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SAF 130A

PRESSURE SYSTEMS
HAZARD AWARENESS

Course Overview

Why Are We Here?
10CFR851 Pressure Safety Requirements
JLab’s Response to 10CFR851
- Pressure Systems Committee
- Definition of Pressure System
- Establish Pressure Systems Policy and Procedures
ES&H Chapter 6151 and Technical Appendices
- Pressure System Policy
- Hazard Avoidance
- Roles and Responsibilities
- Pressure Systems Program Summary
What We Want You To Remember

Why Are We here?

DOE 10CFR851
Worker Safety and Health Program
February 7, 2006

Establishes “requirements for a
worker safety and health program that
reduces or prevents occupational
injuries, illnesses, and accidental
losses by providing DOE contractors
and their workers with safe and
healthful workplaces at DOE sites”

Why Are We Here?
DOE 10CFR851
Establishes mandatory requirements for:
• Construction Safety
• Fire Protection
• Explosives Safety
• Pressure Safety
• Firearms Safety
• Industrial Hygiene
• Biological Safety
• Occupational Medicine
• Motor Vehicle Safety
• Electrical Safety

operator error. poor construction or maintenance can result in leakage or rupture failures: –Pose safety risk to personnel –May jeopardize other critical components –May result in release of hazardous pollution •Hazards include: –Explosion –Fires –Poisoning –Scalding . Why is 10CFR851 concerned with pressure safety? •Over pressurization.

tested. inspected.). use of special material. vessel geometry.” “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” “When national consensus codes are not applicable (because of pressure range. etc. repaired. and operated by trained and qualified personnel in accordance with applicable and sound engineering principles. fabricated.DOE 10CFR851 Pressure Safety “Contractors must establish safety policies and procedures to ensure that pressure systems are designed. contractors must implement measures to provide equivalent protection…” . maintained.

JLab’s Response to 10CFR851 Pressure Safety Requirements • Form a Pressure Systems Committee .

Cryogenics System Engineer. Experimental Hall Engineer. Pressure Systems Committee •Committee chartered to serve as the steering committee for 10CFR851 pressure safety implementation •Members include: Engineering Manager and Administrative Support. Experimental Target Physicist and ESH&Q Representative Ron Bartek Will Oren Kelly Dixon Tim Whitlatch Bert Manzlak Gayle Coleman Dave Meekins . Facilities Management Engineer.

JLab’s Response to 10CFR851 Pressure Safety Requirements • Form a Pressure Systems Committee • Define pressure systems within JLab .

the Pressure Systems Committee: • started with the 10CFR851 definition • applied the exclusions specified in the ASME BPV and B31 Codes • considered the types of systems at JLab. and • added exclusions covered under other regulations or ES&H Chapters . Defining a Pressure System To define a JLab Pressure System.

JLab Definition of Pressure System Pressure System and Vacuum Systems: Any container that holds a liquid or gas under internal (positive) or external (negative or vacuum) pressure different than atmospheric pressure. regardless of the magnitude of the pressure. •pressure and vacuum systems possess potentially lethal hazards •examples of pressure systems include: • gas systems for experimental detectors such as drift chambers even if the gas pressure is low • vacuum chambers • gas and liquid target systems • cryogenic and compressed gas dewars and cylinders •vacuum systems can be especially hazardous when backfilling or purging .

hydraulic and vacuum • Category I – Vacuum systems in which the differential operating • Vacuum systems pressure are can never considered exceed 15 psi. pneumatic. exceeding gauges 15 psig through engineering controls (e. regulators). Examples of Category II vacuum systems pumps include cryostats.g. cold boxes and target andvessels pressure relief devices are integral parts of a pressure system • Category III – Vacuum systems which are not or cannot be protected against pressurization exceeding 15 psig . Examples of Category I vacuum systems pressure include HMS systems and due to HRSpotential their vacuum systems. 10CFR851 Definition of a Pressure System • Pressure systems include all pressure vessels and pressure sources including cryogenics.. injector chambers and dog-leg chambers for catastrophic failure from backfill pressurization • Category II – Vacuum systems which can be protected from • Associated hardware pressurization (e.g.piping. devices). cryogenic transfer lines. andpressure relief fittings.

pressure & vacuum systems •Experimental equipment with vacuum chambers >15 psi •Superconducting magnets -.pressure & vacuum systems •Oil-removal & gas-storage systems integral to the cryo plants •Compressed air & pressurized air reservoirs > 15 psi •Heating & cooling water systems .Examples of Pressure Systems at JLab •Cryomodules -.

JLab’s Response to 10CFR851 Pressure Safety Requirements •Form a Pressure Systems Committee •Define pressure systems within JLab •Develop policy and procedures to implement 10CFR851 pressure safety requirements .

ES&H Chapter 6151 and Technical Appendices The ES&H Manual Chapter 6151 Pressure Systems: • T1 – Pressure System Project Implementation and Documentation Guidance • T2 – Pressure Systems Design Program • T3 – Safety Requirements for Thin Windows • T4 – Pressure Testing Program •T5 – Requirements for Vacuum Systems Other: • ES&H Manual Supplement • Welding and Brazing Program Supplement .

Pressure Systems Program Summary What We Want You To Remember .Roles and Responsibilities .Hazard Avoidance .Definition of Pressure System .Pressure Systems Committee . Course Overview Why Are We Here? 10CFR851 Pressure Safety Requirements JLab’s Response to 10CFR851 . Pressure System Policy . Establish Pressure Systems Policy and Procedures ES&H Chapter 6151 and Technical Appendices .

inspected. repaired. JLab verifies that all pressure systems conform to applicable codes: – ASME BPV Code – ASME B31 Code – State and Local Codes Where ASME Codes cannot be directly applied. Pressure Systems Policy JLab has policies and procedures that ensure all pressure systems are designed. JLab shall implement equivalent measures that ensure a level of safety greater than or equal to the level provided by the ASME Codes. fabricated. tested. . maintained. and operated by trained and qualified personnel in accordance with applicable codes and sound engineering principles.

Pressure Systems Hazard Avoidance • Goal – avoid hazards associated with pressure systems .

fabricate. Key Hazard Avoidance Techniques • design. test according to chapter • never exceed rated capacity • use only for designed purpose • do not modify without authorization • routine inspections • report damage or defects • do not apply heat unless specifically authorized .

Key People – Roles and Responsibilities Design Authority ESH&Q Division Division Heads Facilities Manager Pressure Systems Committee Everyone at JLab .

degree in•Ensure engineering ASME or Code physics.Key People – Roles and Responsibilities Design Authority Design Authority Qualifications Design Authority • 4 yr. at least 5 compliance ESH&Q Division years experience in design according toof related JLab pressure policy Division Heads systems and approval by division head •Where ASME Codes cannot be applied. Appendix T-1 . or ensure equivalent level of safety Facilities Manager • PE and experience in design of related pressure Pressure Systems •Follow JLab policy and procedures per systems and approval by division head the ES&H Manual Welding and Brazing Committee or Program Supplement Everyone at •JLab approval of JLab Engineering •Ensure proper Manager pressure system documentation per ES&H Chapter 6151.

Key People – Roles and Responsibilities Design Authority ESH&Q Division ESH&Q Division Division Heads •Manage JLab Welding and Brazing Program Facilities Manager •Supervise code inspector Pressure Systems •Provide inspection services Committee •Monitor certifications for examiners. welders and inspectors Everyone at JLab .

Key People – Roles and Responsibilities Design Authority ESH&Q Division Division Heads Division Heads •Designate Design Authorities Facilities Manager • Verify organization’s adherence to Pressure Systems JLab’s Welding and Brazing program Committee • Verify recordkeeping complies with Everyone at JLab Chapter 6151 .

Key People – Roles and Responsibilities Design Authority ESH&Q Division Facilities Manager Division Heads •Coordinate and maintain inspection reports Facilities Manager for all pressure vessels Pressure Systems •Under direction of DA. coordinate Committee repair/modification of stamped pressure Everyone at JLab vessels .

Key People – Roles and Responsibilities Design Authority Pressure Systems Committee ESH&Q Division Division Heads • Develop and maintain pressure system program Facilities Manager • Maintain list of Design Authorities Pressure Systems • Act as final JLab authority for non-code Committee qualified design elements Everyone at JLab • Document decisions in pressure systems project folders .

Key People – Roles and Responsibilities Design Authority Everyone at JLab ESH&Q Division •Refer pressure systems questions to Division Heads Design Authority or the PS Committee •Before working on physical plant Facilities Manager pressure systems. consult Maintenance Pressure Systems Services Manager Committee •Alert line management if: Everyone at JLab •A pressure system does not conform to JLab pressure system program •A pressure system or associated equipment is unsafe .

Pressure Systems Program Summary – Design – Purchasing – Fabrication – Installation and Testing – Inspection – Repair/Modification .

Pressure Systems Program Summary The Pressure Systems Program employs a – Design Risk-based Graded Approach – Purchasing Accommodations are included in – Fabrication the Pressure Systems Program to handle – Installation and Pressure Systems with low complexity (commercially available tanks) Testing and Low Hazard Pressure Systems – Inspection – Repair/Modification The Design Authority is responsible for minimum documentation requirements for these systems .

dwgs and specs per Code – Inspection •Conduct technical. peer and/or design reviews – Repair/Modification •Store documentation in Project Folder .Pressure Systems Program Summary – Design Design – Purchasing •Initiate a Project Folder & Checklist within DocuShare – Fabrication •Define design criteria and – Installation and applicable Codes Testing •Complete design calcs.

Pressure Systems Program Summary – Design Purchasing – Purchasing •DA issues Statement of Work defining specific Code – Fabrication QA requirements – Installation and •Follow JLab Purchasing process (highlight Code Testing requirements as required) – Inspection •SOTR verifies receipt inspection (compliance with – Repair/Modification design docs. proper markings. etc) •Store documentation in Project Folder . MDRs.

Pressure Systems Program Summary – Design Fabrication •DA develops fabrication – Purchasing plan – Fabrication •Materials for pressure system fabrication clearly – Installation and marked Testing •Welding and inspection performed per Welding and – Inspection Brazing Supplement – Repair/Modification •Store documentation in Project Folder .

Pressure Systems Program Summary Installation and Test – Design • Installation performed by – Purchasing qualified personnel • Pressure test must be – Fabrication conducted – Installation and • Store documentation in Testing Project Folder • QA shall perform final – Inspection safety walk through before operation and sign-off – Repair/Modification .

Pressure Systems Program Summary Inspection (post operation) – Design • Pressure vessels inspected – Purchasing per Code of VA • Facilities Manager is – Fabrication responsible for inspections – Installation and and maintaining records Testing – Inspection – Repair/Modification .

Pressure Systems Program Summary Repair/Modification – Design •Must be completed under direction of a Design Authority – Purchasing •Maintenance without welding performed by competent – Fabrication technical staff – Installation and •Repairs/modifications to stamped vessels coordinated by Facilities Testing Manager •Documentation follows Appendix – Inspection T1 requirements – Repair/Modification .

What We Want You to Remember • Pressure system safety applies to all .

What We Want You To Remember • Pressure system safety applies to all • Goal = Avoid hazards .

• Pressure and vacuum systems possess potentially lethal hazards • Examples of pressure systems include: • gas systems for experimental detectors such as drift chambers even if the gas pressure is low • vacuum chambers • gas and liquid target systems • cryogenic and compressed gas dewars and cylinders • Vacuum systems can be especially hazardous when backfilling or purging . regardless of the magnitude of the pressure. What We Want You to Remember • Pressure system safety applies to all • Goal = Avoid hazards • Pressure System definition Pressure System : Any container that holds a liquid or gas under internal (positive) or external (negative or vacuum) pressure different than atmospheric pressure.

What We Want You To Remember • Pressure system safety applies to all • Goal = Avoid hazards • Pressure System definition .

What We Want You To Remember • Pressure system safety applies to all • Goal = Avoid hazards • Pressure System definition • ES&H 6151 and related supplements define the requirements for design. repair . installation. purchasing. operation. maintenance. fabrication.

fabrication. purchasing. operation. maintenance. repair • General JLab Staff responsibilities and Design Authority responsibilities . installation. What We Want You To Remember • Pressure system safety applies to all • Goal = Avoid hazards • Pressure System definition • ES&H 6151 defines the new requirements for design.

) but must technical adequacy of the design have DA signoff • Obtains technical reviews of design documentation • Understand that the Pressure • Authorizes repairs or modifications to System Safety Program is in pressure systems revision and will be reissued within • Performs technical reviews of other DAs the next 12 months pressure systems • Design Authority may delegate design work but not their responsibilities . What We Want You To Remember General JLab Staff Design Authority • Must be able to recognize a pressure • Must apply the JLab Pressure Systems system policy to pressure system designs. repairs and modifications • Understand that vacuum systems are • Determines hazard level of a pressure pressure systems system. drawings. Can • Ensures equivalent protection where perform those after approval from a ASME codes cannot be directly applied. • Interprets ASME codes and applies as • Alert line management when repairs appropriate or modifications are needed. etc. DA conducts Peer Reviews • Can perform design work • Establishes design requirements and (calculations. employs graded approach.

html . NEW: PS WEBSITE http://www.jlab.org/eng/pressure_systems/index.

maintenance. installation. purchasing. Will Oren. Kelly Dixon. Gayle Coleman . operation. Dave Meekins. What We Want You To Remember • Pressure system safety applies to all • Goal = Avoid hazards • Pressure System definition • ES&H 6151 defines the new requirements for design. fabrication. Bert Manzlak. Tim Whitlatch. repair • General JLab Staff responsibilities and Design Authority Responsibilities • Pressure Systems Committee is available to help Pressure Systems Committee Ron Bartek.