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Pressure and Vacuum Systems Safety Supplement Part
9: Pressure Equipment In-Service Inspection Program |
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This part specifies the requirements for in-service inspection of pressure equipment located both on site or owned by Jefferson Lab on leased properties. The Inspection Category defined in Part 9: Section 9.1.2 In-Service Inspection Categories as well as any special requirements designated by the DA, System Owner or inspector shall determine the extent of required inspections.
Typically, the inspector shall perform a visual inspection of vessels, piping, and ancillary equipment as required by the Inspection Category. The DA, System Owner or inspector shall use sound engineering principles to determine if further inspection, testing and examination techniques are required.
The Pressure Equipment In-service Inspection Program consists of four Inspection Categories.
· IC4 (Inspection Category 4): ASME boilers and relief devices protecting them.
· IC3: ASME Pressure Vessels and Category M systems and relief devices protecting them.
· IC2: Relief devices providing overpressure protection on Excluded Vessels or piping larger than 6 NPS.
· IC1: All other pressure equipment (e.g. piping, turbo and reciprocating machinery, Excluded Vessels, vacuum equipment such as insulating jackets, etc.).
· Shall ensure that all required inspections are completed.
· Shall ensure their systems have a valid Pressure System number/title and an identified Inspection Category.
· Shall ensure that their ASME vessels and the associated relief devices are identified in the Vessel Inspection Coordinators database.
· Maintains responsibility for their pressure equipment and must cooperate with the Vessel Inspection Coordinator to ensure accurate and complete information is included in the inspection program database.
· Shall ensure in-service inspections of IC2 and IC1 equipment are completed and documented.
· Shall ensure operational inspections and testing of IC4, IC3 and IC2 relief devices are completed and documented.
· May specify additional inspection requirements using sound engineering principles to ensure safety and performance criteria.
· Shall coordinate and document the inspector/inspections for IC4 and IC3 pressure equipment.
· Shall specify the Inspection Category, Type of Inspection required and Inspection Interval for new equipment (new systems and alterations) on Form PS-9 as required by Part 2: Section 2.11 System Turnover.
· May specify additional inspection requirements using sound engineering principles to ensure safety and performance criteria.
· Conducts the inspection of all identified in-service pressure equipment.
· Completes and signs the required inspection forms (Form PS-10, Form PS-11 and/or Form PS-12).
· Provides additional testing means and methods as required for vessel inspections.
· Reviews inspection results with the designated Vessel Inspection Coordinator and/or the System Owner as appropriate.
· May specify additional inspection requirements after inspection of a component or system using sound engineering principles to ensure safety and performance criteria.
The DA and/or System Owner shall determine the required in-service inspection interval for IC4, IC3, and IC2 pressure equipment by consulting Table 1 and considering the following:
· Fatigue, vibration, and pressure pulsing
· System fluid
· Component materials
· Environment in which the component is installed
· The potential for rust, scale, or build-up
· Other relevant factors determined by the System Owner/user or DA
The inspection interval shall not be greater than that given in Table 1 unless a suitable record of acceptable inspections for similar service has been established. EXCEPTION: In-service Inspection Intervals for ASME boilers and Category M fluid equipment shall be no longer than as stated in Table 1. The interval for Operational Inspection and Testing of Category IC4, IC3 and IC2 relief devices shall be no longer than as stated in Table 1: Maximum initial inspection intervals for pressure equipment.
Note that this section may be used as guidance for System Owners and DAs when determining a suitable inspection frequency for IC1 pressure equipment. While these specific intervals are not required, it is a requirement that an interval be defined for IC1 pressure equipment.
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Component
and Fluid Service |
Maximum
Test and/or Inspection Interval (years) |
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Vessel:
Gas (non-corrosive) |
5 |
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Vessel:
Gas (corrosive) |
2 |
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Vessels
and piping: Category M fluid |
1 |
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Vessel:
Liquid (corrosive) |
1 |
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Vessel:
Liquid (non-corrosive) |
5 |
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Dewar
Vessel |
2 |
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Rupture
Disk |
Inspect/Replace every 5 |
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Vessel:
Boiler |
2 |
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IC4
Relief Device |
2 |
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Relief
Device: Gas (non-corrosive) |
5 |
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Relief
Device: Gas (corrosive) |
2 |
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Relief
Device: Category M fluid |
1 |
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Relief
Device: Liquid (corrosive) |
2 |
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Relief
Device: Liquid (non-corrosive) |
5 |
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Relief
Device on Dewar Vessel |
5 |
Table 1: Maximum initial inspection intervals for pressure equipment
The extent of the in-service inspection required for a given component or subsystem is dependent on the most applicable Inspection Category (IC#) and additional requirements specified by the DA and System Owner. The requirements for inspector qualification are also dependent on the type of equipment to be inspected. See Part 1: Section 1.4.3.2 In-Service Inspectors for in-service inspector qualifications.
The Vessel Inspection Coordinator shall be responsible for coordinating the in-service inspection of all IC4 equipment. External and internal inspections of boilers and hot water heaters shall be performed as required in the Commonwealth of Virginia Department of Labor & Industry, Division of Boiler and Pressure Vessel Safety, Boiler & Pressure Vessel Rules & Regulations. The inspector for IC4 boilers shall be qualified as given in Part 1: Section 1.4.3.2 In-Service Inspectors. The Vessel Inspection Coordinator shall supply the inspector with the following:
· Vessel Inspection Form PS-11, Form U-1 or other applicable ASME data report (if available)
· P&ID or relevant section of the P&ID clearly indicating relief devices
· (Upon request) Relevant relief device inspection and test reports in Form PS-5 or Form PS-12.
The inspector shall complete NBIC Form NB-6 or its equivalent (Form PS-11) for each boiler. This documentation shall be reviewed by the Vessel Inspection Coordinator. Upon review of the inspection report, the Vessel Inspection Coordinator shall perform one of the following:
· Approve the boiler for continued operation.
· Conditionally approve the boiler for continued operation allowing the System Owner a reasonable period of time to address minor issues.
· Condemn the boiler, notify the System Owner, and issue a CATS. See Part 9: Section 9.2.5.1 Category IC4 and IC3 Condemned Vessels.
The System Owner shall ensure that relief devices in this category are inspected and tested at an interval no longer than that given in Part 9: Section 9.1.4 Intervals for In-Service Inspection using the procedural guidance provided in Part 9: Section 9.3 In-Service Inspection of IC3 Equipment. Note that new devices may be installed in lieu of testing. New devices shall be registered per Part 4: Section 4.7 Relief Device Registration and filed in the system folder.
The Vessel Inspection Coordinator shall be responsible for coordinating the in-service inspection of all IC3 equipment. Inspectors of IC3 vessels and associated relief devices shall be Jefferson Lab employees or employees of agencies other than Jefferson Lab experienced in pressure vessel inspection. Inspectors shall be qualified as given in Part 1: Section 1.4.3.2.2 Pressure Vessels.
The System Owner or designee shall orient the inspector(s) with regard to the location of the vessel/system, the fluid service, operational history, and method of overpressure protection if necessary. Note that relief devices may not be required on pressure vessels that are protected from overpressure by system design. In such cases, the requirements of Part 4: Section 4.8 Overpressure Protection by System Design shall be met. Where relief devices are required for overpressure protection they must comply with the requirements of Part 4: Section 4.5 Overpressure Protection by Relief Device. If requested by the inspector, the System Owner shall provide relevant relief device inspection/test reports. The System Owner shall ensure that relief devices in this category are inspected and tested at an interval no longer than that given in Part 9: Section 9.1.4 Intervals for In-Service Inspection using the procedures given in Part 9: Section 9.3 In Service Inspection of IC2 Components. Note that new devices may be installed in lieu of testing. New devices shall be registered per Part 4: Section 4.7 Relief Device Registration.
Inspections of vessels in this category shall be performed by following a specified procedure. For inspectors employed by agencies other than Jefferson Lab, the inspection procedure shall be approved by the Vessel Inspection Coordinator. Jefferson Lab employee inspectors shall use an approved vessel inspection procedure (accessed through the Pressure Systems webpage in the DA Toolbox “In-service Inspection” tab) or an equivalent.
The inspector shall complete Form PS-11 for each vessel of this type. This documentation shall be reviewed by the System Owner and, if necessary, the Vessel Inspection Coordinator. Upon review of the inspection report, the inspector (if a Jefferson Lab employee) shall perform one of the following steps below. If an outside inspector is used, the Vessel Inspection Coordinator shall perform one of these stated actions:
· Approve the vessel for continued operation.
· Conditionally approve the vessel for continued operation allowing the System Owner a reasonable period of time to address minor issues.
· Condemn the vessel, notify the System Owner, and issue a CATS. See Part 9: Section 9.2.5.1 Category IC4 and IC3 Condemned Vessels.
The completed Form PS-11 shall be forwarded to the Vessel Inspection Coordinator.
The System Owner or designee shall orient the inspector(s) with regard to the location of the system, the fluid service, operational history, and method of overpressure protection. Note that relief devices may not be required on pressure vessels that are protected from overpressure by system design. In such cases, the requirements of Part 4: Section 4.8 Overpressure Protection by System Design shall be met. Where relief devices are required for overpressure protection they must comply with the requirements of Part 4: Section 4.5 Overpressure Protection by Relief Device. The System Owner shall provide relevant relief device inspection/test reports upon request of the inspector. The System Owner shall ensure that relief devices in this category are inspected and tested at an interval no longer than that given in Part 9: Section 9.1.4 Intervals for In-Service Inspection using the procedures given in Part 9: Section 9.3 In-Service Inspection of IC2 Components. Note that new devices may be installed in lieu of testing. New devices shall be registered per Part 4: Section 4.7 Relief Device Registration.
IC3 Category M systems (piping and relief devices) shall be inspected at least annually by an inspector qualified as given in Part 1: Section 1.4.3.2.3 Relief Devices and/or Part 1: Section 1.4.3.2.4 Piping. The inspector shall complete the Pressure Equipment Inspection Form (Form PS-10), review the Relief Device Operational Inspection and Test Data Sheet (Form PS-12), provide these forms to the System Owner and the Pressure Systems Committee Designee.
The System Owner shall ensure that relief devices in this category are inspected and tested at an interval no longer than that given in Part 9: Section 9.1.4 Intervals for In-Service Inspection using the procedures given in Part 9: Section 9.3 In-Service Inspection of IC2 Components. Note that new devices may be installed in lieu of testing. New devices shall be registered per Part 4: Section 4.7 Relief Device Registration.
The following safety relief devices are exempt from the inspection requirements given in this section. The System Owner shall be responsible for the initial and continued safety of the relief devices exempt from the specific requirements of this section.
· Relief devices with set points less than 15 PSIG OR
· Relief devices on any system where all of the following criteria are met
o The maximum system pressure cannot exceed 15 psid (pounds per square inch differential) at any time including all credible failure modes
o The system fluids are nonflammable, nontoxic, and not harmful to human tissue (as described in ASME B31.3 Para 300.2)
o The system design temperature is greater than -20F and less than 366F
Inspection of relief devices shall be performed by or under the supervision of Jefferson Lab employees qualified as given in Part 1: Section 1.4.3.2.3 Relief Devices or by employees of other agencies holding a National Board VR certificate.
Inspection of IC1 equipment shall be as required by the system DA as indicated on Form PS-9, Pressure System Turnover. If there are no specific inspection requirements defined, inspections shall be defined by the System Owner. The vessel inspection procedures (accessed through the Pressure Systems webpage in the DA Toolbox “In-service Inspection” tab) or their equivalent shall be used for Excluded Vessels. The necessity of using an in-service inspector shall be determined by the System Owner based on the complexity and risk factor associated with the system but in all cases, the System Owner shall ensure that these inspections are performed by competent individuals and documented on Form PS-10 or Form PS-12. This form(s) shall be filed in the appropriate Pressure Systems Folder.
Condemned vessels shall be immediately removed from service after the Vessel Inspection Coordinator has notified the System Owner. A tag identifying the vessel as “CONDEMNED” shall be affixed to the vessel by the System Owner. The vessel shall not be returned to service until inspection deficiencies are corrected and the vessel is re-inspected and deemed acceptable for use. Form PS-11 must be updated and submitted to the Vessel Inspection Coordinator.
If an IC4, IC3 or IC2 relief device is determined to be defective, it shall be replaced immediately or the system shall be deenergized unless there is a relief device, or combination of devices, of adequate capacity, installed in a parallel configuration to relieve any credible overpressure condition. The location of these devices shall comply with the requirements given in ASME BPVC D1 Appendix M. In such cases, a CATS item shall be generated and a suitable replacement shall be installed as soon as reasonably possible.
The System Owner shall notify the Vessel Inspection Coordinator regarding a change in status of an IC4, IC3 and IC2 relief device. New relief devices must be registered by completing Form PS-5. The inspection database shall be updated by the Vessel Inspection Coordinator as required.
Any IC4, IC3 or IC2 relief device returned to service shall pass both the visual inspection and set pressure test (as given in Part 9: Section 9.3 Procedures for Operational Inspection and Testing of Relief Devices) in addition to any testing required by the engineering design prior to returning it to service. Results of the inspection and testing shall be documented on the inspection form (Form PS-12), filed and submitted to the Vessel Inspection Coordinator.
Inspections and tests shall be performed by qualified in-service inspectors. In all cases, the inspector shall complete a Relief Device Operational Inspection & Test Data Sheet (Form PS-12) for each device inspected and tested.
There are two basic types of inspections and tests.
On-stream inspections and tests: These inspections and tests occur while the valve is installed. A test may be as simple as lifting the actuator of a valve or involve closing block valves and checking the opening pressure. This type of test should only be performed on systems known to be free of corrosion, scale, buildup, or other substances that would impede the valve operation.
Shop inspections and tests: These inspections and tests occur in a shop environment with the relief device removed from service. This allows inspection of internal components of the device not accessible when it is installed.
Prior to testing and inspection of pressure relief devices, basic precautions shall be observed and P&IDs shall be made available to the inspector. Personnel performing the tests and inspections (in-service inspectors) shall be familiar with the system on which the relief devices are installed. The System Owner shall brief the in-service inspector and a procedure for safely inspecting and or testing the relief device(s) shall be agreed upon. Approved procedures (accessed through the Pressure Systems webpage in the “In-service Inspection” tab) or their equivalent shall be used. If the valve opening pressure is to be tested (either on-stream or in a shop), then, if possible, the system shall be deenergized prior to any work. On energized systems, blocking valves shall be closed and locked using proper lock, tag, and try procedures. A procedure (OSP/TOSP if appropriate) shall be developed and shall include the procedural information from the Pressure Systems webpage or Document Control or the equivalent.
In all cases Form PS-12 must be completed and filed with the system documentation; for IC4, 3 and 2 devices, a copy shall be forwarded to the Vessel Inpection Coordinator.
Any relief device failing one or more steps of a test or inspection shall be considered defective. All defective devices shall be clearly labeled as such and either sent for repair to an ASME valve shop in possession of a valid VR stamp or disposed of. At no point are Jefferson Lab personnel to attempt a repair of a safety relief device. Any device retained by Jefferson Lab for instructional purposes shall have installed a fixture (welded nut and bolt or removed/galled pipe threads etc.) that prevents the relief device from installation.
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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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