PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING SAF 130B 1 This training was conducted on December.

PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING SAF 130B 1 This training was conducted on December 9, 2015. It is meant as a summary of ES&H Manual Chapter 6151, the new Pressure and Vacuum Systems Safety Supplement and the revised Welding and Brazing Program Supplement. In all cases, the actual language in the Chapter and the Supplements supersedes the information provided herein.

Course Overview Why Are We Here? JLab and other DOE Lab Performance 10CFR851 Requirements Hazard Avoidance Techniques Revised ES&H Manual Chapter 6151 Overview / Major differences The New Pressure and Vacuum Systems Safety Supplement Overview / Major differences Revised Welding and Brazing Program Supplement Overview / Major differences Future Plans Why Are We Here? JLab and other DOE Lab Performance 10CFR851 Requirements Hazard Avoidance Techniques Revised ES&H Manual Chapter 6151 Overview / Major differences The New Pressure and Vacuum Systems Safety Supplement Overview / Major differences Revised Welding and Brazing Program Supplement Overview / Major differences Future Plans 2

JLab and other DOE Lab Performance Why revise the Pressure Safety Program?  Several accidents have occurred here and at other DOE sites.  Our documentation has some holes.  Independent program review by George Rawls, SRNL Sr Fellow Engineer: Focus on ASME Code requirements Clearly identify required examinations, both welding and mechanical Clarify Owner’s Inspection function Create approval process for overpressure protection by system design Why revise the Pressure Safety Program?  Several accidents have occurred here and at other DOE sites.  Our documentation has some holes.  Independent program review by George Rawls, SRNL Sr Fellow Engineer: Focus on ASME Code requirements Clearly identify required examinations, both welding and mechanical Clarify Owner’s Inspection function Create approval process for overpressure protection by system design 3 Form Is Blank Pressure Test Form

“Contractors must ensure that all pressure vessels … and supporting piping systems conform to: (1) The applicable ASME Boiler and Pressure Vessel Code (2) The applicable ASME B31 Code for Pressure Piping (3) The strictest applicable state and local codes” “Contractors must ensure that all pressure vessels … and supporting piping systems conform to: (1) The applicable ASME Boiler and Pressure Vessel Code (2) The applicable ASME B31 Code for Pressure Piping (3) The strictest applicable state and local codes” 4 “When national consensus codes are not applicable (because of pressure range, vessel geometry, use of special material, etc.), contractors must implement measures to provide equivalent protection…” “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.”

§851.24 Functional Areas (excerpt) (a)Contractors must have a structured approach to their worker safety and health program… §851.25 Training and information (excerpt) (c)Contractors must provide training and information to workers who have worker safety and health program responsibilities that is necessary for them to carry out those responsibilities §851.26 Recordkeeping and reporting (excerpt) (a) Recordkeeping. Contractors must: (1)Establish and maintain complete and accurate records of all hazard inventory information, hazard assessments, exposure measurements, and exposure controls. §851.24 Functional Areas (excerpt) (a)Contractors must have a structured approach to their worker safety and health program… §851.25 Training and information (excerpt) (c)Contractors must provide training and information to workers who have worker safety and health program responsibilities that is necessary for them to carry out those responsibilities §851.26 Recordkeeping and reporting (excerpt) (a) Recordkeeping. Contractors must: (1)Establish and maintain complete and accurate records of all hazard inventory information, hazard assessments, exposure measurements, and exposure controls. 5 TRAINING PROCEDURES DOCUMENTATION

Why Are We Here? Hazard Avoidance Techniques design, fabricate, test according to ASME or other Code operate within design parameters use only for designed purpose do not apply heat unless specifically authorized do not work on systems without authorization and training perform maintenance, report damage or defects use Lock, Tag, Try to depressurize/repressurize perform routine in-service inspections 6

Why Are We Here? Hazard Avoidance Techniques design, fabricate, test according to ASME or other Code operate within design parameters use only for designed purpose do not apply heat unless specifically authorized do not work on systems without authorization and training perform maintenance, report damage or defects use Lock, Tag, Try to depressurize/repressurize perform routine in-service inspections Design Authority System Owner 7 Design Requirements System Parameters Code of Record Operating Conditions Calculations Material Selection Component Selection Pressure Relief Welding Parameters Drawings P&ID Reviews Purchasing Receipt Inspection Fabrication Assembly Installation Welding Examination Mechanical Examination Pressure Testing Final Inspection System Turnover Documentation Design Requirements System Parameters Code of Record Operating Conditions Calculations Material Selection Component Selection Pressure Relief Welding Parameters Drawings P&ID Reviews Purchasing Receipt Inspection Fabrication Assembly Installation Welding Examination Mechanical Examination Pressure Testing Final Inspection System Turnover Documentation Design Authority may delegate tasks but not responsibility

Revised ES&H Manual Chapter 6151 9 Content changed to concentrate on purpose, scope and responsibilities New language to clarify “legacy” systems Procedural steps removed and all technical appendices replaced with new Pressure and Vacuum Systems Safety Supplement Newly identified functions: o System Owner o Technician o Vessel Inspection Coordinator Responsible for the operation, maintenance and inspection of a pressure system Performs work functions for the construction, testing, operation, maintenance, inspection, repair and alteration of a pressure system Responsible for coordinating in-service inspection of ASME vessels, etc. Pre-2008 systems are identified as pressure systems and subject to operation, maintenance, in-service inspection, repair and alteration procedures “…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.”

JLab Definition of Pressure System Pressure System: A connected set of piping, piping components and/or pressure vessel(s) used to either convey or contain a fluid under pressure above 0 psig. Pressure sources, fittings, pressure relief devices and associated hardware such as gages and regulators are also integral parts of the pressure system. Vacuum systems which cannot be protected against pressurization exceeding 15 psig from all credible pressure sources are considered pressure systems. 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. Vacuum systems can be especially hazardous when backfilling or purging. 10

“Excepted” Systems Excepted Pressure Systems: (check ES&H Manual 6151 for details) Any system where all of the following are met: o Max. pressure cannot exceed 15 psid including failure modes o Fluid is non-flammable., nontoxic and not damaging to human tissue o Design temperature is between -20F and 366F o Stored energy is below 10000 ft-lbs Any system with a total stored energy (thermo-mechanical and chemical) less than 1000 ft-lb provided the system fluid is not damaging to human tissue Excepted Pressure Systems: (check ES&H Manual 6151 for details) Any system where all of the following are met: o Max. pressure cannot exceed 15 psid including failure modes o Fluid is non-flammable., nontoxic and not damaging to human tissue o Design temperature is between -20F and 366F o Stored energy is below 10000 ft-lbs Any system with a total stored energy (thermo-mechanical and chemical) less than 1000 ft-lb provided the system fluid is not damaging to human tissue 11

Gas/liquified gas cylinders (covered by ES&H Manual 6150) USDOT covered vehicle pneumatic and hydraulic systems SCBA air cylinders Domestic water heaters with a capacity less than 120 gal, less than 210F and heat input below 200000 BTU/hr Domestic appliances covered by national standards ASHRAE compliant systems and devices Roof and floor drains, plumbing and sewers Domestic hot, cold and grey water piping Piping for hand tools downstream of stop valve Instruments (not instrument piping/tubing) Fire protection systems (covered by ES&H Manual 6900) “Excepted” Systems Gas/liquified gas cylinders (covered by ES&H Manual 6150) USDOT covered vehicle pneumatic and hydraulic systems SCBA air cylinders Domestic water heaters with a capacity less than 120 gal, less than 210F and heat input below 200000 BTU/hr Domestic appliances covered by national standards ASHRAE compliant systems and devices Roof and floor drains, plumbing and sewers Domestic hot, cold and grey water piping Piping for hand tools downstream of stop valve Instruments (not instrument piping/tubing) Fire protection systems (covered by ES&H Manual 6900) 12 “Excepted” doesn’t mean hazards aren’t real for those systems! Hazard avoidance must always be considered for any pressurized system!

New Pressure & Vacuum Systems Safety Supplement 14 Table of Contents Part 1 General Program Information Part 2 Pressure System Construction Part 3 Equivalent Measures Part 4 Overpressure Protection Part 5 Repair and Alteration Part 6 Pressure and Leak Testing Part 7 Vacuum Systems Part 8 Operation and Maintenance Part 9 In-service Inspection Program Part 10 Mandatory Forms The Supplement should be considered a “living” document. We understand that this program will evolve and we chose this “Supplement” format to simplify the revision process. Open communication between all parties involved is vital for the success of this program. If you have questions or comments please bring them to the Pressure Systems Committee. Use the Website as a resource. Table of Contents Part 1 General Program Information Part 2 Pressure System Construction Part 3 Equivalent Measures Part 4 Overpressure Protection Part 5 Repair and Alteration Part 6 Pressure and Leak Testing Part 7 Vacuum Systems Part 8 Operation and Maintenance Part 9 In-service Inspection Program Part 10 Mandatory Forms The first section includes general Code discussion, responsibilities, qualifications and documentation requirements

Part 1: General Program Information PS Committee assumes duties of jurisdictional authority o Arbitration and interpretation of Code/policy issues o Provide guidance when requested o Arbitrate and oversee in-service inspection issues ASME Code o Code of Record shall be identified (CODE + EDITION) o Interpretation of Code functions PS Committee assumes duties of jurisdictional authority o Arbitration and interpretation of Code/policy issues o Provide guidance when requested o Arbitrate and oversee in-service inspection issues ASME Code o Code of Record shall be identified (CODE + EDITION) o Interpretation of Code functions B31: The Code sets forth engineering requirements deemed necessary for safe design and construction of pressure piping. All applicable requirements of the selected Code Section shall be met. The Code is not a design handbook; it does not do away with the need for the designer or for competent engineering judgment. BPVC: This Code contains mandatory requirements, specific prohibitions, and nonmandatory guidance for construction activities and inservice inspection and testing activities. The Code is not a handbook and cannot replace education, experience, and the use of engineering judgment. Engineering judgments must be consistent with Code philosophy, and such judgments must never be used to overrule mandatory requirements or specific prohibitions of the Code. 15 Code FunctionB31 CodesBPVC Owner/Operator/UserDA/System Owner DesignerDAna Fabricator/Erector/ Manufacturer DA responsible to ensure duties are met Code Shop Owner’s InspectorJLab InspectorCode Inspector

Responsibilities and Qualifications are summarized for all functions involved Design Authority Responsibilities: Ensure safety of the public, personnel and the environment are primary considerations. Ensure construction, alteration, repair and documentation meet the Supplement Employ, as required, the expertise available through other DAs, the QA/CI Inspector, Welding Committee and the Pressure Systems Committee … Define the in-service inspection requirements Define the operational requirements Define special maintenance requirements Design Authority Responsibilities: Ensure safety of the public, personnel and the environment are primary considerations. Ensure construction, alteration, repair and documentation meet the Supplement Employ, as required, the expertise available through other DAs, the QA/CI Inspector, Welding Committee and the Pressure Systems Committee … Define the in-service inspection requirements Define the operational requirements Define special maintenance requirements 16 Part 1: General Program Information The list continues to summarize tasks involved with meeting Supplement requirements. Note the final 3 are not new but are now given a structured approach:

Responsibilities and Qualifications are summarized for all functions involved Required Documentation o Consult with PSC Designee to create a PS ID number: PS-ABC-XX-123 o Create a meaningful title Responsibilities and Qualifications are summarized for all functions involved Required Documentation o Consult with PSC Designee to create a PS ID number: PS-ABC-XX-123 o Create a meaningful title 17 Carefully choose the system type designation (ABC) and title. This information will be used to inventory the system. Repairs and alterations should refer back to the original PS ID number. If a new number is used, the DA must follow the complete documentation and process requirements for a new system. Carefully choose the system type designation (ABC) and title. This information will be used to inventory the system. Repairs and alterations should refer back to the original PS ID number. If a new number is used, the DA must follow the complete documentation and process requirements for a new system. Part 1: General Program Information Bridget Paul Ext. 7306

18 Part 1: General Program Information Responsibilities and Qualifications are summarized for all functions involved Required Documentation o Consult with PSC Designee to create a PS ID number: PS-ABC-XX-123 o Create a meaningful title o Create a project folder with subfolders Responsibilities and Qualifications are summarized for all functions involved Required Documentation o Consult with PSC Designee to create a PS ID number: PS-ABC-XX-123 o Create a meaningful title o Create a project folder with subfolders Engineering: Design Calculations Reviews Design Drawings Overpressure Protection SOW Fabrication and Procurement Procurement Welding, Brazing, and Soldering Material and Instrument Certifications Mechanical Examinations Leak and Pressure Testing Vessels Overpressure Protection Final Walkthrough Operation and Maintenance System Turnover Operations Maintenance Alterations Alteration 1… Alteration 2… Repairs Repair 1… Repair 2… In-Service Inspections Miscellaneous Engineering: Design Calculations Reviews Design Drawings Overpressure Protection SOW Fabrication and Procurement Procurement Welding, Brazing, and Soldering Material and Instrument Certifications Mechanical Examinations Leak and Pressure Testing Vessels Overpressure Protection Final Walkthrough Operation and Maintenance System Turnover Operations Maintenance Alterations Alteration 1… Alteration 2… Repairs Repair 1… Repair 2… In-Service Inspections Miscellaneous Not all documentation is applicable! If a process step is applicable, associated documentation shall be filed in the appropriate folder. Exemption for ASME B31.5, B31.9, and B31.3 Cat “D”: DA may choose an alternative: System Number and title as normal Top system folder with notations on alternate filing location(s) Single subfolder labeled “Pressure System Forms” where all applicable forms must be filed. Documentation must available within 5 working days upon formal request. Exemption for ASME B31.5, B31.9, and B31.3 Cat “D”: DA may choose an alternative: System Number and title as normal Top system folder with notations on alternate filing location(s) Single subfolder labeled “Pressure System Forms” where all applicable forms must be filed. Documentation must available within 5 working days upon formal request.

Responsibilities and Qualifications are summarized for all functions involved Required Documentation o Consult with PSC Designee to create a PS ID number PS-ABC-XX-123 o Create a meaningful title o Create a project folder with subfolders o Mandatory Forms Responsibilities and Qualifications are summarized for all functions involved Required Documentation o Consult with PSC Designee to create a PS ID number PS-ABC-XX-123 o Create a meaningful title o Create a project folder with subfolders o Mandatory Forms 19 Mandatory Forms: PS-1Project Cover Sheet PS-2Overpressure Protection by Design PS-3Technical/Peer Review PS-4Vessel Registration PS-5Relief Device Registration PS-6 Final Mechanical Examination PS-7Pressure/Leak Test Record PS-8Final Walkthrough PS-9Pressure System Turnover PS-10Pressure Equipment ISI PS-11ASME Vessel/Relief Device ISI PS-12Relief Device ISI Mandatory Forms: PS-1Project Cover Sheet PS-2Overpressure Protection by Design PS-3Technical/Peer Review PS-4Vessel Registration PS-5Relief Device Registration PS-6 Final Mechanical Examination PS-7Pressure/Leak Test Record PS-8Final Walkthrough PS-9Pressure System Turnover PS-10Pressure Equipment ISI PS-11ASME Vessel/Relief Device ISI PS-12Relief Device ISI Part 1: General Program Information

20 Mandatory Forms: PS-1Project Cover Sheet PS-2Overpressure Protection by Design PS-3Technical/Peer Review PS-4Vessel Registration PS-5Relief Device Registration PS-6 Final Mechanical Examination PS-7Pressure/Leak Test Record PS-8Final Walkthrough PS-9Pressure System Turnover PS-10Pressure Equipment ISI PS-11ASME Vessel/Relief Device ISI PS-12Relief Device ISI Mandatory Forms: PS-1Project Cover Sheet PS-2Overpressure Protection by Design PS-3Technical/Peer Review PS-4Vessel Registration PS-5Relief Device Registration PS-6 Final Mechanical Examination PS-7Pressure/Leak Test Record PS-8Final Walkthrough PS-9Pressure System Turnover PS-10Pressure Equipment ISI PS-11ASME Vessel/Relief Device ISI PS-12Relief Device ISI Minimum required before initial startup Part 1: General Program Information

New Pressure & Vacuum Systems Safety Supplement 21 Table of Contents Part 1 General Program Information Part 2 Pressure System Construction Part 3 Equivalent Measures Part 4 Overpressure Protection Part 5 Repair and Alteration Part 6 Pressure and Leak Testing Part 7 Vacuum Systems Part 8 Operation and Maintenance Part 9 In-service Inspection Program Part 10 Mandatory Forms

Part 2: Pressure System Construction 22 1 General 2 Pressure Vessels 3 Pressure Piping 4 Design 5 Reviews 6 Use of Unlisted Components 7 Materials 8 Welding, Brazing and Soldering 9 Examination 10 Inspections 11 System Turnover 1 General 2 Pressure Vessels 3 Pressure Piping 4 Design 5 Reviews 6 Use of Unlisted Components 7 Materials 8 Welding, Brazing and Soldering 9 Examination 10 Inspections 11 System Turnover

Part 2: Pressure System Construction 23 1 General 1 General construction: design review purchasing fabrication assembly installation examination inspection testing documentation

Part 2: Pressure System Construction 24 1 General Pressure systems initiated after January 4, 2016 shall meet requirements in Part 2 For in-process systems, DA can meet Part 2 or follow existing Rev. 3.4 and Complete PS-1 Register vessels and relief devices using PS-4 and 5 Create and file a P&ID Complete Final System Walkthrough and PS-8 Complete System Turnover and PS-9 1 General Pressure systems initiated after January 4, 2016 shall meet requirements in Part 2 For in-process systems, DA can meet Part 2 or follow existing Rev. 3.4 and Complete PS-1 Register vessels and relief devices using PS-4 and 5 Create and file a P&ID Complete Final System Walkthrough and PS-8 Complete System Turnover and PS-9 Existing Ch. 6151 Revision was corrected from 3.3 to 3.4

Part 2: Pressure System Construction 25 2 Pressure Vessel Construction Pressure vessels shall be constructed, to the greatest extent reasonably possible, in full compliance with the ASME Boiler and Pressure Vessel Code 2 categories: ASME Pressure Vessels Excluded Vessels A Code of Record shall be identified whether or not the Code can be fully applied 2 Pressure Vessel Construction Pressure vessels shall be constructed, to the greatest extent reasonably possible, in full compliance with the ASME Boiler and Pressure Vessel Code 2 categories: ASME Pressure Vessels Excluded Vessels A Code of Record shall be identified whether or not the Code can be fully applied ASME Pressure Vessels Type UniqueOff the ShelfRepurposed Code compliance BPVC compliant Original BPVC Code of RecordBPVC Section VIII, Div # and Edition Original Code of Record ManufacturerBuilt by Code shop Built/repaired by Code shop StampU stamp U and/or R stamp DocumentationForm U-1, U-1A, etc. plus full documentation Form U-1, U-1A, etc Form U-1, U-1A, etc and Form R-1, R-1A ReviewTechnical Reviewna Additional Req’ts Registration/ID Tag

Part 2: Pressure System Construction 2 Pressure Vessel Construction 2 Pressure Vessel Construction 26 Excluded Vessels TypeNewRepurposed Code complianceNot fully BPVC compliant Code of RecordBPVC Section VII, Div # and Edition As available ManufacturerBuilt outside or JLabBuilt/repaired outside or JLab Stampna DocumentationEquivalent measures plus full documentation As available or required by PSC chair ReviewPeer ReviewPeer Review or PSC Chair Additional Req’tsRegistration/ID Tag EXCLUDED VESSELS: Excepted/excluded by BPVC Considered to be equipment Requires unlisted material Operating conditions outside of BPVC scope Special geometry Considered to be instrumentation Considered as internal piping Scientific or functional requirements preclude compliance Cannot be tested or examined to Code EXCLUDED VESSELS: Excepted/excluded by BPVC Considered to be equipment Requires unlisted material Operating conditions outside of BPVC scope Special geometry Considered to be instrumentation Considered as internal piping Scientific or functional requirements preclude compliance Cannot be tested or examined to Code Excluded Vessels Type NewRepurposed Code complianceNot fully BPVC compliant Code of RecordBPVC Section VIII, Div # and Edition As available ManufacturerBuilt outside or JLabBuilt/repaired outside or JLab Stampna DocumentationEquivalent measures plus full documentation As available or required by PSC chair ReviewPeer ReviewPeer Review or PSC Chair Additional Req’tsRegistration/ID Tag

Part 2: Pressure System Construction 2 Pressure Vessel Construction  Vessel Numbering B# - PS – ABC – XX – 123 - V# Bldg # Sequential # Pressure System ID #  Tagging – vessel # must be conspicuously and durably displayed on vessel  Registration – complete Form PS-4 and forward to Vessel Inspection Coordinator 2 Pressure Vessel Construction  Vessel Numbering B# - PS – ABC – XX – 123 - V# Bldg # Sequential # Pressure System ID #  Tagging – vessel # must be conspicuously and durably displayed on vessel  Registration – complete Form PS-4 and forward to Vessel Inspection Coordinator 27

Part 2: Pressure System Construction 28 3 Pressure Piping Construction Pressure piping shall be constructed, to the greatest extent possible, in compliance with the ASME B31 Code for Pressure Piping 2 categories: ASME B31 Pressure Piping Excluded Elements A Code of Record shall be identified whether or not a B31 Code can be fully applied 3 Pressure Piping Construction Pressure piping shall be constructed, to the greatest extent possible, in compliance with the ASME B31 Code for Pressure Piping 2 categories: ASME B31 Pressure Piping Excluded Elements A Code of Record shall be identified whether or not a B31 Code can be fully applied EXCLUDED ELEMENTS: Excepted/excluded by all B31 Codes Considered to be equipment Requires unlisted material Operating conditions outside of B31 scope Special geometry Considered to be instrumentation Considered as internal piping Scientific or functional requirements preclude compliance Cannot be tested or examined to Code EXCLUDED ELEMENTS: Excepted/excluded by all B31 Codes Considered to be equipment Requires unlisted material Operating conditions outside of B31 scope Special geometry Considered to be instrumentation Considered as internal piping Scientific or functional requirements preclude compliance Cannot be tested or examined to Code

Part 2: Pressure System Construction 4 Vessel and Piping Design:  DA ensures calculations required by Code, engineering design and JLab are performed and reviewed  Engineering design must be formalized by SOW. Form PS-1 Pressure System Cover Sheet is required for each system and may be used as the SOW.  The Supplement is not a design handbook. The DA must consider many elements… 4 Vessel and Piping Design:  DA ensures calculations required by Code, engineering design and JLab are performed and reviewed  Engineering design must be formalized by SOW. Form PS-1 Pressure System Cover Sheet is required for each system and may be used as the SOW.  The Supplement is not a design handbook. The DA must consider many elements… 29 PS-LCW -16-001 LCW cooling for something Sketch 333044 03493049 Dave Meekins TBD x wrongright 2014 X Water Cat D 100 F 60 psi 101-PS-LCW-16-001-01 >1000 ft-lbs Cooling for something important in Hall A

Part 2: Pressure System Construction Design Considerations Design life of the system Properties of the confined fluid All operating conditions – start-up, normal, shutdown, stand-by and emergency Need for maintenance and in-service inspection Future changes to design conditions Protection against system failure Suitable material selection External forces including thermal, seismic and wind (if applicable) Design Considerations Design life of the system Properties of the confined fluid All operating conditions – start-up, normal, shutdown, stand-by and emergency Need for maintenance and in-service inspection Future changes to design conditions Protection against system failure Suitable material selection External forces including thermal, seismic and wind (if applicable) 30

Part 2: Pressure System Construction 5 Reviews:  Technical Review – formal review by another DA  Peer Review – formal review by at least one DA not associated with the project and not a member of the same group  Form PS-3, Technical/Peer Review Record must be completed 5 Reviews:  Technical Review – formal review by another DA  Peer Review – formal review by at least one DA not associated with the project and not a member of the same group  Form PS-3, Technical/Peer Review Record must be completed 31

Part 2: Pressure System Construction 6 Unlisted Components:  B31 allows use of unlisted components with consent of the Owner. DA assumes this role.  DA shall ensure that all calculations are performed, reviewed and documented.  Qualify unlisted components according to Code. (Note that equivalent measures may not be required)  Unlisted piping components must meet B31.3 304.7.2 6 Unlisted Components:  B31 allows use of unlisted components with consent of the Owner. DA assumes this role.  DA shall ensure that all calculations are performed, reviewed and documented.  Qualify unlisted components according to Code. (Note that equivalent measures may not be required)  Unlisted piping components must meet B31.3 304.7.2 32

Part 2: Pressure System Construction 7 Materials:  DA ensures that materials are compatible with fluid service, system fluids and engineering design  Unlisted materials require Equivalent Measures  Material selection considerations:  Materials of unknown origin shall not be used. DA determines extent of documentation required. 7 Materials:  DA ensures that materials are compatible with fluid service, system fluids and engineering design  Unlisted materials require Equivalent Measures  Material selection considerations:  Materials of unknown origin shall not be used. DA determines extent of documentation required. 33 Fluid compatibilityEngineering DesignExternal fields Temperatures extremesMaterial formWelding/brazing Material degradationCyclic loadingBrittle fracture/toughness

Part 2: Pressure System Construction 8 Welding, Brazing and Soldering:  Pressure Boundary – Joint design, personnel and procedures must meet JLab Welding & Brazing Supplement and the applicable ASME or NB Code  Support Elements – Joint design, personnel and procedures shall meet JLab Welding & Brazing Supplement and the applicable ASME or AWS Structural Welding Code  DA completes Design Parameter Form or equivalent  Examinations and Inspections must follow Code and reports must be filed with system documentation 8 Welding, Brazing and Soldering:  Pressure Boundary – Joint design, personnel and procedures must meet JLab Welding & Brazing Supplement and the applicable ASME or NB Code  Support Elements – Joint design, personnel and procedures shall meet JLab Welding & Brazing Supplement and the applicable ASME or AWS Structural Welding Code  DA completes Design Parameter Form or equivalent  Examinations and Inspections must follow Code and reports must be filed with system documentation 34

Part 2: Pressure System Construction 35 9 Examinations:  Examinations are not Inspections!  DA ensures that all examinations required by Code, JLab policy and engineering design are completed and documented  2 Categories of Examinations: Welding/Brazing – method (RT, UT, VT, etc.) chosen by DA, must meet Code Mechanical – in-process and final  Final mechanical examination is required after installation is complete. Document and file using Form PS-6 9 Examinations:  Examinations are not Inspections!  DA ensures that all examinations required by Code, JLab policy and engineering design are completed and documented  2 Categories of Examinations: Welding/Brazing – method (RT, UT, VT, etc.) chosen by DA, must meet Code Mechanical – in-process and final  Final mechanical examination is required after installation is complete. Document and file using Form PS-6 Examination - observation, by suitable technique, of components, joints, and other elements either before, during or after construction. It may include verification of materials, components, dimensions, joint prep, alignment, welding, supports or assembly. Inspection – verification that all required examinations and tests have been completed and that documentation conforms to Code, JLab policy and engineering design. Examination - observation, by suitable technique, of components, joints, and other elements either before, during or after construction. It may include verification of materials, components, dimensions, joint prep, alignment, welding, supports or assembly. Inspection – verification that all required examinations and tests have been completed and that documentation conforms to Code, JLab policy and engineering design. Mechanical Examination: Materials, components (fittings, valves, etc) and products conform to specifications Applicable procedures for assembly Threaded, bolted and other joints conform to Code and engineering design Alignment, supports and cold spring meet engineering design Dimensional checks of components and materials Mechanical Examination: Materials, components (fittings, valves, etc) and products conform to specifications Applicable procedures for assembly Threaded, bolted and other joints conform to Code and engineering design Alignment, supports and cold spring meet engineering design Dimensional checks of components and materials

Part 2: Pressure System Construction 36 10 Inspections:  All new pressure systems shall be inspected by a Pressure System Construction Inspector  This inspector witnesses final system pressure test (unless otherwise arranged) and completes the Final System Walkthrough (Form PS-8) and signs as Owner’s Inspector 10 Inspections:  All new pressure systems shall be inspected by a Pressure System Construction Inspector  This inspector witnesses final system pressure test (unless otherwise arranged) and completes the Final System Walkthrough (Form PS-8) and signs as Owner’s Inspector Who is this Inspector? Someone meeting B31.3 Para. 340.4 Qualifications of the Owner’s Inspector requirements: DA with 5 years experience or CWI or senior CWI with 5 years experience or Authorized Piping Inspector with 5 years experience Approved by Pressure Systems Committee Independent from system design, fabrication, installation, testing and examination These items are for documentation control. The Final System Walkthrough cannot be performed without actually “walking down” the system, checking pressure relief valves, etc. Mike Martin Ext. 5515 and Jenord Alston Ext. 5859 are primary contacts. For specialized inspection, consult the list on the Pressure System Website.

Part 2: Pressure System Construction 37 11 System Turnover:  After walkthrough and before operation, DA formally turns system over to the System Owner  Using Form PS-9, DA defines and documents: operating requirements special maintenance requirements in-service inspection requirements  Both parties sign and date  Forward to Bridget Paul to prompt entry into “Operating Pressure Systems Database” 11 System Turnover:  After walkthrough and before operation, DA formally turns system over to the System Owner  Using Form PS-9, DA defines and documents: operating requirements special maintenance requirements in-service inspection requirements  Both parties sign and date  Forward to Bridget Paul to prompt entry into “Operating Pressure Systems Database” Ensures the System Owner is identified and notified as well as prompting the new system to be added to the operating system database.

Part 3: Equivalent Measures Equivalent measures shall be used to ensure a level of safety equal to or greater than that required by ASME Pressure Codes FOR EACH EXCLUDED ELEMENT. Documentation shall include all of the following in addition to the standard: –Reason why the Excluded Element cannot fully comply with selected Code of Record –Specific Code requirements that cannot be met –Calculations required by Code, sound engineering principles, and the engineering design –Specifications for special examinations or inspections if applicable –Specific measures taken Equivalent measures shall be used to ensure a level of safety equal to or greater than that required by ASME Pressure Codes FOR EACH EXCLUDED ELEMENT. Documentation shall include all of the following in addition to the standard: –Reason why the Excluded Element cannot fully comply with selected Code of Record –Specific Code requirements that cannot be met –Calculations required by Code, sound engineering principles, and the engineering design –Specifications for special examinations or inspections if applicable –Specific measures taken 39 The most applicable Code of Record must always be identified

Part 3: Equivalent Measures Measures taken to ensure a level of safety equal to or greater than ASME Pressure Code can include: 40  Extensive detailed analysis  Protective barriers  Secondary containment  Specialized testing  Protection of thin sections from accidental damage  Administration controls  Extensive detailed analysis  Protective barriers  Secondary containment  Specialized testing  Protection of thin sections from accidental damage  Administration controls

Part 3: Equivalent Measures The functions defined by ASME BPVC for Excluded Vessels shall be as follows: –The DA and System Owner assume the duties of the Owner/User –The DA assumes the responsibilities of the Manufacturer –The duties of the Inspector are assumed by an In- house Inspector A Peer Review of each Excluded Vessel and/or Element shall be performed. The functions defined by ASME BPVC for Excluded Vessels shall be as follows: –The DA and System Owner assume the duties of the Owner/User –The DA assumes the responsibilities of the Manufacturer –The duties of the Inspector are assumed by an In- house Inspector A Peer Review of each Excluded Vessel and/or Element shall be performed. 41

Part 4: Overpressure Protection 43 1 General Requirements 2 Potential Causes of Overpressure 3 Relief Devices Exposed to Weather 4 Pressure Relieving Requirements 5 Overpressure Protection by Relief Device 6 Installation 7 Relief Device Registration 8 Overpressure Protection by System Design 1 General Requirements 2 Potential Causes of Overpressure 3 Relief Devices Exposed to Weather 4 Pressure Relieving Requirements 5 Overpressure Protection by Relief Device 6 Installation 7 Relief Device Registration 8 Overpressure Protection by System Design

Part 4: Overpressure Protection 44 1 General Requirements  Design must account for all reasonable sources of overpressure and mitigate them through relief devices, design or other method  For systems >15 psi, DA shall Analyze possible failure modes and effects (simple or formalized) Calculate relief capacity Consider discharge effects (reaction forces, venting, environmental factors)  For Excluded Elements and Vessels (MAWP>15psi) use BPVC VIII D1  Overpressure protection analysis requires a technical review 1 General Requirements  Design must account for all reasonable sources of overpressure and mitigate them through relief devices, design or other method  For systems >15 psi, DA shall Analyze possible failure modes and effects (simple or formalized) Calculate relief capacity Consider discharge effects (reaction forces, venting, environmental factors)  For Excluded Elements and Vessels (MAWP>15psi) use BPVC VIII D1  Overpressure protection analysis requires a technical review

Part 4: Overpressure Protection 45 2 Potential Causes of Overpressure Overpressure results from disruption or unbalance of fluid flow or energy. Some causes include: 2 Potential Causes of Overpressure Overpressure results from disruption or unbalance of fluid flow or energy. Some causes include:

Part 4: Overpressure Protection 46 2 Potential Causes of Overpressure Overpressure results from disruption or unbalance of fluid flow or energy. Some causes include: 2 Potential Causes of Overpressure Overpressure results from disruption or unbalance of fluid flow or energy. Some causes include:

Part 4: Overpressure Protection 47 3 Relief Devices Exposed to Weather Consider the following:  Equip with bug screens  Protect exhaust from rain, ice and snow  Made from materials compatible with exposure 3 Relief Devices Exposed to Weather Consider the following:  Equip with bug screens  Protect exhaust from rain, ice and snow  Made from materials compatible with exposure

Part 4: Overpressure Protection 48 4Pressure Relieving Requirements  DA shall determine largest credible relief capacity required and size relief devices appropriately  Max. allowable accumulation shall be in accordance with Code of Record (BPVC VIII D1 for Excluded)  Devices shall be sized such that total capacity is sufficient for calculated mass flow  Relief path shall be analyzed for capacity and pressure drop 4Pressure Relieving Requirements  DA shall determine largest credible relief capacity required and size relief devices appropriately  Max. allowable accumulation shall be in accordance with Code of Record (BPVC VIII D1 for Excluded)  Devices shall be sized such that total capacity is sufficient for calculated mass flow  Relief path shall be analyzed for capacity and pressure drop

Part 4: Overpressure Protection 49 4Pressure Relieving Requirements (cont.)  Considerations for Overpressure from Exposure to Prolonged External Fire  Considerations for Overpressure due to the Loss of Insulating Vacuum 4Pressure Relieving Requirements (cont.)  Considerations for Overpressure from Exposure to Prolonged External Fire  Considerations for Overpressure due to the Loss of Insulating Vacuum  Exposure to external fire can result in very large relief loads  Excellent guidance for liquid hydrocarbon pool fire is in API 521 Section 5.15  JLab Fire Protection Engineer can provide guidance  Fire mitigation may be provided by preventative measures: Adequate drainage, dykes to prevent pooling Removal of brush, debris Elimination or limitation of close flammable material Fire suppression system Insulation and fireproofing  Exposure to external fire can result in very large relief loads  Excellent guidance for liquid hydrocarbon pool fire is in API 521 Section 5.15  JLab Fire Protection Engineer can provide guidance  Fire mitigation may be provided by preventative measures: Adequate drainage, dykes to prevent pooling Removal of brush, debris Elimination or limitation of close flammable material Fire suppression system Insulation and fireproofing  Cryogenic Vacuum Insulation relief depends on many factors: Fluid properties and chemistry Geometry Insulation type and thickness Temperature gradient  Loss of insulating vacuum on high temperature surfaces may result in catastrophic failure, OSP or TOSP is required  Cryogenic Vacuum Insulation relief depends on many factors: Fluid properties and chemistry Geometry Insulation type and thickness Temperature gradient  Loss of insulating vacuum on high temperature surfaces may result in catastrophic failure, OSP or TOSP is required The heat transfer rate is critical in calculating required relief capacity. DA is encouraged to collaborate with other experienced DAs

Part 4: Overpressure Protection 50 5 Overpressure Protection by Relief Device Generally takes 2 forms: Reclosing (spring loaded) and non-reclosing (rupture disk) 5 Overpressure Protection by Relief Device Generally takes 2 forms: Reclosing (spring loaded) and non-reclosing (rupture disk)

Part 4: Overpressure Protection 51 5 Overpressure Protection by Relief Device  Relief Devices with Set Pressure ≥ 15 psig Installed after March 1, 2008 ASME stamped devices only Registered if protecting a vessel, Cat. M system or piping larger than 6 NPS Installed before March 1, 2008 Devices may be ASME, CE/PED or non-certified. At replacement, only ASME stamped devices shall be used Registered if protecting a vessel, Cat. M system or piping larger than 6 NPS 5 Overpressure Protection by Relief Device  Relief Devices with Set Pressure ≥ 15 psig Installed after March 1, 2008 ASME stamped devices only Registered if protecting a vessel, Cat. M system or piping larger than 6 NPS Installed before March 1, 2008 Devices may be ASME, CE/PED or non-certified. At replacement, only ASME stamped devices shall be used Registered if protecting a vessel, Cat. M system or piping larger than 6 NPS

Part 4: Overpressure Protection 52 5 Overpressure Protection by Relief Device (cont.)  Relief Devices with Set Pressure < 15 psig* Not required to meet ASME BPVC Devices may be procured or manufactured, whole or in part, on or off site. * Devices with set pressures < 30 psi, protecting vacuum jackets for cryo piping ≤ 6 NPS are also not required to meet ASME BPVC.  Procure from reputable manufacturers. Capacity shall be determined through calculation or test. Set pressure for reclosing devices shall be verified by test.  JLab made devices shall comply with Supplement  Parallel Plate devices, use max. coefficient of discharge no greater than K d = 0.62 5 Overpressure Protection by Relief Device (cont.)  Relief Devices with Set Pressure < 15 psig* Not required to meet ASME BPVC Devices may be procured or manufactured, whole or in part, on or off site. * Devices with set pressures < 30 psi, protecting vacuum jackets for cryo piping ≤ 6 NPS are also not required to meet ASME BPVC.  Procure from reputable manufacturers. Capacity shall be determined through calculation or test. Set pressure for reclosing devices shall be verified by test.  JLab made devices shall comply with Supplement  Parallel Plate devices, use max. coefficient of discharge no greater than K d = 0.62

Part 4: Overpressure Protection 53 6 Installation  Installed by qualified technicians  Block or stop valves may be installed upstream if ASME BPVC VIII Div 1 App M requirements are met  Direction of discharge is safe 6 Installation  Installed by qualified technicians  Block or stop valves may be installed upstream if ASME BPVC VIII Div 1 App M requirements are met  Direction of discharge is safe

Part 4: Overpressure Protection 54 7 Relief Device Registration  Complete Form PS-5 for each relief device protecting pressure vessels, Cat. M components or piping larger than NPS 6  Exceptions: set points < 15 psig devices where max pressure cannot exceed 15 psid; fluid is nonflammable, nontoxic and not harmful to human issue; and temperature is between -20°F and 366°F 7 Relief Device Registration  Complete Form PS-5 for each relief device protecting pressure vessels, Cat. M components or piping larger than NPS 6  Exceptions: set points < 15 psig devices where max pressure cannot exceed 15 psid; fluid is nonflammable, nontoxic and not harmful to human issue; and temperature is between -20°F and 366°F

Part 4: Overpressure Protection 55 8 Overpressure Protection by System Design  If fluid is water <130°F and system does not have a vessel, no further requirements  For all others, DA writes a report addressing: 8 Overpressure Protection by System Design  If fluid is water <130°F and system does not have a vessel, no further requirements  For all others, DA writes a report addressing:  Reason  Detailed failure analysis (FMECA, etc.)  Detailed analysis of maximum credible pressure  Requirements for periodic inspections and testing of controls

Part 4: Overpressure Protection 56 8 Overpressure Protection by System Design (cont.)  Unless the system is B31.3 Cat D piping, B31.5 piping and B31.9 piping, the report must be approved by PSC Chair using Form PS-2  For new ASME pressure vessels, Form U-1 or U-1A shall indicate overpressure protection by system design  Repurposed ASME pressure vessels with overpressure protection by design require written approval by PSC Chair. 8 Overpressure Protection by System Design (cont.)  Unless the system is B31.3 Cat D piping, B31.5 piping and B31.9 piping, the report must be approved by PSC Chair using Form PS-2  For new ASME pressure vessels, Form U-1 or U-1A shall indicate overpressure protection by system design  Repurposed ASME pressure vessels with overpressure protection by design require written approval by PSC Chair.

Part 5: Repair and Alteration 58 1 General 2 Repair or Alteration of Pressure Vessels 3 Repair or Alteration of Relief Devices 4 Repair and Alteration Procedures 5 Design Calculations 6 Repairs and Alterations Requiring Welding, Brazing or Hot Work 7 Examinations and Testing 8 Inspections 9 Documentation 1 General 2 Repair or Alteration of Pressure Vessels 3 Repair or Alteration of Relief Devices 4 Repair and Alteration Procedures 5 Design Calculations 6 Repairs and Alterations Requiring Welding, Brazing or Hot Work 7 Examinations and Testing 8 Inspections 9 Documentation

Part 5: Repair and Alteration 59 1 General  Repairs and alterations to pressure systems, regardless of initial fabrication date, shall be performed by qualified personnel under the direction of a DA  Definition of Repair:  Definition of Alteration:  Applicable Codes: 1 General  Repairs and alterations to pressure systems, regardless of initial fabrication date, shall be performed by qualified personnel under the direction of a DA  Definition of Repair:  Definition of Alteration:  Applicable Codes: any work performed on an existing system that is not considered maintenance and does not change the fluid service or any aspect of the design specification For Category M, maintenance where the pressure boundary is breached is a repair! Maintenance on flammable fluid systems where the pressure boundary is breached or hot work is performed close to the pressure boundary is a repair! Maintenance work that requires welding, grinding, cutting or brazing on the pressure boundary is a repair! Repairs on components NPS 5 or smaller that do not require welding are considered maintenance. any work performed on an existing system that may change any aspect of the design specification or fluid service; this includes changes to structural supports and piping extensions ASME BPVC, ASME B31, NBIC Part 3 Rules for Repair and Alteration, ASME PCC-2 Repair of Pressure Equipment and Piping, and for Pressure Relief: API 520 Sizing, Selection and Installation of Pressure-Relieving Devices and API 521 Guide for Pressure-Relieving and Depressuring Systems

Part 5: Repair and Alteration 60 2Repair or Alteration of Pressure Vessels  Repairs or alterations to ASME Pressure Vessels, excluding those not affecting the pressure boundary, shall be performed by an organization with a valid “R” Stamp (coordinate with FM&L Dept)  Repairs or alterations to Excluded Vessels (including legacy vessels without an ASME stamp) shall be performed in accordance to Section 4 Repair and Alteration Procedures 2Repair or Alteration of Pressure Vessels  Repairs or alterations to ASME Pressure Vessels, excluding those not affecting the pressure boundary, shall be performed by an organization with a valid “R” Stamp (coordinate with FM&L Dept)  Repairs or alterations to Excluded Vessels (including legacy vessels without an ASME stamp) shall be performed in accordance to Section 4 Repair and Alteration Procedures

Part 5: Repair and Alteration 61 3Repair or Alteration of Relief Devices  Repairs or alterations to “ASME”, “V”, “UV”, “HV”, “UV3”, “TV”, or NBIC “VR” stamped relief devices shall be performed by an organization with a valid “VR” Stamp  Relief devices with set pressures greater than 15 psig requiring repair shall be replaced with Code devices 3Repair or Alteration of Relief Devices  Repairs or alterations to “ASME”, “V”, “UV”, “HV”, “UV3”, “TV”, or NBIC “VR” stamped relief devices shall be performed by an organization with a valid “VR” Stamp  Relief devices with set pressures greater than 15 psig requiring repair shall be replaced with Code devices

Part 5: Repair and Alteration 62 4 Repair and Alteration Procedures  Repairs to piping shall comply with original Code, most applicable current ASME Code, NBIC Part 3, or PCC-2. Equivalent measures are required if these cannot be applied.  All design and fabrication for alterations and tie-ins shall comply with current Code (B31, NBIC Part 3, PCC-2). Equivalent measures are required if these cannot be applied.  For alterations, consider the following: 4 Repair and Alteration Procedures  Repairs to piping shall comply with original Code, most applicable current ASME Code, NBIC Part 3, or PCC-2. Equivalent measures are required if these cannot be applied.  All design and fabrication for alterations and tie-ins shall comply with current Code (B31, NBIC Part 3, PCC-2). Equivalent measures are required if these cannot be applied.  For alterations, consider the following: Changes to design temperature and effect on materials Changes to design pressure and effects on relief devices and wall thickness Seismic, wind and other loadsFlow paths and changes to relief paths Changes in fluid service and effects on loads, temperatures, pressures, corrosion allowance, etc. Tie-ins to existing systems: understand upstream conditions ensure adequate relief capacity

Part 5: Repair and Alteration 63 4 Repair and Alteration Procedures Repairs and Alterations to Energized Systems Case 1: Work on a component/branch that is isolated by valve lineup or system configuration and locally deenergized (parts unaffected by the work remain energized) Case 2: Work on a component or branch that is fully or partially energized The component or branch to repaired/altered shall be isolated (Case 1 above) provided no unacceptable service interruption or unsafe condition is created. Work to non-pressure containing components may be performed with safety assured by procedures reviewed by DA 4 Repair and Alteration Procedures Repairs and Alterations to Energized Systems Case 1: Work on a component/branch that is isolated by valve lineup or system configuration and locally deenergized (parts unaffected by the work remain energized) Case 2: Work on a component or branch that is fully or partially energized The component or branch to repaired/altered shall be isolated (Case 1 above) provided no unacceptable service interruption or unsafe condition is created. Work to non-pressure containing components may be performed with safety assured by procedures reviewed by DA CASE 1 (Locally Deenergized)  An OSP or TOSP detailing the system configuration and preparation prior to and following the work as well as the repair/alteration procedure itself shall be written by or approved by the DA in addition to normal procedural signoffs.  If the system fluid is flammable, Category M, or considered hazardous by the ES&H manual then the isolated component or branch of the system shall be purged by an inert fluid prior to any repair or alteration. The procedure for purging shall be included in the OSP or TOSP. CASE 2 (Fully or Partially Energized)  An OSP or TOSP detailing the system configuration and preparation prior to and following the work as well as the repair/alteration procedure itself shall be written by or approved by the DA in addition to normal procedural signoffs.  The DA shall provide detailed procedures in the OSP or TOSP to ensure personnel and equipment safety.  Work on systems where the system fluid is Category M shall require written approval from the Jefferson Lab Director.  Special considerations for alterations requiring “Hot Tapping”. Hot Tapping:  Hot tapping where the system fluid is water shall require only the approvals included in signoff of the OSP/TOSP.  Hot tapping where the applicable Code and fluid Category is B31.3 Cat. D (other than water), B31.5, or B31.9 and the piping is not larger than NPS 6 (DN 150) shall require only the approvals included in signoff of the OSP/TOSP.  All other hot tapping operations shall require written approval from the Jefferson Lab Director in addition to the approvals included in the signoff of the associated OSP/TOSP.

Part 5: Repair and Alteration 64 4 Repair and Alteration Procedures Repairs and Alterations to Deenergized Systems  Standard work planning tools (i.e. THA, Atlis, TOSP, AHA, etc.) shall be written to ensure personnel and equipment safety. These documents shall describe any required system configuration and preparation prior to and following the work as well as the repair/alteration procedure itself (if required).  If the system fluid is flammable, Category M, or considered hazardous by the ES&H Manual, then the system must be purged by an inert fluid prior to any repair or alteration of any pressure retaining components. 4 Repair and Alteration Procedures Repairs and Alterations to Deenergized Systems  Standard work planning tools (i.e. THA, Atlis, TOSP, AHA, etc.) shall be written to ensure personnel and equipment safety. These documents shall describe any required system configuration and preparation prior to and following the work as well as the repair/alteration procedure itself (if required).  If the system fluid is flammable, Category M, or considered hazardous by the ES&H Manual, then the system must be purged by an inert fluid prior to any repair or alteration of any pressure retaining components.

Part 5: Repair and Alteration 65 5 Design Calculations  DA determines nature and extent of calculations required. Tech Review required where design meets ASME or NBIC; Peer Review required otherwise  Calculations are required for all repairs and alterations involving welding or brazing  Where piping or Excluded Vessels are affected, calculations showing that the repair meets or exceeds the original design requirements are required  Calculations for alterations and tie-ins shall be the same as those for new construction 5 Design Calculations  DA determines nature and extent of calculations required. Tech Review required where design meets ASME or NBIC; Peer Review required otherwise  Calculations are required for all repairs and alterations involving welding or brazing  Where piping or Excluded Vessels are affected, calculations showing that the repair meets or exceeds the original design requirements are required  Calculations for alterations and tie-ins shall be the same as those for new construction

Part 5: Repair and Alteration 66 6Repairs and Alterations Requiring Welding, Brazing or Hot Work  Where welding or brazing is required, additional requirements are in Welding and Brazing supplement  If the system fluid is flammable, considered hazardous or Cat M, the system shall be purged with an inert fluid and the purged condition verified prior to performance of hot work (Exclusions for “Hot Tapping”) 6Repairs and Alterations Requiring Welding, Brazing or Hot Work  Where welding or brazing is required, additional requirements are in Welding and Brazing supplement  If the system fluid is flammable, considered hazardous or Cat M, the system shall be purged with an inert fluid and the purged condition verified prior to performance of hot work (Exclusions for “Hot Tapping”)

Part 5: Repair and Alteration 67 7Examinations and Testing  Welding and brazing shall meet the examination requirements of the applicable code  DA ensures one or more of the following are performed:  Cat. M Fluid Systems and High Pressure Piping must meet requirements in the most recent edition of B31.3 7Examinations and Testing  Welding and brazing shall meet the examination requirements of the applicable code  DA ensures one or more of the following are performed:  Cat. M Fluid Systems and High Pressure Piping must meet requirements in the most recent edition of B31.3 Hydrostatic Pressure Test per B31, PCC-2 or NBIC Part 3 Pneumatic Pressure Test per B31, PCC-2 or NBIC Part 3 (PVC, CPVC, PVDF, etc. shall not be pneumatically tested) Initial Service Leak Test if fluid service is Cat. D or Normal, not flammable, toxic or harmful; exclusive use is prohibited unless allowed by original code of construction Sensitive Vacuum Leak Test, exclusive use is prohibited if design pressure is greater than 15 psi Nondestructive Examination per BPVC Section V, exclusive use of VT is prohibited if greater then NPS 5 Hydrostatic Pressure Test per B31, PCC-2 or NBIC Part 3 Pneumatic Pressure Test per B31, PCC-2 or NBIC Part 3 (PVC, CPVC, PVDF, etc. shall not be pneumatically tested) Initial Service Leak Test if fluid service is Cat. D or Normal, not flammable, toxic or harmful; exclusive use is prohibited unless allowed by original code of construction Sensitive Vacuum Leak Test, exclusive use is prohibited if design pressure is greater than 15 psi Nondestructive Examination per BPVC Section V, exclusive use of VT is prohibited if greater then NPS 5

Part 5: Repair and Alteration 68 8Inspections Repairs and alterations requiring welding or brazing shall meet the requirements defined in the Welding and Brazing Supplement 8Inspections Repairs and alterations requiring welding or brazing shall meet the requirements defined in the Welding and Brazing Supplement

Part 5: Repair and Alteration 69 9 Documentation Documentation for repair or alteration shall be filed in the ORIGINAL PRESSURE SYSTEM FOLDER! Pressure System ID numbers and new folders are for discreet systems, not repairs or alterations of existing ones! 9 Documentation Documentation for repair or alteration shall be filed in the ORIGINAL PRESSURE SYSTEM FOLDER! Pressure System ID numbers and new folders are for discreet systems, not repairs or alterations of existing ones!

Part 6: Pressure and Leak Testing  ASME and NBIC require pressure/leak testing for new construction, alterations and repairs  All personnel directly involved in the testing shall be qualified  Test witnessed by inspector unless waived by DA, System Owner and inspector  DA or pressure test engineer must determine stored energy of system  3 types of tests: hydrostatic, pneumatic or hydro- pneumatic  ASME and NBIC require pressure/leak testing for new construction, alterations and repairs  All personnel directly involved in the testing shall be qualified  Test witnessed by inspector unless waived by DA, System Owner and inspector  DA or pressure test engineer must determine stored energy of system  3 types of tests: hydrostatic, pneumatic or hydro- pneumatic 71

Part 6: Pressure and Leak Testing 72  OSP or TOSP required if: stored energy is above 100kJ exposure to Cat. M fluid and system or component has not been fully cleaned and released test fluid is not inert test fluid is air at > 250 psi test must be performed on a radioactively contaminated system  OSP or TOSP required if: stored energy is above 100kJ exposure to Cat. M fluid and system or component has not been fully cleaned and released test fluid is not inert test fluid is air at > 250 psi test must be performed on a radioactively contaminated system  Calculate stored mechanical energy of the test volume by: Ideal Gas Laws Brode equation for a gaseous volume Baker equation for a gaseous volume* Aslonov-Golinsky equation for a gaseous volume Enthalpy tables Equation for stored energy for liquids*  Ensure consistency with units!  If test fluid is reactive, flammable or explosive the chemical potential energy must also be included. * Included in Supplement

Part 6: Pressure and Leak Testing  OSP or TOSP must include: Roles and responsibilities Rational for selection of test type Stored energy of test Qualification of personnel Protection for personnel performing test; personnel near or potentially exposed; and equipment Test rig or pressure manifold Schematic of test set-up ODH hazards Detailed procedure for performing test Inspection requirements before, during and after test Recovery procedure if applicable  OSP or TOSP must include: Roles and responsibilities Rational for selection of test type Stored energy of test Qualification of personnel Protection for personnel performing test; personnel near or potentially exposed; and equipment Test rig or pressure manifold Schematic of test set-up ODH hazards Detailed procedure for performing test Inspection requirements before, during and after test Recovery procedure if applicable 73

Part 6: Pressure and Leak Testing  Pressure Test form (PS-7) shall be completed by test engineer, technician and inspector as applicable  DA ensures that documentation is filed appropriately  Pressure Test form (PS-7) shall be completed by test engineer, technician and inspector as applicable  DA ensures that documentation is filed appropriately 74

Category 0 – Vacuum systems in which the differential operating pressure can never exceed 15 psi and: total volume is less than 35 ft 3 or cross section is less than 33 in 2 relieving pressure source cannot exceed 15 psig in any failure mode system is not an insulating vacuum for cryo components no thin windows more than 6 inches in diameter Category 0 – Vacuum systems in which the differential operating pressure can never exceed 15 psi and: total volume is less than 35 ft 3 or cross section is less than 33 in 2 relieving pressure source cannot exceed 15 psig in any failure mode system is not an insulating vacuum for cryo components no thin windows more than 6 inches in diameter Part 7: Vacuum Systems Category I – Vacuum systems not used to insulate cryogenic surfaces in which the differential operating pressure can never exceed 15 psi Category 2 – Vacuum systems which can be protected from pressurization exceeding 15 psig through engineering controls (e.g. pressure relief devices). Category 3 – Vacuum systems which are not or cannot be protected against pressurization exceeding 15 psig. Category 0 Vacuum Systems: designed, repaired and altered by a Vacuum Technician. No further requirements. Category 1 Vacuum Systems: designed, repaired, altered, and documented by a Responsible Vacuum Engineer DESIGN – buckling analysis with factor of safety = 2 FABRICATION – use Welding & Brazing Supplement TESTING – in addition to performance leak testing, pressure test per Supplement DOCUMENTATION – maintained by Responsible Vacuum Engineer Small (<35ft 3 ) Category 2 Vacuum Systems: designed, repaired, altered by a Resp. Vacuum Engineer, requirements for PRESSURE RELIEF only per Supplement - max. pressure cannot exceed 15 psid. Coded relief devices not required. Purge system acceptable under defined conditions Large (> 35ft 3 ) Category 2 Vacuum Systems: designed, repaired, altered and documented by a Responsible Vacuum Engineer PRESSURE RELIEF – max. pressure cannot exceed 15 psid. Coded relief devices not required. Purge system acceptable under defined conditions FABRICATION – use Welding & Brazing Supplement TESTING - in addition to performance leak testing, pressure test per Supplement DOCUMENTATION – maintained by Responsible Vacuum Engineer Category 3 Vacuum Systems: DA must follow the full rigor of ES&H Manual Chapter 6151 and its Supplement 76

Part 7: Vacuum Systems Requirements for Thin Windows:  For Category 1 and 2, window design safety assured by DA  Design shall consider  Design calculations or proof test, and testing (during forming process or pressure test) required  Thin windows on Category 3 systems must meet ASME code or equivalent. RULES IN PART 7 ARE NOT EQUIVALENT! Requirements for Thin Windows:  For Category 1 and 2, window design safety assured by DA  Design shall consider  Design calculations or proof test, and testing (during forming process or pressure test) required  Thin windows on Category 3 systems must meet ASME code or equivalent. RULES IN PART 7 ARE NOT EQUIVALENT! 77 Material compatibility Life cycle and fatigue Effects from radiation or corrosion Accidental damage from puncture, etc. Magnitude of deformation Crack and tear propagation

Part 8: Operation and Maintenance Operation  System Owner is responsible for safe operation  DA must identify operating requirements on Form PS-9 for new or in-process systems Operation  System Owner is responsible for safe operation  DA must identify operating requirements on Form PS-9 for new or in-process systems 79

Part 8: Operation and Maintenance Maintenance  System Owner is responsible for long term maintenance  DA must identify special maintenance requirements on Form PS-9 for new or in-process systems such as Replacement for thin windows Replacement for parts exposed to cyclic loading Cathodic corrosion protection replacement  System Owner responsible for developing routine maintenance requirements such as Paint and basic corrosion control Manufacturer’s required maintenance Support hanger spring replacement Support roller lubrication /replacement Maintenance  System Owner is responsible for long term maintenance  DA must identify special maintenance requirements on Form PS-9 for new or in-process systems such as Replacement for thin windows Replacement for parts exposed to cyclic loading Cathodic corrosion protection replacement  System Owner responsible for developing routine maintenance requirements such as Paint and basic corrosion control Manufacturer’s required maintenance Support hanger spring replacement Support roller lubrication /replacement 80

Part 9: In-Service Inspection Program 82 Inspection Categories  IC4 : 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 (piping, turbo and reciprocating machinery, excluded vessels, etc.) Inspection Categories  IC4 : 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 (piping, turbo and reciprocating machinery, excluded vessels, etc.) Change from Dec 9 training: #’s are reversed so that higher numbers reflect higher risk.

Part 9: In-Service Inspection Program 83 Inspection Type The inspector shall perform a visual inspection of vessels, piping, and ancillary equipment. The inspector shall use sound engineering principles to determine if further inspection and examination techniques are required. Inspection Type The inspector shall perform a visual inspection of vessels, piping, and ancillary equipment. The inspector shall use sound engineering principles to determine if further inspection and examination techniques are required.

Part 9: In-Service Inspection Program 84 Inspection and Testing Intervals DA shall determine the required inspection interval by 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 Inspection and Testing Intervals DA shall determine the required inspection interval by 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

Part 9: In-Service Inspection Program 85 Inspection Interval (for IC4, IC3 and IC2) Component and Fluid Service Maximum Test and or Inspection Interval (years) Vessel: Gas (non-corrosive)5 Vessel: Gas (corrosive)2 Vessels and piping: Category M fluid 1 Vessel: Liquid (corrosive)1 Vessel: Liquid (non-corrosive)5 Dewar Vessel2 Rupture DiskInspect/Replace every 5 Vessel: Boiler2 IC1 Relief Device2 Relief Device: Gas (non- corrosive) 5 Relief Device: Gas (corrosive)2 Relief Device: Category M fluid1 Relief Device: Liquid (corrosive) 2 Relief Device: Liquid (non- corrosive) 5 Relief Device on Dewar Vessel5 Interval may be increased after suitable record of satisfactory inspections for equipment other than for ASME boilers and Cat. M systems.

Part 9: In-Service Inspection Program 86 Inspection Interval (For IC1) For IC1 Components and Systems only: DAs may use the table for guidance. These specific intervals are not required however an interval must be defined and documented. Inspection Interval (For IC1) For IC1 Components and Systems only: DAs may use the table for guidance. These specific intervals are not required however an interval must be defined and documented.

Part 9: In-Service Inspection Program 87 Full performance of the In-Service Inspection Program will be phased in over the next year or so. Facilities will continue their Boiler and Vessel Inspection Program. DAs must identify the In-Service Inspection requirements for all in-process and new systems through Form PS-9. Full performance of the In-Service Inspection Program will be phased in over the next year or so. Facilities will continue their Boiler and Vessel Inspection Program. DAs must identify the In-Service Inspection requirements for all in-process and new systems through Form PS-9. Ron Bartek x7671

Mandatory Forms: PS-1Project Cover Sheet PS-2Overpressure Protection by Design PS-3Technical/Peer Review PS-4Vessel Registration PS-5Relief Device Registration PS-6 Final Mechanical Examination PS-7Pressure/Leak Test Record PS-8Final Walkthrough PS-9Pressure System Turnover PS-10Pressure Equipment ISI PS-11ASME Vessel/Relief Device ISI PS-12Relief Device ISI Mandatory Forms: PS-1Project Cover Sheet PS-2Overpressure Protection by Design PS-3Technical/Peer Review PS-4Vessel Registration PS-5Relief Device Registration PS-6 Final Mechanical Examination PS-7Pressure/Leak Test Record PS-8Final Walkthrough PS-9Pressure System Turnover PS-10Pressure Equipment ISI PS-11ASME Vessel/Relief Device ISI PS-12Relief Device ISI 89 Part 10: Mandatory Forms

Revised Welding and Brazing Program Supplement ES&H Manual Chapter 6122 defines hot work safety requirements Welding & Brazing Supplement provides the quality requirements for welding and brazing operations including design, examination and inspection Supplement Covers: design and classification of joints; qualifications of procedures, welders, examiners and inspectors; material control; documentation ES&H Manual Chapter 6122 defines hot work safety requirements Welding & Brazing Supplement provides the quality requirements for welding and brazing operations including design, examination and inspection Supplement Covers: design and classification of joints; qualifications of procedures, welders, examiners and inspectors; material control; documentation 91 Ch. 6122 covers safety of performing the weld The WBS covers the quality of the weld itself

Revised Welding and Brazing Program Supplement 92 Old Category or ClassNew Category Class A Class B Code Class CLow Risk Joint must follow the requirements detailed in the Welding & Brazing Supplement. Joint is exempt from the requirements. Welding & Brazing Supplement is optional.

Revised Welding and Brazing Program Supplement 93 “CODE” Weld or Braze: All 6151 covered pressure systems All structures supporting loads >100lbs at any height AND having RC>1 All structures supporting any load at heights >6 ft AND having RC>1 All material handling equipment supporting loads >100 lbs OR any load at ≥6 ft All buildings or structures for human occupancy Any welded components assessed in final configuration under normal or off-normal conditions having RC>1 “CODE” Weld or Braze: All 6151 covered pressure systems All structures supporting loads >100lbs at any height AND having RC>1 All structures supporting any load at heights >6 ft AND having RC>1 All material handling equipment supporting loads >100 lbs OR any load at ≥6 ft All buildings or structures for human occupancy Any welded components assessed in final configuration under normal or off-normal conditions having RC>1 Exceptions: Ch. 6151 excepted systems (RC≤1) Unmodified UL listed equipment Unmodified ASME vessels with “U” or “UM” stamp Modified or repaired ASME vessels with “R” stamp Exceptions: Ch. 6151 excepted systems (RC≤1) Unmodified UL listed equipment Unmodified ASME vessels with “U” or “UM” stamp Modified or repaired ASME vessels with “R” stamp

Produce welds and brazes according to the Welding and Brazing Supplement. Does NOT have to follow the requirements of the Welding and Brazing Supplement. Structural or Material Handling Weld/Braze Load >100# or Height >6’? Yes No Pressure System? Excepted in ES&H Manual Chapter 6151, Section 2.1 or Pressure & Vacuum Systems Safety Supplement, Part 2: Section 8.1.1? Yes Start Yes No Building/Structure for Human Occupancy? No Yes Risk Code >1? Yes No Risk Code >1? No Yes Material Handling Fixture? Yes No Revised Welding and Brazing Program Supplement 94

Generate drawings/sketches containing weld/braze geometries, process, filler and base metals. Determine most applicable code to follow or use equivalent measures where no consensus Code can be directly applied. Ensure welds/brazes meet consensus code requirements or those of this Welding and Brazing Supplement. Related documentation shall be accessible to all JLab employees. Additional requirements are given in Pressure and Vacuum Systems Safety Supplement Part 2: Section 8. Analyze and appropriately review the design of all welds/brazes. Ensure that all reviews, testing, material qualifications, examination, and all related documentation are complete. Write specification on drawing, design parameter form or other document that contains design information (eg, temperatures, pressures, and loads), testing, examination and inspection requirements No Yes Start Welding/Brazing performed by JLab? Revised Welding and Brazing Program Supplement File Documentation in appropriate database. 95

Revised Welding and Brazing Program Supplement 96 Key points to remember:  New classification for welds – Code and Low Risk  Inspection requirements are provided in WBS, involve the QA/CI Inspector Mike Martin Ext. 5515 Key points to remember:  New classification for welds – Code and Low Risk  Inspection requirements are provided in WBS, involve the QA/CI Inspector Mike Martin Ext. 5515

Future Plans Create a database of Operating Pressure Systems Review existing Docushare database Interview associated DAs or System Owners Compile data and develop methods for real time updating Create a database of Operating Pressure Systems Review existing Docushare database Interview associated DAs or System Owners Compile data and develop methods for real time updating 98

Future Plans Create a database of Operating Pressure Systems Review existing Docushare database Interview associated DAs or System Owners Compile data and develop methods for real time updating Incorporate AIMS Software Replace DocuShare with tool that has intuitive UI that is easier to use Provide asset integrity management (AIMS) database Manage all inspection data Create a database of Operating Pressure Systems Review existing Docushare database Interview associated DAs or System Owners Compile data and develop methods for real time updating Incorporate AIMS Software Replace DocuShare with tool that has intuitive UI that is easier to use Provide asset integrity management (AIMS) database Manage all inspection data 99

Future Plans Create a database of Operating Pressure Systems Review existing Docushare database Interview associated DAs or System Owners Compile data and develop methods for real time updating Incorporate AIMS Software Replace DocuShare with tool that has intuitive UI that is easier to use Provide asset integrity management (AIMS) database Manage all inspection data ASME Training Specific to JLab Reinstate Sharing Lessons Learned Implement ISI Program Facilities and Ron Bartek will continue current program Projected 12 to 18 months until full implementation Create a database of Operating Pressure Systems Review existing Docushare database Interview associated DAs or System Owners Compile data and develop methods for real time updating Incorporate AIMS Software Replace DocuShare with tool that has intuitive UI that is easier to use Provide asset integrity management (AIMS) database Manage all inspection data ASME Training Specific to JLab Reinstate Sharing Lessons Learned Implement ISI Program Facilities and Ron Bartek will continue current program Projected 12 to 18 months until full implementation 100

What We Want You To Remember 101 Pressure Systems Committee Ron Bartek, Kelly Dixon, Gayle Coleman, Will Oren (Chair), Tim Whitlatch, Dave Meekins, (not pictured) Ed Daly, George Perry and Steve Smith We’re Here to Help

PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING SAF 130B 1 This training was conducted on December.

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PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING SAF 130B 1 This training was conducted on December.

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Presentation on theme: "PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING PRESSURE AND VACUUM SYSTEMS DESIGN AUTHORITY TRAINING SAF 130B 1 This training was conducted on December."— Presentation transcript:

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