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Pressure and Vacuum Systems Safety Supplement Part
2: Pressure System Construction |
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Pressure systems with a design initiated on or after January 4, 2016 shall meet the requirements of Part 2 of this Supplement. For pressure systems under construction prior to the above start date, the assigned DA shall choose to either follow Part 2 of this Supplement or continue following Revision 3.4 of ES&H Manual Chapter 6151 Pressure and Vacuum Safety Program and its Technical Appendices. If Revision 3.4 is followed, the DA must still complete Form PS-1, Form PS-4 and Form PS-5 of this Supplement; create and file a P&ID; and complete the steps defined in Part 2: Section 2.10 Inspections and Part 2: Section 2.11 System Turnover.
The tasks associated with new construction are as follows:
· Design
· Technical Review or Peer Review
· Purchasing
· Fabrication
· Assembly
· Installation
· Examination
· Inspection
· Testing
· Documentation
Note that alterations and repairs are not considered new construction and are considered in Part 5: Repair and Alteration.
The DA assigned to new construction shall determine which requirements are applicable and ensure that they are met. In all cases, the DA shall ensure that adequate overpressure protection is provided. The DA is encouraged to consult other DAs and the Pressure Systems Committee for guidance. The responsibilities of the DA shall terminate upon completion of all construction activities and the pressure system is turned over to a System Owner.
For pressure systems built on-site by subcontractors, the DA/SOTR is responsible for ensuring that the contract includes requirements for personnel to be appropriately trained and qualified to perform the work as well as trained in the hazards of pressure if exposed. Training and qualification through the subcontractor is acceptable.
This Part does not apply to Category 0, 1, and 2 vacuum systems or components. These components shall meet the requirements of Part 7: Vacuum Systems.
Pressure vessels not excepted from the Pressure and Vacuum Systems Safety Program shall be designed and fabricated, to the greatest extent that is reasonably possible, in full compliance with the ASME BPVC. Vessels shall be categorized as follows:
· ASME Pressure Vessels: Vessels which have been designed and constructed in full compliance with the ASME Boiler and Pressure Vessel Code.
· Excluded Vessels: Vessels that cannot be designed and/or constructed in full compliance with the ASME Boiler and Pressure Vessel Code.
Vessels that are in full compliance with the ASME BPVC must bear the required marking or “Code Stamp”. A Code Stamp may only be affixed by an organization possessing a valid ASME Code Stamp and a valid Certificate of Authorization from the ASME. ASME Pressure Vessels may be designed by Jefferson Lab but shall not be fabricated by Jefferson Lab.
The applicable Code for all vessels shall be the ASME Boiler and Pressure Vessel Code. Every reasonable effort shall be made to design and construct pressure vessels in full compliance with the Code. In cases where an ASME BPVC Section cannot be directly applied or is expressly excluded (cf. ASME BPVC VIII D1 U-1(c)(2)), in any aspect of design or fabrication, the DA shall employ sound engineering principles and select a Division and Section (if applicable) of the Code that is most applicable. The selected Code is known as the most applicable ASME Code. All vessels where the Code cannot be directly applied shall be considered an Excluded Vessel. The requirements for Excluded Vessels are given in Part 2: Section 2.2.3 Excluded Vessels.
Below is a list of the codes and standards that may be applicable to Jefferson Lab pressure vessel construction and installation (included are brief descriptions of where these Codes may be applicable):
Pressure vessels:
· ASME Boiler and Pressure Vessel Code
o Section I: Rules
o Section II: Specifications for materials including tables of allowable stresses.
o Section IV: Rules for Construction of Heating Boilers
o Section V: Specifications for non-destructive testing
o Section VIII: Rules for construction of pressure vessels. This Section is split into 3 divisions.
§ Division 1 is the standard set of rules.
§ Division 2 is alternative rules where more detailed analysis is required but, lower factors of safety are allowed.
§ Division 3 consists of rules for high pressure vessels.
o Section IX: Welding and Brazing Qualifications
Pressure-Relieving Devices:
· American Petroleum Institute (API)
o API 520: Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries applies to the sizing and selection of pressure relief devices used in refineries, chemical facilities and related industries and gives excellent guidance for selecting relief devices
o API 521: Guide for Pressure-relieving and Depressuring Systems. This Code gives guidance for determining the causes of overpressure and mitigating measures that can be taken.
Installation:
· National Board Inspection Code (NBIC) / NB-23
o Part 1: Installation
o Part 2: Inspection
o Part 4: Pressure Relief Devices
For all new construction, the Code of Record for a pressure vessel shall be that version (or Code year) of the most applicable ASME BPVC Division in effect 6 months prior to the start date of the vessel 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 vessel regardless of whether or not the Code can be fully applied.
ASME Pressure Vessels shall be categorized as follows:
· Vessels of a unique design built for a specific Jefferson Lab purpose.
· Standard or off the shelf vessels such as air compressor tanks, propane vessels, and others considered to be of standard design.
The DA shall specify (or cause to be specified) the applicable Division and Section of the Code and all critical aspects of the engineering design as given below:
· Basic use requirements
o Fluid Service such as lethal or flammable service
o Metal temperatures (minimum and maximum)
o Maximum internal pressure and coincident temperatures
o Maximum external pressure and coincident temperatures
o Function
o Geometry
o Insulation
o Supports
o Nozzle and piping attachments
· Material requirements
o Special environmental conditions such as exposure to rain, wind, snow, ice, magnetic fields
o Corrosion allowances
o Hydrogen or hydrocarbon exposure
· Loading
o Wind, rain, seismic, etc. loading
o Cyclic loads
o Loads from attachments such as ancillary piping and compressors.
o Thermal gradients and other loads
· Overpressure protection
o Type and capacity
o Consider all credible failure modes.
Additional guidance can be found in ASME BPVC Section VIII D1 Appendix KK.
ASME Pressure Vessels may be designed by Jefferson Lab or another organization. The associated calculations shall be reviewed by the system DA and the Authorized Inspector (AI) as required by Code. A Jefferson Lab technical review (see Part 2: Section 2.5.1.1 Technical Review) shall also be performed.
Fabrication of vessels of unique design shall be performed by an agency possessing a valid ASME Stamp as required by the Code of Record.
The following documentation shall be required (or recommended as noted)
· Design drawings
· Design calculations and associated reviews
· Welding documentation (recommended only)
o Weld maps
o Welding and Brazing PQR and WPQ/BPQ
· Material certifications (recommended only)
· Testing records (recommended only)
· Manufacturers Data Report (i.e. Form U-1 or U-1A etc.)
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The DA shall ensure that this documentation is filed in the appropriate folder in the Pressure Systems database as required in Part 1: Section 1.5 Required Documentation.
A nameplate bearing an ASME stamp (e.g. U or UM stamp) must be affixed to all vessels meeting the full requirements of the Code. The DA shall ensure that the manufacturer’s data report (e.g. Form U-1 or U-1A) is obtained from the manufacturer and filed in the appropriate folder in the Pressure Systems database as required in in Part 1: Section 1.5 Required Documentation. Form U-1, U-1A, etc. shall be considered as sufficient review and documentation of the required calculations, examinations and other fabrication documents.
The DA shall ensure that the basic requirements listed in Part 2: Section 2.2.2.1.1 Basic Requirements are met by the standard vessel.
Vessels where the ASME BPVC cannot be directly applied to all areas of construction (design and fabrication) are considered Excluded Vessels. These vessels present challenges that can be as unique as the engineering design and applications for which they are intended. The DA may determine that the ASME BPVC does not directly apply to a vessel for one or more of the following reasons:
· The vessel is expressly excepted or excluded from all Divisions of the ASME BPVC.
· The vessel is considered to be equipment such as a mechanical pump, compressor, or turbo machinery.
· The vessel must be fabricated from unlisted materials.
· The vessel must operate under extreme conditions outside the scope of the ASME BPVC
· The vessel has special geometry, including thin sections, weld geometries, etc.
· The vessel is considered to be instrumentation.
· The vessel is considered as internal piping
· Scientific or functional requirements of the engineering design preclude strict adherence to Code requirements. Examples of this include some experimental target vessels and some superconducting magnets.
· The vessel cannot be tested or examined using methods given in the Code.
Excluded Vessels shall be designed and fabricated to meet the requirements of the most applicable ASME BPVC Section and Division to the greatest extent that is reasonably possible. For vessels designed on-site, the DA shall be responsible for the determination of the most applicable Code. For those designed off-site, the DA shall be responsible for the Code selection and shall either determine the applicable Code Section and Division or approve this selection.
For the specific Code requirements that cannot be met, Equivalent Measures shall be employed as required in Part 3: Equivalent Measures (paying particular attention to the definition and duties of the “Owner/User”, the “Manufacturer”, and the “Inspector” described therein). Design documentation, drawings, calculations, etc. shall be peer reviewed and filed in the appropriate pressure system folder.
Design and fabrication of these vessels shall also conform to the requirements given in Part 2: Sections 2.4 Design, Part 2: Section 2.5 Reviews, Part 2: Sections 2.6 Use of Unlisted Components, and Part 2: Section 2.7 Materials with the exception that the applicable Code is the ASME BPVC.
The DA shall determine the extent of examination required by Code and the engineering design and ensure that these examinations are completed by individuals qualified as given in Part 1: Section 1.4.2 Examiners. Examinations shall also meet the requirements of Part 2: Section 2.9 Examination with the exception that the applicable Code is the ASME BPVC.
The DA shall ensure that the testing required by the Code is completed and documented as required in Part 6: Pressure and Leak Testing.
Welding inspections shall be completed by the Jefferson Lab QA/CI Inspector or an individual designated by the QA/CI Inspector. The DA shall determine the extent of any additional inspections and the qualifications of the inspectors. This determination shall be peer reviewed.
Vessels may be repurposed or procured as preowned for use at Jefferson Lab. These vessels may be ASME Pressure Vessels or Excluded Vessels (e.g. superconducting magnets).
The DA shall ensure that vessels meet the basic requirements of the engineering design as given in Part 2: Section 2.2.2.1.1 Basic Requirements. The DA shall further consider the current condition of the vessel including wall thickness after possible corrosion, exposure to fluids incompatible with the current system fluid, etc. These considerations may require that the MAWP or other operating limit of the vessel be derated.
Reconditioned vessels that required repair or alteration shall have been repaired or altered by an agency possessing a valid National Board R Stamp. The Form R-1 or R-1A shall be filed with the original manufactures data report (Form U-1 or U-1A etc.). A current valid inspection shall also be filed with these forms. This inspection shall conclude that the vessel is acceptable for use in the current system.
The acceptance of Excluded Vessels not originally fabricated by Jefferson Lab or authorized subcontractors of Jefferson Lab shall be performed on a case by case basis. The Pressure Systems Committee Chair shall determine the requirements for acceptance and review. Independent review such as the experimental equipment review process may be considered acceptable.
The acceptance of Excluded Vessels fabricated by Jefferson Lab or an authorized subcontractor of Jefferson Lab shall be determined by Jefferson Lab peer review (see Part 2: Section 2.5.1.2 Peer Review).
All pressure vessels and boilers are to be numbered with a specific and unique number for each vessel. This number shall be conspicuously and durably displayed on the vessel. The numbering scheme shall be as follows:
· The Jefferson Lab Building Identification Number – The System abbreviation as in PS number (see Part 1: Section 1.5.2 Numbering Convention) - Sequential number of vessel in system: B#-PS-ABC-XX-123-V#
· The Building number B# shall be the building in which the vessel is located or services. B# shall be 00 for portable vessels.
· For example: The helium after cooler on Compressor #1 in the CHL addition would display the following tag:
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08-PS-CHL-XX-001-1 |
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· A second vessel would then be labeled with -2 instead of -1.
The DA is responsible for the initial tagging of the vessels. Once operational, the System Owner shall be responsible for the continued integrity of this marking (i.e. readability).
This number shall also be clearly applied to the vessel in the system P&ID (see Part 1: Section 1.5.5 Folder Content).
The DA shall complete a pressure vessel registration form (Form PS-4) for each new pressure vessel (Excluded and ASME). This form shall be provided to the Vessel Inspection Coordinator along with a copy of the associated P&ID. This form shall also be filed in the appropriate folder in the Pressure Systems database.
The DA shall assign the appropriate in-service inspection type and frequency as given in Part 9: Section 9.2 In-service Inspection Expectations and Procedures. If other types of inspections are required, the DA or System Owner shall note this requirement.
The DA shall ensure that all vessels are considered in the performance of the walkthrough and turnover as given in Part 2: Sections 10 Inspections and Part 2: Section 11 System Turnover.
Pressure piping shall be designed, fabricated, tested, and inspected, to the greatest extent possible, in compliance with the ASME B31 Code for Pressure Piping. Where full compliance is not possible, equivalent measures as defined in Part 3: Equivalent Measures shall be applied. The requirements for the construction of pressure piping are given in Part 2: Section 2.3 Pressure Piping, Section 2.4: Design, Section 2.5 Reviews, Section 2.6, Use of Unlisted Components, Section 2.7 Materials, and Section 2.8 Fabrication by Welding, Brazing and Soldering. Part 2: Sections 2.10 Inspections and Section 2.11 System Turnover shall be completed after leak testing and prior to system operation.
The DA shall be responsible for the determination of the applicable ASME B31 Piping Code(s) and/or other relevant Code(s) for each component in a pressure system. The application of multiple Piping Codes may be required depending on the complexity of the system. The applicable Code(s) for pressure piping and associated components depend upon their end use or purpose. If used to generate power, ASME B31.1 applies. If used as building services, ASME B31.9 applies. If used as part of a process, ASME B31.3 applies. If a pressure component is clearly not within the scope of these or other B31 Codes, the Code permits the DA to select any B31 Code System determined to be generally acceptable.
Every reasonable effort shall be made to design and construct pressure components in full compliance with these Codes. In cases where an ASME Piping Code cannot be directly applied or is expressly excluded (cf. ASME B31.3 300.1.3), in all aspects of design or fabrication, the DA shall employ sound engineering principles and select an ASME Piping Code that is most applicable. The selected Code is known as the most applicable ASME Code. All components where ASME Codes cannot be directly applied shall be considered Excluded Elements. The requirements for Excluded Elements are given in Part 2: Section 2.3.2 Excluded Elements.
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 system design (a later version may also be used, if available, at the discretion of the DA). For pressure systems that are constructed complete by subcontractors, the latest edition issued at least 6 months prior to the original contract date shall be used. For building services, the Code of Record shall be chosen as stated in applicable building codes. A Code of Record shall be determined for each component regardless of whether or not an ASME Pressure Code can be fully applied.
Below is a list of Codes which may be used in Jefferson Lab pressure system construction and installation:
Pressure Piping:
· 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 - 2002 - 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 - 2003 - 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 - 2002 - Slurry Transportation Piping Systems
o B31.12 Hydrogen Piping and Pipelines
Pressure-Relieving Devices:
· American Petroleum Institute (API)
o API 520:Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries applies to the sizing and selection of pressure relief devices used in refineries, chemical facilities and related industries and gives excellent guidance for selecting relief devices
o API 521: Guide for Pressure-relieving and Depressuring Systems. This Code gives guidance for determining the causes of overpressure and mitigating measures that can be taken.
Installation:
· National Board Inspection Code (NBIC) / NB-23
o Part 1: Installation
o Part 2: Inspection
o Part 4: Pressure Relief Devices
Components where ASME Pressure Codes cannot be directly applied to all areas of construction (design and fabrication) are considered Excluded Elements. These components present challenges that can be as unique as the engineering design and applications for which they are intended. The DA may determine that the ASME Codes listed in Part 2: Section 2.3.1 Applicable Codes do not directly apply to a system, subsystem, or component for the following reasons:
· The component(s) is expressly excepted or excluded from all the ASME Codes listed in Part 2: Section 2.3.1 Applicable Codes.
· The component(s) is considered to be a mechanical pump, compressor, or turbo machinery.
· The component(s) must be fabricated from unlisted materials.
· The component(s) must operate under extreme conditions outside the scope of the ASME B31 Piping Code.
· The component(s) has special geometry, including thin sections, weld geometries, etc.
· The component(s) is considered to be instrumentation.
· The component(s) is considered as internal piping
· Scientific or functional requirements of the engineering design preclude strict adherence to Code requirements.
· The component(s) cannot be tested or examined using methods given in the ASME Codes.
In such cases, the component(s) shall be considered an Excluded Element. Excluded Elements shall be designed and fabricated to meet the requirements of the most applicable Code as much as is reasonably possible. For components designed on-site, the DA shall be responsible for the determination of the most applicable Code. For components designed off-site, the DA shall be responsible for this Code selection and shall either determine this Code or approve the selection of the most applicable Code. For the specific Code requirements that cannot be met Equivalent Measures shall be employed as required in Part 3: Equivalent Measures.
The DA shall ensure that all calculations and considerations required by the applicable Code, the engineering design, and Jefferson Lab policy are performed. The DA may make use of work performed by others but shall assume responsibility for the applicability and accuracy of such work. All calculations shall be reviewed. For components where ASME Pressure Codes can be directly applied, a Technical Review (see Part 2: Section 2.5.1.1 Technical Reviews) shall be performed. For components where an ASME Pressure Code cannot be directly applied, a Peer Review (see Part 2: Section 2.5.1.2 Peer Review) shall be required. For work performed by organizations other than Jefferson Lab, the assigned DA shall ensure that all calculations and documentation required by Code and/or the engineering design are completed and reviewed. All documentation shall be filed as required in Part 1: Section 1.5 Required Documentation.
The engineering design shall be formalized in a general statement of work (SOW) or system specification for the construction of the pressure system. For simple systems, Form PS-1 Pressure Systems Cover Sheet may suffice. The engineering design shall be as consistent as reasonably possible with the most applicable ASME Pressure Code(s) while maintaining the functionality, performance, and applicability required by the owner/user. The DA shall be responsible for developing the engineering design.
A Technical Review is a formal review performed by any other DA. This review shall be documented on Form PS-3. The reviewer shall ensure that the required calculations or other aspects of the design have been performed according to the Code of Record. The assigned DA may perform Technical Reviews of calculations performed by other DAs or qualified individuals employed by organizations other than Jefferson Lab.
A formal review of the design, construction, or other aspect of a component performed by at least one DA not associated with the project and not a member of the same group as the system DA. Peer Reviews may also be conducted by qualified individuals (e.g. professional engineers with applicable experience) not employed by Jefferson Lab. This review shall be documented on Form PS-3.
Note that many common components such as Swagelok tube and piping fittings are unlisted. The ASME B31 Piping Code allows for the use of unlisted components with the consent of the owner. The assigned DA shall assume this duty of the owner. Therefore the use of unlisted components is solely at the discretion of the DA. The DA shall ensure that all required calculations are performed and properly documented; technical or peer reviews shall be performed as appropriate. No justification for the necessity for using unlisted components is required; however, the pressure design for these components shall be substantiated as required by the applicable Code. Specific guidance and a list of preapproved unlisted components are given on the Pressure Systems webpage.
Qualification of unlisted components shall be as required by the most applicable ASME Code. Note that the required use (possibly forced by the engineering design) of unlisted components does not necessary imply that their use is not fully compliant with the selected Code. Equivalent measures may not be required. Unlisted piping components shall meet the requirements listed in ASME B31.3 304.7.2. The choice of the qualification method shall be at the discretion of the DA.
The DA shall carefully consider the choice of materials for all pressure components (equipment vessels and piping). The selected materials shall be compatible with the fluid service, system fluids, and the engineering design. Where specialized materials not listed in the applicable Code(s) (i.e. unlisted materials) are required, equivalent measures given in Part 3: Equivalent Measures shall be applied.
The DA shall consider at least the following when selecting materials for use:
· Fluid compatibility
o Gaseous vs liquid states
o Corrosion, rust, scale etc.
o Embrittlement which is often affected by pressure.
o Flammability
o Many non-metallic materials (e.g. PVC, CPVC, etc.) are unsuitable for gaseous service.
· Engineering design may have the greatest effect on the material choice.
o Performance
o Compatibility with experimental requirements
· External fields may degrade a material or apply additional loading
o Ionizing radiation (Non-metallic materials may be especially impacted by prolonged exposure to radiation)
o Static magnet and electrical
o RF fields
· Temperature extremes may reduce the allowable stress and/or force special requirements for testing.
o Cryogenic requirements
o High temperature ovens and bakeouts.
o Non-metallic materials may be unsuitable for any service in extreme temperatures.
· Material form must be compatible with application. Bar may not be allowed for some components due to the grain structure for example.
o Plate
o Wrought
o Tube/pipe
o Casting
o Forged
o Bar
o Etc.
· Welding/Brazing may significantly change the properties of the base metal such as annealing aluminum thereby decreasing the maximum allowable stress.
o Base metal
o Weld metal
o Heat affected zone
o Resulting weld chemistry
o Flux
· Material degradation from exposure to sunlight and seasonal or diurnal temperature changes may be possible.
o Exposure times
· Cyclic loading
· Brittle fracture and toughness may be of concern especially for cryogenic systems.
· Other environmental factors
o Electrolysis
The above list is in no way complete. The DA shall employ sound engineering principles when making material selections.
Materials of unknown origin shall not be used. This does not necessarily require material certifications or mill test reports (CMTR). ASTM markings (including heat#) on piping material may be acceptable when specific chemistry is not required such as having a low carbon content. The DA shall determine the extent of documentation required.
All welding, brazing, and soldering operations affecting the pressure boundary of a component shall be performed by certified personnel using qualified procedures. Personnel and procedures shall meet the requirements of the Jefferson Lab Welding and Brazing Supplement and of the applicable ASME or NB Code of construction or post construction. Where ASME Pressure Codes do not directly apply, the DA shall determine the most applicable Code. See Part 2: Section 2.8.5 Unlisted Materials for requirements relating to unlisted materials.
Welding and brazing performed on support elements, not directly attached to a pressure boundary by weld or braze, shall be performed by certified personnel using qualified procedures. The personnel and procedures shall meet the requirements of the most applicable ASME Pressure Code or AWS Structural Welding Code and the Jefferson Lab Welding and Brazing Supplement.
Welding, brazing, and soldering operations include the following:
· Design of welded, brazed, or soldered connections (including design drawings and analyses)
· Weld, braze, and solder operations directly affecting the pressure boundary of any pressure component.
· Welding or brazing operations performed on support elements
· Certifications of welders, brazers, and solderers
· Certifications of examiners
· Certifications of Inspectors
· Qualification of welding, brazing, and soldering procedures
· Welding/brazing documentation
· Welding, brazing, and soldering of unlisted materials
The requirements of this section are applicable to all pressure components and attachments to their pressure boundaries (see exceptions below). These requirements also apply to support elements of pressure equipment including piping hangers, rollers, springs, structural supports and attachments, etc.
The following are exempt from the requirements of this section:
· Category 0 Vacuum systems: all weld, braze, and solder joints
· Category 2 Vacuum systems: all weld, braze and solder joints on components less than 35 ft3 in volume or having no cross section larger 33 in2.
· Welding, brazing, and soldering, not directly affecting a pressure boundary, for supports for small elements such as instrumentation or signage.
Welding, brazing, and soldering performed on a pressure boundary of a Category 1 or 2 (see above for size exception) vacuum system component shall be performed by qualified personnel using qualified procedures. These procedures shall meet the requirements of ASME B31.3 or the most applicable AWS Code.
The DA shall ensure that all welding, brazing, and soldering joint designs meet the requirements of the code of construction and those given in the Welding and Brazing Supplement. (Note: Joint designs may be other than those listed explicitly in the code of construction. See for example ASME B31.3 § 304.7.2.)
The DA shall complete the Design Parameter Form for welds and brazes or provide the specifications on a drawing, specification, or other document (e.g. statement of work). These specifications shall include:
· Applicable Code
· Design pressures/temperatures
· Leak/Test pressure and method
· Sensitive Leak test specification (if applicable)
· Examination requirements and methods
· Inspections required
· Other applicable NDE
Note: Welding and brazing examinations are not to be considered inspections.
Examinations of welds and brazes shall be performed as required by the most applicable ASME, NB, or AWS Code. These examinations shall be performed by personnel qualified to perform the specified examination process. Examinations shall not be performed by the welder(s), operator(s), or brazer(s) performing the actual weld or braze.
The extent of the required examinations shall be specified by the DA. The examiner shall complete a weld examination report; the DA shall ensure that this report is filed with the pressure system documentation as required in Part 1: Section 1.5.5 Folder Content.
Inspections of welds and brazes shall be performed where required by the applicable code and the engineering design. These inspections shall be performed by a CWI as given in Part 1: Section 1.4.3.3 Welding and Brazing Inspectors. The inspector (at his or her discretion) may inspect the following:
· Welds, brazes, fitting, etc.
· Qualification records for procedures, welders, and brazers
· Quality program documentation
The inspector shall complete a weld inspection report; the DA shall ensure that this report is filed with the pressure system documentation as required in Part 1: Section 1.5.5 Folder Content.
Welding procedure specifications (WPS) used by employees of Jefferson Lab for welds directly affecting a pressure boundary, shall meet the requirements of ASME BPVC IX. These procedures shall be approved and maintained by the designated CWI. Where a welding procedure is only to be used on support elements not directly attached (by welding) to a pressure boundary, the WPS shall conform to either ASME BPVC Section IX or the most applicable AWS Code.
Welding procedures used by agencies other than Jefferson Lab shall meet the requirements of the Code of construction/post construction. Certified copies of these procedures shall be filed with the pressure system documentation as required in Part 1: Section 1.5.5 Folder Content.
Standard welding procedures may be used by Jefferson Lab employees provided that they are approved by the designated CWI and meet the requirements of the most applicable Code. Standard procedures may be used by other agencies provided that they are used within the limits of the most applicable Code.
Excluded Elements shall be welded using procedures that conform, as much as practicable, to the requirements of ASME BPVC Section IX. For welding to be performed by Jefferson Lab employees, these procedures shall be approved by the designated CWI. For welding performed by agencies other than Jefferson Lab, a Peer Review shall be performed to approve the procedure. Certified copies of these procedures shall be filed with the pressure system documentation as required in Part 1: Section 1.5.5 Folder Content. See Part 2: Section 2.8.5 Unlisted Materials for additional requirements and guidance.
Brazing procedures specifications (BPS) used by Jefferson Lab employees shall meet the requirements of ASME BPVC IX. These procedures shall be approved and maintained by the designated CWI.
Brazing procedures used by agencies other than Jefferson Lab shall meet the requirements of the code of Construction. Certified copies of these procedures (if BPS’s are required) shall be filed with the pressure system documentation as required in Part 1: Section 1.5.5 Folder Content.
Excluded Elements shall be brazed using procedures that conform, as much as practicable, to the requirements of ASME BPVC Section IX. For brazing to be performed by Jefferson Lab employees, these procedures shall be approved by the designated CWI. For brazing performed by agencies other than Jefferson Lab, a Peer Review shall be performed to approve the procedure. Certified copies of these procedures shall be filed with the pressure system documentation as required in Part 1: Section 1.5.5 Folder Content. See Part 2: Section 2,8.5 Unlisted Materials for additional requirements and guidance.
The joining of piping and tubing by soldering shall conform to ASTM B828.
Design drawings and sketches drawn by Jefferson Lab personnel shall be signed by the DA. Drawings and sketches specifying weld, braze, and solder joints shall detail the following:
· Weld symbols shall conform to AWS A2.4. Other standards may be used provided that the chosen standard is clearly indicated on the drawing or sketch.
· Code for welding and examination
· Base and filler metal specifications
· Examination requirements
· WPS (for welds to be performed by Jefferson Lab employees)
This drawing or sketch may be used as a traveler/weld map. The drawing or sketch shall be filed with the pressure system documentation as given in Part 1: Section 1.5.5 Folder Content.
At the discretion of the DA, a Design Parameter Form provided in the WBS may be used in lieu of a detailed list of specifications, requirements and/or as a traveler.
The DA shall determine the signature requirements and content for drawings and sketches drawn by agencies other than Jefferson Lab.
The DA shall determine the extent of documentation required for qualifications. The documents or reference number with alternate storage location shall be filed with the pressure system documentation as required in Part 1: Section 1.5.5 Folder Content.
Documentation such as weld/braze maps providing weld traceability shall detail the following:
· Unique welder or brazer identification
· Base and filler metal heat or lot numbers
· Examiner identification
Examination and inspection reports shall be filed with the pressure system documentation as required in Part 1: Section 1.5.5 Folder Content.
In all soldering operations, the filler shall melt below 840°F. Soldering may be performed within the limits of the code of construction. Personnel shall perform soldering operations in conformance with ASTM B828 or CDA Copper Tube Handbook. Use of solder joints is prohibited under the following conditions:
· Flammable or toxic fluid service.
· Fluid service temperatures above 250°F.
· Gaseous service in piping with a cross sectional area larger than 12.6 in2 (4 in ID piping)
When designing solder joints, the DA shall consider the following:
· Corrosion effects and other chemistry associated with the solder and flux.
· Effects on the base metal temper from heat affects associated with soldering operations.
Attachments of thermal-couples, instrumentation, etc. to the pressure boundary of a component may be made using low temperature soft solder at the discretion of the DA.
Welding or brazing with unlisted base or filler metals shall be allowed provided a WPS or BPS is developed. This procedure shall conform as much as possible to ASME BPVC Section IX. Limitations or other effects (e.g. reduced fracture toughness, reduced temper, etc.) shall be noted on the WPS or BPS as applicable. These limitations shall be considered by the engineering design. Procedures used by Jefferson Lab employees shall be approved by the designated CWI.
The DA shall ensure that all examinations required by Code, Jefferson Lab policy, and the engineering design are completed. The DA shall determine the extent of the examinations required.
Examinations shall be categorized as follows:
· Welding/Brazing examinations
· Mechanical examinations
Welding examinations shall be completed by certified individuals as given in Part 1 Section 1.4.2.1 Welding and documented as required in Part 2: Section 2.8.1.4 Examinations. The selection of the method chosen for welding examinations shall be at the sole discretion of the DA responsible for the system. These examinations shall meet the requirements of the most applicable ASME Code and the engineering design. The DA may seek advice and council when making this determination but, with the exception of a peer review, shall not be constrained in this decision. The DA may choose RT (radiographic testing), UT (ultrasonic testing), VT (visual testing) or any other method approved by Code.
The following additional examinations shall be performed where applicable and in accordance with the Code of Record:
· Materials, components (e.g. fittings, valves, etc.), and products to ensure that they meet specifications and the requirements of engineering design.
· Applicable procedures for assembly, glue bonding, etc.
· Assembly of threaded, bolted and other joints shall conform to Code and engineering design.
· Alignment, supports, and cold spring meet requirements of the engineering design.
· Dimensional checks of components and materials shall meet the requirements of Code and the engineering design.
In-process mechanical examinations shall be performed and documented as applicable and in accordance with the Code of Record. A final mechanical examination shall be completed when installation is complete. This examination shall be performed by qualified individuals (see Part 1: Section 1.4.2.2 Mechanical) and documented by completing Form PS-6. The DA shall ensure that these examinations (in-process and final) are completed and that all documentation is filed in the appropriate pressure system folder.
All new pressure systems (equipment, vessels, and piping) shall be inspected by one or more qualified pressure system construction inspectors. Except as otherwise noted, all references to “inspector(s)” without a qualifier such as “in-service” shall refer to this qualified pressure system inspector. These inspector(s) shall meet the qualifications given in Part 1: Section 1.4.3 Inspectors. The inspector shall not be involved in any design or fabrication process associated with the pressure system. The inspector shall complete the final system walkthrough as given in Part 2: Section 2.10.1 Inspections, and witness the final system pressure test. Upon agreement of the inspector, the System Owner, and the system DA, the inspector may forego the witness of the final system pressure test.
For all new construction (equipment, vessels, and piping), an inspector or team of inspectors shall perform a final system walkthrough prior to system startup. The completed final walkthrough shall include the following:
Form PS-1 Pressure System Project Cover Sheet is complete and filed.
Form PS-2 complete and filed if applicable.
Review of construction documentation including:
o Review of pressure/leak test documentation, completed and filed (Form PS-7)
o Technical and Peer Reviews have been performed and filed (Form PS-3).
o Ensure that welding and brazing inspections have been performed if applicable
o Ensure that final mechanical examination has been performed, (Form PS-6)
o Ensure that fabrication documents (e.g. weld and non-weld examinations, and material certs) have been filed.
Review of P&ID, critical elements (i.e. relief devices, vessels, relief paths etc.) match as-built condition.
Conspicuous and durable Jefferson Lab specific tags are installed on pressure vessels and boilers
Form PS-4 and Form PS-5 are filed for vessels and their relief valves
General physical system condition and readiness.
Checks on all relief devices providing overpressure protection.
o Through direct visual examination, relief devices (providing overpressure protection) are installed and that the relief paths are free (e.g. stop valves are locked open, test plugs removed etc.) and direction of discharge is safe.
Upon completion of a successful system walkthrough, the inspector shall issue a final inspection report (Form PS-8) stating that the pressure system is acceptable for use. The DA shall file this with the system documentation. When the system contains piping, the inspector(s) shall be aware that they are acting as the B31 “Owners Inspector.”
After completion of the final system walkthrough and prior to normal operations, the DA shall turn the system over to the System Owner. The DA shall ensure that the following tasks are completed on Form PS-9:
· Operating requirements are defined and documented.
· Any special maintenance requirements are defined and documented such as
o Replacement intervals for thin windows upon lifetime/exposure limits
o Replacement intervals for parts exposed to cyclic loading
o Cathodic corrosion protection replacement
· In-Service Inspection requirements are defined and documented. See Part 9: Pressure Equipment In-Service Inspection Program for details.
Both the DA and System Owner shall sign and date the form. The DA shall forward the completed form to the Pressure Systems Committee Designee for filing and incorporation into the operating pressure systems database.
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ISSUING AUTHORITY |
SUPPLEMENT AUTHOR |
APPROVAL DATE |
REVIEW DATE |
REV. |
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QA/CI Dept. |
11/06/15 |
11/06/20 |
1.0 |
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