ASME B31.3 Paragraph 300.2

3.      The system design temperature is within the range -20°F and 366°F.

 

Vacuum systems connected to pressure sources must be considered pressure systems unless adequate measures have been taken to prevent pressurization above 15 psig.

 

ASME Code for Pressure Piping B31  The national consensus code used as the standard for piping system design, fabrication, testing and inspection at Jefferson Lab. Sections of B31 which apply to piping systems at Jefferson Lab include:

·         B31.1 Power Piping

·         B31.3 Process Piping*

·         B31.5 Refrigeration Piping

·         B31.9 Building Services Piping

 

*ASME B31.3 Process Piping shall be used as the primary standard for Jefferson Lab piping systems.  Other sections of B31 are applied as appropriate based on sound judgment of the Design Authority and proven practices in the respective field.

 

7.0            Revision Summary

 

Revision 3.4 – 11/14/14 – Periodic Review – Updated Responsibilities to include Pressure System and Vacuum System Owner and Pressure System and Vacuum System Technician per M.Logue 

Revision 3.3 – 05/20/14 – Added Required Safety Training Table.

Revision 3.2 – 05/17/13 – Added notice and updated title to reflect current lab operations.

Revision 3.1 – 04/14/11 – Updated links to ES&H Manual Chapter 6122 and Welding and Brazing Supplement.

 

 

ISSUING AUTHORITY

TECHNICAL POINT-OF-CONTACT

APPROVAL DATE

REVIEW DATE

REV.

ESH&Q Division

Will Oren & Dave Kausch

11/14/14

11/14/17

3.4

This document is controlled as an on line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 11/21/2014.