ES&H Manual

Pressure and Vacuum Systems Safety Supplement

Part 8: Operation and Maintenance

 

 

Part 8:               Operation and Maintenance

 

8.1           Operation

 

The requirements of this section apply to all pressure systems regardless of design or fabrication date. The System Owner is responsible for the safe operation of the pressure system.

 

In the event that ownership of a system is reassigned, the new System Owner is responsible for communicating this change to the Pressure Systems Committee Designee.

 

Reasonable steps shall be taken to ensure that the system is operated by qualified personnel with adequate training. Operators of pressure systems shall meet the qualifications given in Part 1: Section 1.4.4 Operators and Users. Operators of pressure systems shall have specific system training as determined by the System Owner. This training shall include understanding of the operational characteristics of the system, operating strategies, inherent hazards associated with the system and requirements for addressing all credible failure scenarios, and emergency procedures.

 

The System Owner shall develop to the extent deemed necessary operating procedures required for the safe and reliable operation of the system. These procedures shall be maintained by the System Owner. These may be filed in the Operations folder for the pressure system in the Pressure Systems database.

 

In all cases, operation of the system shall conform to the engineering design limits. System Owners and/or Operators shall regularly check the pressure system considering the following items:

 

       Check pressure relief valves, gages, rupture disks, vessels, piping and other system components (compressors, pumps, etc.) for leaks, degradation, corrosion and blockage.

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

       Monitor and maintain pressure systems within operational parameters with installed instrumentation

 

If a system is taken out of operation permanently, the System Owner is responsible for communicating this change to the Pressure Systems Committee Designee.

 

If a pressure vessel or boiler is removed from service, the System Owner must notify the Vessel Inspection Coordinator of a change in status. The pressure equipment database shall be updated to reflect this change. Before a vessel is placed back into service, it must be re-inspected as described in Part 9: Section 9.2 In-service Inspection Expectations and Procedures.

 

The System Owner shall notify the Vessel Inspection Coordinator regarding a change in status of a relief device protecting a pressure vessel/boiler or a Category M system or piping larger than 6 NPS. The master list shall be updated, by the Vessel Inspection Coordinator or Pressure Systems Committee Designee, as required.

 

8.2           Maintenance

 

The requirements of this section apply to all pressure systems regardless of design or fabrication date. Work on Category M, or other hazardous (as determined by the ESH manual) systems where the system pressure boundary is breached shall be considered a repair. Work on flammable fluid systems where the pressure boundary is breached or hot work is performed near the pressure boundary and the fluid system cannot be inerted shall be considered a repair. Work which requires hot work (welding, grinding, cutting and/or brazing operations) on the pressure boundary shall be considered a repair. Machining operations not considered hot work on components not larger that NPS 5 (DIN 125) may be considered maintenance provided that the original system design specification is maintained.

 

Examples of maintenance activities include:

 

         Painting and corrosion control

         Oil changes

         Wear pad replacement

         Valve seal replacement

         Filter cartridge replacement

 

The System Owner shall be responsible for maintaining the integrity and placement of vessel identification markings.

 

8.2.1   General

 

Pressure systems and components shall be maintained in compliance with schedules and requirements given by equipment manufacturers, the system DA, the System Owner, and other applicable Jefferson Lab policies. The required maintenance of a pressure system shall be determined as follows:

 

       DA responsible for the system construction shall determine any special maintenance requirements (on Form PS-9) 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

       The System Owner shall be responsible for developing routine maintenance requirements such as:

o  Maintaining paint and basic corrosion control measures

o  Keeping relief device discharge paths unobstructed (i.e. removing wasp nests etc.)

o  Basic equipment maintenance required by manufacturers

o  Support hanger spring replacement.

o  Support roller lubrication and replacement

 

In all cases, the System Owner is responsible for the long term maintenance and safe operation of the system. In the event that ownership of a system is reassigned, the new Owner is responsible for communicating this change to the Pressure Systems Committee Designee. All personnel performing maintenance on a pressure system shall be qualified as determined by their supervisor.

 

Maintenance work shall be completed by competent technical staff under the direction of the System Owner. It is recommended that documentation be filed in a readily accessible manner such as an electronic logbook or the Pressure System project folder within the Pressure Systems database. It shall be the responsibility of the System Owner to maintain this documentation.

 

Maintenance work requiring the system or part of the system to be deenergized (e.g. valve seal replacement, pump bearing replacement, filter cartridge replacement, etc.) shall be performed under the direct supervision of personnel trained in the safe operation of the system. The deenergized state of the system shall be determined by suitable method prior to performing the maintenance work. Proper lock, tag, and try procedures shall be used where appropriate.

 

8.2.2   Energizing the System after Maintenance Work

 

Caution shall be exercised when energizing a system following maintenance work. The system shall be energized by personnel trained in the safe operation of the system. The integrity of all disassembled components shall be considered untested until an informal in-service leak test is performed. Personnel not directly involved in the in-service leak test shall maintain a safe distance during the test. Personnel performing the test shall stand at a safe distance (keeping arms and legs away from hazardous locations) and inspect for leaks only after the system pressure is stabilized.

 

8.2.3   Pressure Relief Valve Preventive Maintenance

 

Pressure relief valves are mechanical devices that require periodic preventive maintenance even though external inspection and test results indicate acceptable performance. There may be wear on internal parts, galling between sliding surfaces or internal corrosion, and fouling which will not be evident from an external inspection or test. Periodic re-establishment of seating surfaces and the replacement of soft goods such as o-rings and diaphragms are also well advised preventive maintenance activities that can prevent future problems. If the valve is serviced, a complete disassembly, internal inspection, and repair as necessary, such that the valves condition and performance are restored to a like new condition, should be done by an organization accredited by the National Board.

 

Service records with test results and findings should be maintained for all overpressure protection devices. A service interval of no more than three in-service inspection intervals or ten years, whichever is less, is recommended to maintain device condition. Results of the internal inspection and maintenance findings can then be used to establish future service intervals.

 

 

ISSUING AUTHORITY

SUPPLEMENT AUTHOR

APPROVAL DATE

REVIEW DATE

REV.

 

 

QA/CI Dept.

PS Committee/Chair

11/06/15

11/06/20

1.0

 

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