SAF 130A
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PRESSURE SYSTEMS HAZARD AWARENESS SAF 130A
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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 - PowerPoint PPT Presentation
Transcript of SAF 130A
PRESSURE SYSTEMSHAZARD AWARENESS
SAF 130A
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 10CFR851Worker 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
“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…”
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.”
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 OrenKelly Dixon Tim WhitlatchBert Manzlak Gayle ColemanDave 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
• Vacuum systems are considered pressure systems due to their potential for catastrophic failure from backfill pressurization
• Associated hardware (e.g., gauges and regulators), fittings, piping, pumps and pressure relief devices are integral parts of a pressure system
• Category I – Vacuum systems in which the differential operating pressure can never exceed 15 psi. Examples of Category I vacuum systems include HMS and HRS vacuum systems, injector chambers and dog-leg chambers
• Category II – Vacuum systems which can be protected from pressurization exceeding 15 psig through engineering controls (e.g. pressure relief devices). Examples of Category II vacuum systems include cryostats, cryogenic transfer lines, cold boxes and target vessels
• 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 PolicyJLab 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 AuthorityESH&Q DivisionDivision HeadsFacilities ManagerPressure Systems CommitteeEveryone at JLab
Key People – Roles and Responsibilities
Design AuthorityESH&Q DivisionDivision HeadsFacilities ManagerPressure Systems
CommitteeEveryone at JLab
Design Authority•Ensure ASME Code compliance according to JLab policy
•Where ASME Codes cannot be applied, ensure equivalent level of safety
•Follow JLab policy and procedures per the ES&H Manual Welding and Brazing Program Supplement
•Ensure proper pressure system documentation per ES&H Chapter 6151, Appendix T-1
Design Authority Qualifications• 4 yr. degree in engineering or physics, at least 5
years experience in design of related pressure systems and approval by division head
or• PE and experience in design of related pressure
systems and approval by division heador• approval of JLab Engineering Manager
Key People – Roles and Responsibilities
Design AuthorityESH&Q DivisionDivision HeadsFacilities ManagerPressure Systems
CommitteeEveryone at JLab
ESH&Q Division
•Manage JLab Welding and Brazing Program•Supervise code inspector•Provide inspection services•Monitor certifications for examiners, welders and inspectors
Key People – Roles and Responsibilities
Design AuthorityESH&Q DivisionDivision HeadsFacilities ManagerPressure Systems
CommitteeEveryone at JLab
Division Heads
• Designate Design Authorities
•Verify organization’s adherence to JLab’s Welding and Brazing program
•Verify recordkeeping complies with Chapter 6151
Key People – Roles and Responsibilities
Design AuthorityESH&Q DivisionDivision HeadsFacilities ManagerPressure Systems
CommitteeEveryone at JLab
Facilities Manager
•Coordinate and maintain inspection reports for all pressure vessels
•Under direction of DA, coordinate repair/modification of stamped pressure vessels
Key People – Roles and Responsibilities
Design AuthorityESH&Q DivisionDivision HeadsFacilities ManagerPressure Systems
CommitteeEveryone at JLab
Pressure Systems Committee
•Develop and maintain pressure system program
•Maintain list of Design Authorities•Act as final JLab authority for non-code qualified design elements
•Document decisions in pressure systems project folders
Key People – Roles and Responsibilities
Design AuthorityESH&Q DivisionDivision HeadsFacilities ManagerPressure Systems
CommitteeEveryone at JLab
Everyone at JLab•Refer pressure systems questions to Design Authority or the PS Committee
•Before working on physical plant pressure systems, consult Maintenance Services Manager
•Alert line management if:•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
– Design– Purchasing– Fabrication– Installation and
Testing– Inspection– Repair/Modification
The Pressure Systems Program employs a
Risk-based Graded Approach
Accommodations are included inthe Pressure Systems Program
to handlePressure Systems with low complexity
(commercially available tanks)and
Low Hazard Pressure Systems
The Design Authorityis responsible for minimum
documentation requirements for these systems
Pressure Systems Program Summary
– Design– Purchasing– Fabrication– Installation and
Testing– Inspection– Repair/Modification
Design • Initiate a Project Folder & Checklist within DocuShare
•Define design criteria and applicable Codes
•Complete design calcs, dwgs and specs per Code
•Conduct technical, peer and/or design reviews
•Store documentation in Project Folder
Pressure Systems Program Summary
– Design– Purchasing– Fabrication– Installation and
Testing– Inspection– Repair/Modification
Purchasing•DA issues Statement of Work defining specific Code QA requirements
•Follow JLab Purchasing process (highlight Code requirements as required)
•SOTR verifies receipt inspection (compliance with design docs, proper markings, MDRs, etc)
•Store documentation in Project Folder
Pressure Systems Program Summary
– Design– Purchasing– Fabrication– Installation and
Testing– Inspection– Repair/Modification
Fabrication•DA develops fabrication plan
•Materials for pressure system fabrication clearly marked
•Welding and inspection performed per Welding and Brazing Supplement
•Store documentation in Project Folder
Pressure Systems Program Summary
– Design– Purchasing– Fabrication– Installation and
Testing– Inspection– Repair/Modification
Installation and Test• Installation performed by
qualified personnel• Pressure test must be
conducted• Store documentation in
Project Folder• QA shall perform final
safety walk through before operation and sign-off
Pressure Systems Program Summary
– Design– Purchasing– Fabrication– Installation and
Testing– Inspection– Repair/Modification
Inspection (post operation)• Pressure vessels inspected
per Code of VA• Facilities Manager is
responsible for inspections and maintaining records
Pressure Systems Program Summary
– Design– Purchasing– Fabrication– Installation and
Testing– Inspection– Repair/Modification
Repair/Modification•Must be completed under direction of a Design Authority
•Maintenance without welding performed by competent technical staff
•Repairs/modifications to stamped vessels coordinated by Facilities Manager
•Documentation follows Appendix T1 requirements
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 RememberDesign 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
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
http://www.jlab.org/eng/pressure_systems/index.html
NEW: PS WEBSITE
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 CommitteeRon Bartek, Kelly Dixon, Bert Manzlak,
Dave Meekins, Will Oren, Tim Whitlatch, Gayle Coleman
