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SAF 130A

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

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SAF 130A

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  1. SAF 130A PRESSURE SYSTEMS HAZARD AWARENESS

  2. 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

  3. 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”

  4. 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

  5. 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

  6. 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…”

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

  8. 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

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

  10. 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

  11. 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

  12. 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

  13. 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

  14. 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

  15. 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

  16. 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

  17. 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.

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

  19. 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

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

  21. Key People – Roles and Responsibilities Design Authority ESH&Q Division Division Heads Facilities Manager Pressure Systems Committee Everyone 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 head • or • approval of JLab Engineering Manager

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

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

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

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

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

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

  28. 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 in • the Pressure Systems Program • to handle • Pressure Systems with low complexity (commercially available tanks) • and • Low Hazard Pressure Systems • The Design Authority • is responsible for minimum documentation requirements for • these systems

  29. 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

  30. 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

  31. 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

  32. 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

  33. 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

  34. 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

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

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

  37. 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

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

  39. 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

  40. 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

  41. What We Want You To Remember 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 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

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

  43. 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

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