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Pressure and Vacuum Systems Safety Supplement Part 1: General Program
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This Supplement describes the detailed specific requirements of the Pressure and Vacuum Systems Safety Program at Jefferson Lab. All revisions to this Supplement must be approved by the Pressure Systems Committee.
The purpose of this program is to ensure that all personnel at Jefferson Lab involved in the construction, repair, alteration and operation of pressure and vacuum systems are cognizant of the hazards associated with these systems and construct, repair, alter and operate these systems in a safe manner. Except as otherwise noted, all references to “pressure system(s)” shall be considered to include both pressure and vacuum systems.
As stated in ES&H Manual Chapter 6151 Pressure and
Vacuum Systems Safety Program, a pressure system is defined as any
combination of vessels, piping, instrumentation (e.g. gauges), and/or equipment
(e.g. pumps or compressors) either containing a fluid under internal pressure
or exposed to external fluid pressure. Note
that vacuum systems are a subclass of pressure systems.
The requirements of
this Supplement apply to all pressure systems and components not explicitly
excepted in ES&H Manual Chapter 6151 Pressure and
Vacuum Systems Safety Program – Exceptions
This document is intended for Jefferson Lab internal use only and shall not be released for any purpose, other than as a reference, to agencies other than Jefferson Lab. This document shall not be considered a design handbook.
The Jefferson Lab Pressure Systems Committee shall assume the duties of the jurisdictional authority. These duties include:
· Arbitration and interpretation of Code and policy issues.
· Provide guidance, formal or informal, when requested.
· Arbitrate and oversee all in-service inspection issues.
The terms shall, should and may are used throughout this document. Shall indicates an action that is required or mandatory with regard to the pressure safety program. Should indicates an action that is considered good practice in most cases, but is not considered mandatory and, in some cases, such action may not be appropriate. The term may indicates an action that is fully optional.
All work on pressure systems and/or components considered construction, alteration, or repair shall be performed under the supervision of an assigned Jefferson Lab Design Authority (henceforth known as the DA). The DA shall be responsible for all aspects of the task that has been assigned. The DA may delegate all or part of the work associated with any of these tasks but shall not delegate any responsibility. The DA shall ensure that the overall safety of the public, Jefferson Lab personnel and the environment are the primary consideration of any engineering design. The responsibilities of the DA shall terminate upon completion of all activities related to the assigned task and the system is turned over to an assigned Jefferson Lab System Owner.
Pressure system operation (normal and off normal) and maintenance work shall be performed under the supervision of an assigned Jefferson Lab System Owner. The System Owner is also responsible for ensuring that in-service inspection of pressure systems under their purview are performed and documented at prescribed intervals. In-service inspection of ASME Pressure Vessels, associated relief devices, and Category M equipment shall be coordinated and supervised by the Vessel Inspection Coordinator. The System Owner may delegate all or part of the work associated with any of these tasks but shall not delegate any responsibility.
The ASME Boiler and Pressure Vessel Code (BPVC) and B31 Code for Pressure Piping are the core of the Pressure and Vacuum Systems Safety Program. While these specific ASME Codes are usually considered to be codes of construction this program references them for maintenance, operation, design, construction, repair, alteration, etc.
Pressure system design and construction initiated post 2/28/2008 shall comply with the ASME BPV Code and/or B31 Code for Pressure Piping as applicable. Every reasonable effort shall be made to ensure that the requirements of these ASME Codes are met. It is recognized, however, that these Codes may not directly apply to all pressure equipment or components in a system. Where the DA has determined that these Codes do not apply to a given component or system, that component or system shall be considered an Excluded Element.
For new construction, the Code of Record for a pressure component shall be that version (or Code year) of the most applicable ASME Pressure Code in effect 6 months prior to the start date of the design (a later version may also be used, if available, at the discretion of the DA or if required by building codes). A Code of Record shall be determined for each component regardless of whether or not an ASME Pressure Code can be directly applied.
Repairs shall comply with the original Code of Record (or, if unknown, current code in effect at time of repair), NBIC Part 3, ASME PCC-2 or other suitable post construction code. Alterations shall comply with the ASME Code in effect at time of the alteration, NBIC Part 3, ASME PCC-2 or other suitable post construction code. For repairs and alterations where codes do not directly apply, sound engineering practices and equivalent measures shall be used.
Jefferson Science Associates LLC functions as an Owner/Operator/User under the ASME Pressure Codes in its capacity as the management and operating contractor of Jefferson Lab for the U.S. Department of Energy under Contract No. DE-ACO5-06OR23177; assuming all liability as the legal entity responsible for compliance in accordance with its Federal Contract. As such, JSA/JLAB has the overall responsibility for Code compliance and establishment of requirements for design, construction, examination, inspection, testing, operation, maintenance, alteration, and repair of its pressure systems.
As Owner/Operator, JSA/JLAB will assign specific responsibilities and duties to its employees acting in their capacity as employees of the Owner/Operator; specifically as the Jefferson Lab Design Authority (the DA), Jefferson Lab Inspector, Jefferson Lab System Owner, and fabricator/manufacturer/erector. The DA, System Owner, and Inspectors employed by Jefferson Lab may refer to the Jefferson Lab Pressure Systems Committee for guidance, review or arbitration regarding any aspect of the performance of their duties. In performance of their duties, the DA, System Owner, and Inspectors employed by Jefferson Lab may delegate any fraction of the work, but shall not delegate the responsibility.
The ASME B31 Codes define four organizations and their functions, involved in the design, fabrication, examination, inspection, testing, and operation of pressure piping. These are summarized below:
1) The Owner/Operator:
i) Has overall responsibility for Code compliance
ii) Shall establish requirements for design, construction, examination, inspection, testing, operation, and maintenance.
2) The Designer:
i) Is responsible to the owner to ensure that the design complies with Code requirements
3) The Fabricator/Erector/Manufacturer:
i) Is responsible for providing materials, components, and workmanship in compliance with Code.
4) The Owner’s Inspector:
i) Responsible to the owner to verify that all required testing, examinations, and inspections are complete
ii) Verifies the fabricators quality system is acceptable and implemented and that all required certifications and records are complete.
At Jefferson Lab, these concepts are not directly applicable. The organizations and their duties shall be as assigned below:
The duties of the Owner/Operator shall be assumed by the Jefferson Lab Design Authority (DA) (assigned to the construction, alteration, or repair) and the Jefferson Lab System Owner assigned to the system. The overall responsibility for compliance with Code and Jefferson Lab policies shall be assumed by the DA. The responsibility for the performance and operability of the system shall be shared by the DA and the System Owner. The DA shall be responsible for establishing the requirements for the engineering design, construction, operation and initial maintenance of the system. The System Owner shall assume full responsibility for the safe operation and long term maintenance of the system. The responsibilities of the DA shall terminate upon completion of the construction, alteration, or repair.
The duties of the Designer shall be fully assumed by the DA. The DA shall be fully responsible for ensuring that the engineering design complies with Jefferson Lab policy and Code requirements where applicable.
The DA shall be responsible for ensuring that duties of the Fabricator/Erector/Manufacturer are met. The DA shall be fully responsible for ensuring that the fabrication and procurement of all components in the system comply with Jefferson Lab policy and Code requirements. This includes all components fabricated off site.
The duties of the Owner’s Inspector shall be assumed by one or more Jefferson Lab Inspectors meeting the qualifications given in Section 1.4.3. The inspector shall be an employee of the ES&H division or a qualified individual that is independent of the fabrication, manufacturing, erection, design, testing, and examination functions.
The DA (or designee under the supervision of the DA) shall serve as the Subcontracting Officer’s Technical Representative (SOTR) for any work contracted to organizations other than Jefferson Lab (i.e. subcontractors). The contract shall clearly state the specific Code functions assumed by the subcontracting agency. The DA shall take reasonable measures to ensure that these functions and the related requirements of the Code are fulfilled.
The ASME BPVC identifies three organizations and their specific responsibilities involved in the design, fabrication, examination, inspection, testing, and operation of ASME Pressure Vessels. These are summarized below:
1. The Owner/User
a. It is the responsibility of the user or an agent acting on behalf of the user to provide a certified User’s design.
b. It is the user's responsibility to specify, or cause to be specified, the effective Code edition, Section, and Division to be used in the construction of the vessel.
c. The User shall specify the performance requirements of the design specification.
2. The Manufacturer
a. Is responsible for the structural and pressure retaining integrity of the vessel or part thereof.
b. Shall ensure that the requirements in the User’s design specification are met.
3. The Inspector
a. Shall be an employee of an ASME accredited Authorized Inspection Agency (or may be employed by the manufacturer when the manufacturer is also the user).
b. Shall perform the specified duties of the ASME BPVC Section and Division used for the vessel construction.
The concepts are directly applicable at Jefferson Lab. The organizations and their duties shall be as assigned below:
The duties of the Owner/User shall be jointly assumed by the DA and System Owner. The DA and System Owner shall specify the performance requirements and a certified User’s design. The DA shall specify, or cause to be specified, the effective Code edition, Section, and Division to be used in the construction of the vessel.
The Manufacturer and Inspector shall be as given by the Code Section and Division. Jefferson Lab presently does not manufacture or serve as the ASME Code Inspector for any ASME Pressure Vessel or Boiler.
For vessels that cannot fully comply with the ASME BPVC see Part 3: Equivalent Measures.
This section describes the general responsibilities of individuals and groups with regard to the Pressure and Vacuum Systems Safety Program. In some cases, individuals listed describe functions rather than personnel descriptions. Specific responsibilities are given in applicable sections of this Supplement.
· Shall ensure that the overall safety of the public, Jefferson Lab personnel and the environment are the primary consideration of any engineering design.
· Shall ensure that pressure system construction, alteration, repair and documentation meet the requirements of this Supplement.
· Shall employ, as required, the expertise available through other Design Authorities, the QA/CI Inspector, the Welding Committee and the Pressure Systems Committee as well as the experience and lessons learned documented in the Pressure Systems project files database.
· Shall ensure that adequate overpressure protection is provided.
· Shall initiate pressure system documentation in a project file consistent with the requirements specified in this Supplement and populate those folders with required documentation prior to system startup.
· Shall maintain required training.
· For any new pressure vessel brought onto the Jefferson Lab site or to be operated by Jefferson Lab off site, the DA shall perform the following:
o Complete required information on vessel registration form (Form PS-4). This form shall be submitted to the Vessel Inspection Coordinator.
o Complete relief device registration (Form PS-5) for the device(s) protecting the vessel and submit the form to the Vessel Inspection Coordinator.
o Ensure all pressure vessel documentation has been checked, verified and filed into the appropriate pressure system folder.
· For any existing vessel returned to service:
o Conduct an operational readiness review and submit a new registration form (Form PS-4) to the Vessel Inspection Coordinator.
o Complete relief device registration (Form PS-5) for the device(s) protecting the vessel and submit the form to the Vessel Inspection Coordinator.
o Ensure all pressure vessel documentation has been checked, verified and filed into the appropriate pressure system folder.
· Vacuum systems:
o DA shall ensure that the vacuum system design, fabrication and testing of Category 3 vacuum systems meets the requirements of this Supplement. The DA shall ensure that thin windows on Category 1 and 2 vacuum systems meet the requirements of Part 7: Section 7.7 Requirements for Components with Thin Windows.
· Shall determine the scope and type of test required on new construction and repairs, or alterations to pressure systems based on applicable codes, the engineering design, and sound engineering judgment.
· Shall define the In-service Inspection requirements for a new pressure system under their purview.
· Shall define operational requirements for any new pressure system under their purview.
· Shall define special maintenance requirements for any new pressure system under their purview.
· Shall support, oversee and/or supervise, as needed, the QA/CI Inspector.
· Shall monitor current requirements and certifications necessary for mechanical examination personnel.
· Shall provide welding inspection as required by ASME Codes or by engineering requirements.
· Shall monitor current requirements and certifications necessary for welding examination and inspection personnel.
· If requested by the System Owner or DA, the welding inspector shall perform a final system walk-through and verify that required documentation of the pressure system is complete before operation of that pressure system.
· When requested by the DA, the welding inspector shall also serve as the pressure system construction inspector.
· Shall designate a Vessel Inspection Coordinator.
· Shall support, oversee and/or supervise the Vessel Inspection Coordinator in the performance of the In-service Inspection Program.
· Responsible for coordinating the required in-service inspections of all IC4 and IC3 components.
· Maintains a database of the following: (information to be provided by DAs)
o ASME Boilers/Pressure Vessels and relief devices protecting them.
o Category M pressure systems and relief devices protecting them.
· Maintains inspection records both current as well as one previous inspection for IC4 and IC3 vessels.
· Issues CATS for any ASME Boilers or Vessels that have failed or have been condemned.
· Conveys the results of any failed or condemned ASME Boiler or Vessel to the responsible System Owner
· Issues CATS entry for any relief devices on ASME Boilers or Pressure Vessels that have failed and have not been immediately replaced by an acceptable device.
· Conveys the results of any failed relief devices on ASME Boilers or Pressure Vessels to the System Owner.
· Conducts the inspection of all identified in-service pressure equipment.
· Completes and signs the required inspection forms (Form PS-10, Form PS-11 and Form PS-12).
· Reviews inspection results with the designated Vessel Inspection Coordinator when appropriate.
· Provides additional testing means and methods as required for vessel inspections.
· Conducts the inspection of all identified relief devices.
· Reviews inspection results with the designated Vessel Inspection Coordinator or the System Owner in the case of relief devices installed to protect piping and Excluded Vessels.
· Committee Chair
o Shall maintain a list of qualified DAs.
o Shall review and approve safety documents (e.g. OSPs, TOSPs etc.) and perform specific duties given in this Supplement.
o Shall approve systems where overpressure protection is provided by system design.
o May enlist the aid of the Pressure System Committee and other subject matter experts as needed.
· General Committee
o Shall arbitrate issues of conflict related to pressure safety, Code, and Jefferson Lab policies.
o Shall assume the responsibilities of the jurisdictional authority.
· Designee (located within the Document Control Group)
o Assist in the creation of the pressure system identification number
o Assist in the creation of pressure system folders and subfolders in the pressure system database
o Assist in inputting documentation into folders/subfolders as directed by DAs or System Owners
o Update the pressure system database with new information upon notification by a new System Owner in the event of a change in the designated System Owner for a pressure system. If the change involves an IC4 or IC3 component, communicate the change to the Vessel Inspection Coordinator
o Upon notification from a System Owner, update the pressure system database when a pressure system is permanently taken out of service. If the change involves an IC4 or IC3 system, communicate the change to the Vessel Inspection Coordinator.
· Shall maintain appropriate qualifications
· Shall witness final pressure system tests.
· Shall certify that pressure vessels have passed required pressure testing.
· Shall perform final system walkthrough and issue an inspection report (Form PS-8).
· Shall review system documentation for completeness.
· Shall maintain appropriate training
· Shall design, fabricate, install, operate, maintain, and alter pressure systems and components at the direction of the System Owner or DA.
· Shall be qualified and trained as required by the DA.
· Shall determine the stored energy of the pressure test.
· Shall be responsible for determining the need for and preparation of, if required, an OSP, TOSP, or SOP governing the pressure or leak test.
· Shall supervise pressure tests on new construction and repairs or alterations to pressure systems and components.
· Shall witness the pressure system test for all newly constructed systems.
· Shall ensure that all personnel involved in the pressure test are trained and qualified and are cognizant of the hazards associated with the test.
· Shall maintain appropriate training
· Shall install the pressure test equipment and perform the pressure test under the direction of the DA or Test Engineer.
· Shall perform required examinations and log data in the required testing documentation and sign the pressure test form (Form PS-7).
· Shall maintain appropriate training
· Shall ensure that the design, fabrication and testing of Category 1 and 2 vacuum systems meet the requirements of this Supplement. Note that the responsibility for the design of thin windows on Category 1 and 2 vacuum systems shall be assumed by the DA.
· Shall determine the category for each new vacuum system or existing vacuum system requiring repair or alteration.
· Shall maintain appropriate training.
· Shall ensure that systems under their purview have a valid Pressure System number/title and an identified Inspection Category.
· Shall ensure that ASME vessels and the associated relief devices under their purview are identified in the Vessel Inspection Coordinators database.
·
Shall ensure that systems under their purview
are maintained and operated by qualified personnel.
· Shall ensure that pressure systems under their purview are inspected and/or tested in compliance with this Supplement.
· Shall ensure that pressure systems under their purview continue to be maintained and operated in a safe manner compliant with this Supplement.
· Notifies Pressure Systems Committee Designee if a system is taken out of operation permanently or if system ownership changes.
· Notifies Vessel Inspection Coordinator of a change in status of any existing IC4 or IC3 pressure vessels such as “Removed from Service”, relocation, or changes in operational parameters (e.g. change of fluid service).
· When notified by the Vessel Inspection Coordinator of a vessel that has been condemned by an inspector, removes the vessel from service as soon as safely possible.
· Maintains the integrity and placement of vessel identification markings.
· Shall work with the Vessel Inspection Coordinator to complete in-service inspections of IC4 and IC3 systems.
· Shall ensure that in-service inspections of IC2 and IC1 systems are completed and documented.
· Maintains test and inspection records of relief devices.
· Notifies Vessel Inspection Coordinator of a change in status of any relief device actively providing overpressure protection for an ASME Boiler or Pressure Vessel.
· Shall ensure that corrective action is taken when notified of deficient relief devices.
· Shall develop operational procedures and inspection/maintenance plans as necessary.
· Shall determine the category for each new vacuum system or existing vacuum system requiring repair or alteration.
· Responsible for the design and fabrication of Category 0 vacuum systems.
· Shall maintain appropriate training.
This section describes the qualifications for personnel designing, fabricating, inspecting, operating, repairing, altering, and testing pressure systems or pressure components. Owners of pressure systems shall also be qualified as described in this section.
Design Authorities (DAs) must demonstrate the ability to design and supervise construction of pressure systems according to the applicable ASME Codes. The qualifications and experience required of the DA 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 the policies and procedures contained in this Supplement, the ES&H Manual Chapter 6151 Pressure and Vacuum Systems Safety Program, and the ES&H Manual Welding and Brazing Program Supplement. Design Authorities shall maintain Pressure System Hazard Awareness SAF 130A and Pressure System Safety for Design Authorities SAF 130B and Pressure System Owner Training SAF130C. Approval of the Jefferson Lab Engineering Manager is required if the individual does not meet at least one of the following criteria:
· Completion of an engineering, physics or chemistry degree, requiring four or more years of full-time study, plus a minimum of five years of experience in the design of related pressure vessels or piping.
· Professional Engineering registration, recognized by any state or territory within the United States, and experience in the design of related pressure vessels or piping.
Examiners shall have training and experience commensurate with the needs of the specific examinations as determined by the specified ASME Code, engineering design, and the DA.
All examiners that are Jefferson Lab employees shall be approved by the Jefferson Lab ASNT Level III or Level III designate within ES&H (QA/CI Inspector).
All visual examiners shall have at least one of the following qualifications (specific to the specified examination process):
· Shall be certified to ASNT SNT-TC-1A Level II.
· Shall meet the requirements of Jefferson Lab procedure NDT-PQ-100.
Mechanical examiners shall be Jefferson Lab employees approved by ES&H. These examiners shall meet the requirements of the Jefferson Lab procedure NDT-PQ-100 or shall be certified to ASNT SNT-TC-1A Level II.
For pressure systems 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. The inspector shall be independent from the design, manufacturing, erection, testing, or examination processes. Jefferson Lab employee inspectors shall have one or more of the following qualifications:
· DA with specific approval by Pressure Systems Committee.
· CWI (certified welding inspector) or senior CWI, possessing a valid certificate as defined by AWS QC1, with approval by Pressure Systems Committee.
· Authorized piping inspector with 5 years of experience as defined in ASME B31.3 340.4(b) 4 with approval by Pressure Systems Committee.
Inspectors employed by other agencies shall be qualified as given by the code of construction. Outside Inspectors of Excluded Elements and Vessels shall meet the qualifications given in ASME B31.3 340.4. See the following references.
· ASME B31.1 136.1.4
· ASME B31.3 340.4
· ASME B31.5 537.4
· ASME B31.9 (no specific requirements)
· ASME B31.12 GR-4.2.3
Inspectors of ASME boilers in operation shall be qualified as follows:
· Commonwealth of Virginia certified inspector as qualified in the Commonwealth of Virginia Boiler and Pressure Vessel Rules and Regulations.
Inspectors of pressure vessels, other than boilers, 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. Inspectors shall have one or more of the following qualifications:
· A Commonwealth of Virginia certified inspector as qualified in the Commonwealth of Virginia Boiler and Pressure Vessel Rules and Regulations.
· Properly trained and certified API 510 inspector.
· DA with specific approval by Pressure Systems Committee.
· Authorized piping inspector with 5 years of experience as defined in ASME B31.3 340.4(b) 4.
Inspectors of relief devices shall be designated by Jefferson Lab and shall be an employee of Jefferson Lab or an employee of an organization holding a valid “VR” or other similar National Board stamp. Inspectors shall have one or more of the following qualifications:
· A Commonwealth of Virginia certified inspector as qualified in the Commonwealth of Virginia Boiler and Pressure Vessel Rules and Regulations.
· Authorized piping inspector with 5 years of experience as defined in ASME B31.3 340.4(b) 4.
· Properly trained and certified API 510, 570 or 576 inspector.
· DA with specific approval by Pressure Systems Committee.
· Visual Examiner meeting the requirements of Jefferson Lab procedure NDT-PQ-100 and approved by the Pressure Systems Committee.
Inspectors of piping shall be designated by Jefferson Lab and shall be an employee of Jefferson Lab or an employee of an organization holding a valid National Board stamp. Inspectors shall have one or more of the following qualifications:
· A Commonwealth of Virginia certified inspector as qualified in the Commonwealth of Virginia Boiler and Pressure Vessel Rules and Regulations.
· Authorized piping inspector with 5 years of experience as defined in ASME B31.3 340.4(b) 4.
· Properly trained and certified API 570 inspector.
· DA with specific approval by Pressure Systems Committee.
· Visual Examiner meeting the requirements of Jefferson Lab procedure NDT-PQ-100 and approved by the Pressure Systems Committee.
Inspections of welds and brazes, where required by Code or the engineering design, shall be performed by personnel meeting one or more of the following:
· An employee of the ES&H division designated as the QA/CI Inspector with CWI or senior CWI certification, possessing a valid certificate as defined by AWS QC1, with at least 5 years of experience.
· Inspectors employed by outside organizations to inspect welds or brazes performed by Jefferson Lab employees
o CWI or senior CWI, possessing a valid certificate as defined by AWS QC1, with at least 5 years of experience.
· Inspectors employed by outside organizations to inspect welds or brazes performed by outside organizations shall be qualified as given by the code of construction or post construction.
Note: Inspections are not examinations (see Part 2: Section 2.8 Fabrication by Welding, Brazing, and Soldering).
Operators of pressure systems shall meet the following requirements.
· Operators of pressure systems shall have hazard awareness training that includes basic principles of pressure technology and pressure safety (SAF 130A Pressure System Hazard Awareness Training).
· Shall maintain system specific training required by the System Owner(s). This training shall include implementation of standard and emergency operating strategies.
· Shall meet additional qualifications and maintain training as required by supervisor.
Fabricators of pressure systems and components shall meet the following qualifications:
· Shall have experience working with pressure equipment as required by supervisor; this may include on the job training.
· Personnel performing assembly and testing of pressure equipment shall maintain Pressure System Hazard Awareness Training SAF 130A.
· Personnel performing any work on energized systems shall maintain Pressure System Hazard Awareness Training SAF 130A.
· Shall meet any additional qualifications and maintain training as required by the DA responsible for the system, the System Owner, and the work supervisor/coordinator.
· Shall maintain Pressure System Hazard Awareness Training SAF 130A
· Shall have experience with the design and fabrication of vacuum systems and vessels.
· Additional qualifications shall be determined by the individual's supervisor.
· Owners of pressure systems shall fully understand the function and operation of pressure systems under their purview.
· Owners shall be aware of the requirements of this Supplement and maintain Pressure System Hazard Awareness Training SAF 130A and Pressure System Owner Training SAF 130C.
· The qualifications of the competent technical individual shall be determined by the individual's supervisor; each individual shall, as a minimum, complete Pressure System Hazard Awareness Training, SAF130A.
Welders and brazers of pressure equipment employed by Jefferson Lab shall maintain the following training and qualifications:
· SAF 130A (Pressure System Hazard Awareness)
· SAF 150 (Welding Safety).
· Shall maintain certifications detailed by the DA and line management for the appropriate welding and brazing procedures and processes.
· Shall have knowledge of their individual certifications.
· Shall meet additional or superseding certifications given in ASME Codes of construction or post construction (e.g. ASME BPVC Section IX and ASME B31.3. ¶ 333).
· Shall meet the requirements given in the ES&H Manual Welding and Brazing Supplement.
Welders and brazers of pressure equipment fabricated off site for use at Jefferson Lab shall be certified as required in the specified ASME Code of Construction. These certifications shall meet the requirements of ASME BPVC Section IX (except where superseded by the code of construction or the engineering design) with regard to WPS/PQR, WPQ/BPQ, and documentation. These certifications shall be detailed in a SOW where appropriate. Where ASME Codes are not applicable, procedures, welders, and brazers shall be qualified as given in Part 2: Section 2.8.2 Qualification of Procedures and Part 2: Section 2.8.5 Unlisted Materials. This shall be detailed and documented as required by a SOW where welding or brazing is to be performed by agencies other than Jefferson Lab.
This section describes the required and recommended documentation for pressure system construction, repair, alteration, maintenance, in-service inspection, and operation.
For each new pressure system, the DA shall consult with the Pressure Systems Committee Designee to create a unique identification number. The naming/numbering convention for all pressure systems shall be as given in Part 1: Section 1.5.2 Numbering Convention.
The DA shall create a corresponding title for the pressure system which includes clear terms describing the system and its location, if relevant.
The DA shall create a Project Folder within the Pressure Systems database with assistance from the Pressure Systems Committee Designee as required. Each pressure system shall have a top folder, labeled with the pressure system number and title, in the pressure systems database. This database may be accessed from the Pressure Systems webpage. The sub-folder structure and contents shall be as given in Part 1: Section 1.5.5 Folder Content.
Given the diverse and unique nature of pressure systems and the work performed on them at Jefferson Lab, it is recognized that not all documentation requirements are applicable. The DA (for construction, alterations, or repairs) or System Owner shall determine the extent of the documentation required by Code, the engineering design, and this Supplement. If it is determined that a certain document is required then it shall be filed as given in Part 1: Section 1.5.5 Folder Content (this will facilitate review of this documentation). Documentation packages (e.g. vendor documentation for a purchased compressor skid) for well-defined subsystems may be filed as a single document in the Fabrication and Procurement folder. If this package contains design drawings, calculations, etc. it shall also be filed or linked in the Engineering folder. Note also that some documentation listed below is optional.
For systems where the Code of construction is either ASME B31.3 Category “D”, B31.5 or B31.9, the DA responsible for the system or the System Owner may choose not to use the standard subfolders as a filing system. The DA is still responsible for creating the unique identification number as given in Part 1: Section 1.5.2 Numbering Convention and a Project Folder within the Pressure Systems database with a top folder, labeled with the pressure system number and title, in the pressure systems database. A note shall be added to the folder description that identifies the alternate location of the applicable documentation. All applicable mandatory forms shall be stored in a subfolder labeled Pressure Systems Forms. The DA shall determine the extent and type of documentation required to meet the applicable Code of construction and is responsible for maintaining that documentation. This documentation shall be made available, for review or reference, within 5 working days upon request of the Pressure Committee Chair.
The extent of required documentation for Category 0, 1, and 2 vacuum systems is given in Part 7: Vacuum Systems. The Responsible Vacuum Engineer, Vacuum Technician or System Owner may choose to file documentation for Category 0, 1, and 2 vacuum systems in the pressure system database at their discretion. Documentation for Category 3 vacuum systems shall follow the requirements detailed in this Part.
The numbering convention for pressure systems shall be as shown in Figure 1‑1: Pressure System Identification Number. The initial two letter designation “PS” shall apply to all systems. The following two or three letter designation “AB(C)” is the group designator and shall indicate the owner group or system type. This is followed by the year designator which is a two digit designation for the year the design of the system was initiated or “XX” for systems in operation prior to February 28, 2008. The final three digits shall increment from 001 to 999 as needed for each system designed in the given group and year. This sequence shall typically reset to 001 for each year and group. A group may use these three digits to codify their particular pressure systems according to a written procedure maintained and documented by that group. In these special cases, the final digit shall reset to 1 for each year, group and system.
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PS-ABC*-XX**-123*** |
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*Group Designation ACC –
Accelerator AT – Acid
Transfer CG –
Compressed Gas CRM –
Cryomodule CRY –
Cryogenics DCW –
Domestic Chilled Water DIA –
Diagnostics DMP – Dump FAC –
Facilities FEL – Free
Electron Laser FS – Fire
Suppression HallA –
Hall A HYD –
Hydraulic (Oil) LCW – Low
Conductivity Water LHE Liquid
Helium MAG –
Magnet OPT –
Optical PHY –
Physics SPT –
Support SRF –
Superconducting RF STK –
Structural Shapes TGT –
Target UTL –
Utilities VAC -
Vacuum |
**Year of
Initial Construction (XX if
Unkown) |
***Sequential
Number From 001
to 999 |
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Figure 1‑1: Pressure System Identification Number
These forms are standardized forms that shall be used when applicable for pressure system documentation. These forms are available on the Pressure Systems webpage.
The following list details the subfolder structure and content for each pressure system. Detailed content is described in the following section.
· Engineering:
o Design Calculations
o Reviews
o Design Drawings
o Overpressure Protection
o SOW
· Fabrication and Procurement
o Procurement
o Welding, Brazing, and Soldering
o Material and Instrument Certifications
o Mechanical Examinations
o Leak and Pressure Testing
o Vessels
o Overpressure Protection
· Final Walkthrough
· Operation and Maintenance
o System Turnover
o Operations
o Maintenance
· Alterations
o Alteration 1…
o Alteration 2…
· Repairs
o Repair 1…
o Repair 2…
· In-Service Inspections
· Miscellaneous
Each pressure system in the database shall have a top folder with the structure or sub-folders as described in this section. The documentation to be stored in each subdirectory is also given in this section. The Pressure Systems Committee Designee is available to help with the input of documentation into appropriate folders.
· Engineering-Design Calculations
o Design Calculations
· Engineering-Reviews
o Technical Reviews of all Code calculations and Engineering Design (Form PS-3)
o Peer Reviews of all equivalent measures for all Excluded Vessels or Elements (Form PS-3)
o Other reviews such as Division Safety Reviews (optional).
· Engineering-Design Drawings
o All drawings and sketches relating to the pressure system. A list of Jefferson Lab drawing numbers including revision level for all unaltered drawings filed in the document control system is acceptable. Copies of initialed redline drawings are also acceptable.
o A copy of the system P&ID shall be filed.
· Engineering-Overpressure Protection
o Calculation showing the determination of the required relief capacity and the adequacy of the overpressure protection system.
o Description of the overpressure protection subsystem
o Relief device data sheets (Form PS-5) for all relief devices providing overpressure protection.
o For systems where overpressure protection is by system design, all documents required in Part 4: Section 4.8 Overpressure Protection by System Design shall be filed in this folder including Form PS-2.
· Engineering-SOW
o Completed Form PS-1: System description and statement of work or project description that contains the following:
§ Date design was initiated
§ Define the responsible DA and System Owner,
§ List of all applicable codes
§ List of elements for which ASME Codes do not apply
§ P&ID number(s)
o Statements of work for specific procurement or in house activities
o Engineering change orders
· Fabrication and Procurement-Procurement
o Purchase orders
· Fabrication and Procurement - Welding, Brazing, and Soldering
o WPS/BPS/PQR for all welding/brazing procedures (Jefferson Lab and other fabricators). Listing the procedure numbers and where they are stored within the QA/CI documentation system is acceptable.
o Weld/braze maps or traceability documents
o WPQ/BPQ for all welders and brazers performing welding and brazing on any pressure component. Listing the qualification numbers and where they are stored within the QA/CI documentation system is acceptable.
o Weld/braze examinations
o Weld/braze inspections
· Fabrication and Procurement - Material and Instrumentation Certifications
o MTRs: mill test reports
o CMTRs: certified mill test reports
o COCs: Certificates of conformance or compliance
o Relevant material testing reports (i.e. impact test reports).
o Instrumentation calibrations/certifications.
· Fabrication and Procurement – Mechanical Examinations
o All examinations other than welding (Form PS-6)
· Fabrication and Procurement - Leak and Pressure Testing
o Pressure/leak test forms (Form PS-7)
o OSPs, TOSPs etc. (optional)
o If additional NDE is performed in lieu of a leak/pressure test, the results of these examinations shall also be filed. A justification for using NDE instead of standard leak/pressure testing should also be filed.
· Fabrication and Procurement - Vessels
o Form U-1, U-1A, etc. shall be filed for each ASME Pressure Vessel in the system.
o Form PS-4 for each vessel
· Fabrication and Procurement – Overpressure Protection
o Relief device data sheets (Form PS-5) for all relief devices providing overpressure protection.
· Final Walkthrough
o The results of the final system walkthrough as described in Part 2: Section 2.10.1 Final System Walkthrough Error! Reference source not found. and documented in Form PS-8.
· Operation and Maintenance – System Turnover
o Completed Form PS-9
· Operation and Maintenance - Operations
o All contents of this folder are optional
o Operational procedures and manuals
o Operations logs etc.
· Operation and Maintenance - Maintenance
o All contents of this folder are optional
o All maintenance related documentation describing work performed on the system. Including the following:
§ Corrosion protection
§ Painting
§ Valve seat replacement
· Alterations-Alteration 1 (A separate folder shall be created for each alteration)
o Brief description of the alteration and a procedure for performing the alteration.
o Relevant calculations
o Welding documentation
o Welding/brazing procedures used as needed
o Welder/brazer qualifications for each welder/brazer performing the alteration
o Weld maps or traceability documents
o Weld examinations and inspections
o Drawings as needed. Pictures of the alteration may also be stored here.
o A copy of the altered system P&ID shall be filed
o SOWs for work performed by organizations other than Jefferson Lab.
o Procurement documentation as determined by the responsible DA.
o Material certifications and additional test such as impact testing (if required)
o Any additional NDE and testing to return the system to service.
o Other pertinent documentation as determined by the System Owner or DA responsible for the alteration.
· Repairs-Repair 1 (A separate folder shall be created for each repair)
o Brief description of the repair and a repair procedure if needed
o Relevant calculations as described
o Welding documentation as needed
o Welding/brazing procedures used
o Welder/brazer qualifications for each welder/brazer performing the repair
o Weld maps or traceability documents
o Weld examinations and inspections
o Material certifications and additional test such as impact testing (if required)
o Drawings as needed. Pictures of the repair may also be stored here.
o SOWs for work performed by organizations other than Jefferson Lab.
o Procurement documentation as determined by the responsible DA.
o Any additional NDE and testing to return the system to return the system to service.
o Other pertinent documentation as determined by the System Owner or DA responsible for the repair.
· In-Service Inspections
o Inspection procedures and requirements
o All in-service inspection reports (Form PS-10, Form PS-11 and Form PS-12) for any system component other than ASME Vessels and Boilers. These may be filed in separate folders as needed for organizational purposes.
o Form PS-11 for ASME Vessels and Boilers shall be stored in a separate database on the Pressure Systems webpage
· Miscellaneous
o Vendor manuals or information
o Any documentation deemed useful by the System Owner or DA
o All contents of this folder are optional.
NOTE: Not all documentation is applicable. The system DA or System Owner shall determine the extent of documentation to be filed in the pressure system subfolders for each system.
· AHA: Activity Hazard Analysis
· API: American Petroleum Institute
· ASCE: American Society of Civil Engineers
· ASHRAE: American Society of Heating Refrigeration and Air conditioning Engineers
· ASME: American Society of Mechanical Engineers
· ASNT: American Society of Nondestructive Testing
· ASTM: American Society for Testing and Materials
· AWS: American Welding Society
· BPQ: Brazer Performance Qualification
· CATS: Corrective Actions Tracking System
· CE/PED – Conformité Européene (European Conformity)/Pressure Equipment Directive - Pressure Equipment Directive 97/23/EC of the European Union outlining standards for the design and fabrication of pressure equipment.
· CMTR: Certified mill test report
· COC: Certificate of Conformance (or compliance)
· DA: Jefferson Lab Design Authority
· FMECA: Failure Mode Effects and Criticality Analysis
· FML: Jefferson Lab Facilities Management and Logistics
· LHe: Liquid helium
· LN2: Liquid nitrogen
· MDMT: Minimum Design Metal Temperature
· MAWP: Maximum Allowable Working Pressure
· MTR: Mill test report
· NBIC: National Board Inspection Code (NB-23)
· NDE: Non-destructive examination
· NDT: Non-destructive test
· NPS: Nominal pipe size
· OSP: Operational safety procedure
· PQR: Procedure Qualification Record
· PT: Liquid penetrant test
· QA: Quality Assurance
· QC: Quality Control
· RT: Radiographic test
· SOP: Standard Operating Procedure
· SOW: Statement of work
· SOTR: Subcontracting Officer’s Technical Representative
· TOSP: Temporary operational safety procedure
· USDOT: US Department of Transportation
· UT: Ultrasonic test
· VR: Valve Repair
· VT: Visual test
· WBS: Jefferson Lab Welding and Brazing Supplement
· WPQ: Welder/Operator Performance Qualification
· WPS: Welding Procedure Specification
· Accumulation: pressure increase above the MAWP or Design Pressure of a system, vessel, or component realized during a relief event
· Alteration: any work performed on an existing system that may change any aspect of the design specification or fluid service; this includes changes to the structural supports for piping or vessels and extension to piping.
· ASME Pressure Code: Any one of the following ASME Codes:
o ASME Boiler and Pressure Vessel Code
o ASME B31 Pressure Piping Code
o ASME PCC-2 Repair of Pressure Equipment and Piping
· ASME Pressure Vessel: Any vessel designed and fabricated in compliance with ASME BPVC bearing an ASME Code stamp (e.g. a U stamp for a Section VIII Div 1 vessel).
· Blow Down: Difference between opening pressure and closing pressure of a relief device.
· Category D Fluid Service: A fluid service, defined in ASME B31.3, in which all of the following apply:
o The fluid handled is nonflammable, nontoxic, and not damaging to human tissues as defined in ¶ 300.2
o The design gage pressure does not exceed 150 psi.
o The design temperature is not greater than 366°F
o The minimum fluid temperature caused by anything other than atmospheric conditions is not less than −20°F
· Construction: (or new construction) refers to any and all of the following activities performed on a new system: Design, Review, Purchasing, Fabrication, Assembly, Installation, Examination, Inspection, Testing, and Documentation.
· Credible Pressure Source: Any source of fluid pressure derived from normal operating conditions or reasonable failure mode such as fire or rupture of thin walled vessel. Other sources of pressure include condensed or plated room temperature gasses on cryogenic surfaces located inside an insulating vacuum chamber.
· Employee of Jefferson Lab: For the purposes of this Supplement employee shall refer to any employee of Jefferson Lab or temporary contract labor.
· Engineering Design: The detailed design governing a pressure system developed from process and mechanical requirements, conforming to Code requirements, and including all necessary specifications, drawings, and supporting documents.
· Examination: The observation, by suitable technique, of whatever portions of components, joints, and other elements that are exposed to such observation either before, during, or after manufacture, fabrication, assembly, erection, inspection, or testing. This examination may include verification of the applicable requirements for materials, components, dimensions, joint preparation, alignment, welding or joining, supports, assembly, and erection. Examinations are performed without damaging the test object.
· Excluded Element: Pressure component for which there are no directly applicable ASME Codes.
· Excluded Vessel: A pressure vessel not in full compliance with the requirements of the ASME BPVC.
· Hot Tapping: The method of making a connection or tie-in to existing piping or pressure vessels while the piping or vessel is on-stream and under pressure.
· Hydro-Pneumatic Test: A pressure or tightness test where the test fluid is a combination of gas and liquid.
· Hydrostatic Test: A pressure or tightness test where the test fluid is liquid.
· In-Service Inspection Category:
o IC4: ASME boilers and relief devices protecting them.
o IC3: ASME Section VIII Pressure Vessels and Category M systems and relief devices protecting them.
o IC2: Relief devices providing overpressure protection on Excluded Vessels or piping larger than 6 NPS.
o IC1: All other pressure equipment (e.g. piping, turbo and reciprocating machinery, Excluded Vessels, vacuum equipment such as insulating jackets, etc.).
· Inspection: Denotes the activities, performed by an Inspector, to verify that all required examinations and tests have been completed, and to ensure that all the documentation for material, fabrication, and examination conforms to the requirements of the applicable Code and the engineering design.
· Leak Test: A test that is performed post fabrication and prior to initial operation of a piping system to verify that the piping system is leak free.
· Listed Material: Any material with an accepted published specification, such as ASTM B209 for aluminum alloys.
· Low Temperature Cryogenic Component: Component with a MDMT of less than 77K (321F) or
· May: indicates an action that is permitted but not required with regard to the pressure safety program
· New Construction: See Construction
· Normal Fluid Service: fluid service, defined in ASME B31.3, as a service other than Category D or M.
· Peer Review: Review of work performed on a pressure system or component that is performed by one or more design authorities or subject matter experts from an organization or group that is not involved in the design or construction of the system or component. These reviews are required for any component where it is determined, by the system DA that national consensus codes do not directly apply.
· Pneumatic Test: A pressure or tightness test where the test fluid is a gas.
· Pressure System: any combination of vessels, piping, instrumentation (e.g. gauges), and/or equipment (e.g. pumps or compressors) either containing a fluid under internal pressure or exposed to external fluid pressure. Note that vacuum systems are a subclass of pressure systems.
· Pressure System Maintenance: any work performed on an existing system that does not change the fluid service or any aspect of the design and does not require welding or brazing. These activities include inspection, painting, corrosion control, gasket replacement, relief device maintenance, replacement of filter cartridges, etc.
· Pressure System Modification: See alteration
· Pressure System Operator: Operator or user of pressure equipment for any purpose other than testing.
· Pressure System Owner: Individual responsible for the operation, maintenance and in-service inspection of a pressure system.
· Pressure Test: A test performed to ensure the gross integrity of a pressure system or component. This test may be performed on new construction or on systems and/or components where the pressure boundary has been altered or repaired.
· Pressure Vessel: A container that contains a fluid under internal or external pressure not used for the sole purpose of conveying fluid from one point to another.
· Repair: any work performed on an existing system that does not change the fluid service or any aspect of the original design specifications including MAWP or design pressure, maximum/minimum design temperatures, piping/vessel routes and locations, sizes, and supports. Work not expressly considered an alteration shall be considered a repair.
· Responsible Vacuum Engineer: Individual responsible for the design, fabrication, documentation, etc. of Category 1 and 2 vacuum systems. The qualifications of these individuals shall be determined by their supervisors.
· Shall: indicates an action that is required or mandatory with regard to the pressure safety program
· Should: indicates an action that is considered good practice in most cases but, is not considered mandatory. In some cases, such action may not be appropriate.
· Stored Energy: Energy contained in the system fluid(s) considering pressure and chemical energies only.
· Technical Review: A review of design calculations or specifications to verify accuracy and compliance to predetermined requirements; national consensus codes; industry standards; or common scientific, engineering practice. This review shall be completed by a DA other than the DA responsible for the design.
·
ES&H Manual Chapter 6122 – Hot Work (i.e. Welding, Brazing,
Cutting and Grinding) Safety Program.
·
ES&H Manual Chapter 6151 – Pressure and
Vacuum Systems Safety Program
· American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel (BPV) Code Section VIII: Rules for Construction of Pressure Vessels, Divisions I & II and Sections I, IV, and VI
· ASME B31 Code for Pressure Piping:
o B31.1 Power Piping: applicable to piping generally found in electric power production and district heating plants
o B31.3 Process Piping: General piping code most applicable for piping systems at Jefferson Lab not associated with building services.
o B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids
o B31.5 Refrigeration Piping and Heat Transfer Components: Applicable to HVAC systems.
o B31.8 Gas Transmission and Distribution Piping Systems
o B31.9 Building Services: Applicable to piping carrying nonhazardous fluids at moderate temperatures typical in building services such as hot and cold water as well as instrument air systems.
o B31.11 Slurry Transportation Piping Systems
o B31.12 Hydrogen Piping and Pipelines
· ASME Boiler and Pressure Vessel Code Case 2286, July 17, 1998
· Vacuum Systems Consensus Standard for Department of Energy Accelerator Laboratories, July 20, 2008 Draft.
· J.L. Western, Technical Memo 1380 Brookhaven National Laboratory
· W.C. Young, Roark’s Formulas for Stress and Strain, Sixth ed. (1988).
· S. Timoshenko and S. Woinowsky-Krieger. Theory of Plates and Shells (1959).
· American Petroleum Institute (API)
o API 576 Inspection of Pressure Relieving Devices.
o API 520 Sizing Selection and Installation of Pressure-relieving Devices
o API 521 Guide for Pressure-relieving and Depressuring Systems
· American Society of Mechanical Engineers (ASME) PTC-25
· National Board Inspection Code Parts 1, 2, 3 and 4 (NB-23)
· Jefferson Lab Welding and Brazing Supplement.
Revision 1.1 – 01/10/19
- Updated Section 1.7 to comply with
January 2019 DOE revisions to 10 CFR 851. Remove years associated with
standards.
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QA/CI Dept. |
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