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Pressure Safety Requirement – Assist Visit 10CFR Part 851 Review February 12, 2015 Team Audrey Daly Dave Meekins Will Oren George Rawls Steve Smith.

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Presentation on theme: "Pressure Safety Requirement – Assist Visit 10CFR Part 851 Review February 12, 2015 Team Audrey Daly Dave Meekins Will Oren George Rawls Steve Smith."— Presentation transcript:

1 Pressure Safety Requirement – Assist Visit 10CFR Part 851 Review February 12, 2015 Team Audrey Daly Dave Meekins Will Oren George Rawls Steve Smith

2 Scope Of Review Documents – 6151 Pressure and Vacuum System Safety Program – Pressure and Vacuum System Safety Supplement – Welding and Brazing Supplement Facilities – Hall A and D – Central Helium Liquefier Plant 2 – N Access Building and Service Building – LCW Building Systems Interviews – Mike Martin – Chris Perry – Carroll Jones – Scott Thompson – Mike Embler – Isaac Snowburg – Eric Sun – Bert Manzlak

3 10 CFR Part CFR Part 851 Section 4. Pressure Safety (a) Contractors must establish safety policies and procedures to ensure that pressure systems are designed, fabricated, tested, inspected, maintained, repaired, and operated by trained and qualified personnel in accordance with applicable and sound engineering principles. (b) Contractors must ensure that all pressure vessels, boilers, air receivers, and supporting piping systems conform to: (1) The applicable American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (2004); sections I through section XII including applicable Code Cases (2) The applicable ASME B31 (Code for Pressure Piping) standards as indicated below; and or as indicated in paragraph (b)(3) of this section: (3) The strictest applicable state and local codes.

4 10 CFR Part CFR Part 851 Section 4. Pressure Safety (c) When national consensus codes are not applicable (because of pressure range, vessel geometry, use of special materials, etc.), contractors must implement measures to provide equivalent protection and ensure a level of safety greater than or equal to the level of protection afforded by the ASME or applicable state or local code. Measures must include the following: (1) Design drawings, sketches, and calculations must be reviewed and approved by a qualified independent design professional (i.e., professional engineer). Documented organizational peer review is acceptable. (2) Qualified personnel must be used to perform examinations and inspections of materials, in- process fabrications, nondestructive tests, and acceptance test. (3) Documentation, traceability, and accountability must be maintained for each pressure vessel or system, including descriptions of design, pressure conditions, testing, inspection, operation, repair, and maintenance. Paragraph (C) Has the Largest Effect on National Labs

5 Pressure Safety The ASME Pressure Vessel and Piping Codes provide Methodology to ensure a Design Margin and Pressure Safety All elements in of the methodology are required to provide the design margin. The Pressure and Vacuum Safety Program provides the Jefferson Lab approach to achieving the ASME methodology for pressure systems. ASME Methodology  Scope  Materials  Design  Fabrication  Examination  Inspection  Testing Design Margin in ASME Code  1.5 on the Yield Strength  2.4 to 3.5 on Tensile Strength  Distortion vs. Burst Pressure Minimum of 1.5 on Yield or 3 on Tensile Strength as Equivalent for Pressure Retaining Equipment

6 Recommendations Streamline the Pressure And Vacuum Safety Supplement to focus on ASME requirements and functions – Reorganize existing sections for: Pressure Vessels Piping Pressure Protection (Safety Valves) Equivalent Measures to address (Components unique to JLab) Maintenance and Modification to Systems Repair of Pressure Equipment Fitness for Service Further development: – Clearly identify non-welding related examination requirements for piping systems – Clearly identify extent of required examination requirements for piping systems – Clarify the Owners Inspection function for piping systems – Clearly identify code required documentation. – Evaluate use of In-Process examination to satisfy the Code requirement for volumetric weld examination

7 Recommendations Provide specific training on ASME Code Methodology – Materials – Design (Current ASME Training is focused only on the design) – Fabrication – Examination – Testing – Inspection Expand the PHY Experimental Readiness Review methodology to the entire Lab; include a formal DA review for offsite fabricated equipment not originated by JLab Review the process used to determine B31 Code scope for piping systems; i.e., which B31 Code book to use when A more formal approval process is needed for the overpressure protection by system design

8 Extent of Required Examination Examination Requirement Category DNormalCategory MHigh PressureSevere Cyclic Materials& Components Random VT 100 % VTRandom VT Fabrication Including Welds Random VT5% Random VT100% VT Longitudinal WeldsRandom VT100% VT 100% VT & RT or UT100% VT Mechanical JointsRandom VT 100% for Pneumatic Test 100% VT Supports& ErectionRandom VT 100% VT Socket WeldsRandom VT5% VT100% VTNot Allowed100% MT or PT Fabricated Branch Connections Not RT or UT Random VT5% VT100% VT100% RT or UT100% MT or PT Brazed JointsRandom VT5% In-ProcessNot AllowedOwner SpecifiedNot Allowed Solder JointsRandom VTNot Allowed Completed System Meets Design Random VT 100% VT Circumferential Groove Welds Random VT 5% Random RT or UT 20% Random RT or UT 100% RT or UT

9 Types of Non-welding Examinations Piping alignments and as-built tolerances Bending and forming are performed to engineering and ASME B31.3 requirements Bolting/torquing requirements Cleanliness requirements are met Flanged joints are properly installed Overall piping layout (configuration), including hangers and supports, is in accordance with the design requirements Proper use of lubricants Material identification requirements are satisfied Proper installation of threaded joints Pressure/leak tests satisfy applicable requirement


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