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
 Why is 10CFR851 concerned with
pressure safety?
•Over pressurization, 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
DOE 10CFR851 Pressure Safety
“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.”

“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, vessel geometry, use of special material,
etc.), contractors must implement measures to provide
equivalent protection…”
 JLab’s Response to 10CFR851
Pressure Safety Requirements

• Form a Pressure Systems Committee

 Pressure Systems Committee
•Committee chartered to serve as the steering committee for
10CFR851 pressure safety implementation

•Members include: Engineering Manager and Administrative Support,

Cryogenics System Engineer, Facilities Management Engineer,
Experimental Hall Engineer, Experimental Target Physicist and ESH&Q
Representative

Ron Bartek Will Oren

Kelly Dixon Tim Whitlatch
Bert Manzlak Gayle Coleman
Dave Meekins
 JLab’s Response to 10CFR851
Pressure Safety Requirements

• Form a Pressure Systems Committee

• Define pressure systems within JLab

 Defining a Pressure System

To define a JLab Pressure System, 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
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
 10CFR851 Definition of a
Pressure System
• Pressure systems include all
pressure vessels and pressure
sources including cryogenics,
pneumatic, hydraulic and vacuum
• Category I – Vacuum systems in which the differential operating
• Vacuum systems
pressure are
can never considered
exceed 15 psi. Examples of Category I vacuum
systems
pressure include HMS
systems and
due to HRSpotential
their vacuum systems, 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.,
exceeding gauges
15 psig through engineering controls (e.g.
andpressure relief fittings,
regulators), devices).piping,
Examples of Category II vacuum systems
pumps
include cryostats, cryogenic transfer lines, 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 Pressure Systems at JLab

•Cryomodules -- 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
 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
 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
 Pressure Systems Policy
JLab has policies and procedures that ensure all pressure
systems are designed, fabricated, tested, inspected, maintained,
repaired, and operated by trained and qualified personnel in
accordance with applicable codes and sound engineering
principles.
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, JLab shall
implement equivalent measures that ensure a level of safety
greater than or equal to the level provided by the ASME Codes.
 Pressure Systems Hazard Avoidance
• Goal – avoid hazards
associated with pressure
systems
 Key Hazard Avoidance Techniques
• design, fabricate, 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
Key People – Roles and Responsibilities

Design Authority
Design Authority Qualifications
Design Authority
• 4 yr. degree in•Ensure
engineering
ASME or Code
physics, 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,
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,
Appendix T-1
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
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,
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 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, MDRs, etc)
•Store documentation in
Project Folder
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
 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, 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
 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,
purchasing, fabrication, installation,
operation, maintenance, repair
 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, purchasing,
fabrication, installation, operation,
maintenance, repair
• General JLab Staff responsibilities
and Design Authority responsibilities
 What We Want You To Remember
General JLab Staff
• Must be able to recognize a pressure
system
• Understand that vacuum systems are
pressure systems
• Alert line management when repairs
or modifications are needed. Can
perform those after approval from a
DA
• Can perform design work
(calculations, drawings, etc.) but must
have DA signoff
• Understand that the Pressure
System Safety Program is in
revision and will be reissued within
the next 12 months
Design Authority
• Must apply the JLab Pressure Systems
policy to pressure system designs,
repairs and modifications
• Determines hazard level of a pressure
system; employs graded approach.
• Interprets ASME codes and applies as
appropriate
• Ensures equivalent protection where
ASME codes cannot be directly applied;
conducts Peer Reviews
• Establishes design requirements and
technical adequacy of the design
• Obtains technical reviews of design
documentation
• Authorizes repairs or modifications to
pressure systems
• Performs technical reviews of other DAs
pressure systems
• Design Authority may delegate design
work but not their responsibilities
 NEW: PS WEBSITE

http://www.jlab.org/eng/pressure_systems/index.html
 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, purchasing,
fabrication, installation, operation,
maintenance, repair
• General JLab Staff responsibilities
and Design Authority Responsibilities
• Pressure Systems Committee is
available to help
Pressure Systems Committee
Ron Bartek, Kelly Dixon, Bert Manzlak,
Dave Meekins, Will Oren,
Tim Whitlatch, Gayle Coleman