Inspection and Testing of Pressure Systems

Los Alamos National Laboratory Laboratory Implementation Guidance LIG 402-1200-02.1 Original Issue Date: May 15, 2001. Revision Date: August 14,2003 Nonmandatory Document

1.0 1.1

INTRODUCTION Background

LIR 402-1200-01, Pressure, Vacuum, and Cryogenic Systems, gives the maximum intervals between pressure system inspections and lists the national codes and standards to which these inspections, and pressure tests, must adhere. This document provides supplemental guidance in these areas. 1.2 In this Document Section 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 2.0 PURPOSE Title Introduction Purpose Scope Definitions Precautions and Limitations Guidance Documentation Referrals

The purpose of this LIG is to provide guidance for inspecting and testing pressure systems. Initial testing helps determine the integrity of the pressure system, but these steps alone do not ensure the continued safety of any pressure system. Many pressure system failures result from degradation over time, and from improper operation and maintenance. 3.0 SCOPE

The recommendations contained in this LIG should be considered by all workers involved in fabrication, installation, operation, and maintenance of Laboratory pressure systems. 4.0 4.1 HSR HSR-5 HCP kJ LANL LIG LIR MAWP MOP psia psig PSC PT TNT UT DEFINITIONS Acronyms Health, Safety and Radiation Protection (Division) Industrial Hygiene and Safety (Group) Hazard Control Plan kilojoule Los Alamos National Laboratory Laboratory Implementation Guidance Laboratory Implementation Requirement maximum allowable working pressure maximum operating pressure pounds per square inch absolute pounds per square inch gauge Pressure Safety Committee dye-penetrant testing trinitrotoluene ultrasonic testing

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Inspection and Testing of Pressure Systems

Los Alamos National Laboratory Laboratory Implementation Guidance LIG 402-1200-02.1 Original Issue Date: May 15, 2001. Revision Date: August 14,2003 Nonmandatory Document

4.2

Terms

benign serviceAny pressure system that is sufficiently compatible with the materials of construction so that no component of the pressure system loses more than 0.001 in. of thickness per year of operation as the result of corrosion or erosion. compressed gasGas stored and used at pressures greater than nominal atmospheric pressure (14.7 psia at sea level and 11.3 psia in Los Alamos). Compressed gas is supplied in cylinders, tube trailers, and through piping systems. corrosion allowanceThe thickness of material added by design to allow for material loss due to corrosion or erosion for the operating life of the vessel. corrosive serviceAny pressure service that, because of chemical or other interaction with the containers materials of construction, contents, or external environment, could cause the useful thickness of the pressure container to diminish, through any structural deterioration mechanism, by more than 0.001 in. per year. hazard control measuresEngineering design steps, administrative actions, ventilation, and personal protective equipment to mitigate workplace hazards. hazard control planA document that defines the work, describes the proposed system, identifies the associated hazards, and shows the controls that will be implemented to reduce those hazards to an acceptable level. maximum allowable working pressure (MAWP)The maximum pressure at which a system is safe to operate over its entire lifetime. It is based on the weakest pressurized component of the system. The vent setting for the primary pressure relief device is the MAWP. maximum operating pressure (MOP)The highest pressure allowed during normal operation. It is usually 10%20% below the MAWP. national codes and standardsDocuments published by nationally recognized organizations that give requirements based on the cumulative experience and engineering judgment. pressure relief systemA system designed to relieve excess internal pressure that includes pressure relief devices (relief valves and/or rupture disks), piping from the pressure vessel to the relief device, and piping from the relief device to the release point. pressure systemA connected system consisting of pressure vessels; interconnecting hardware (including piping, tubing and fittings); instrumentation; and devices such as valves, pressure relief equipment, and flare systems. pressure vesselA sealed container for holding pressurized fluids. Pressure Safety CommitteeExperts that review and approve pressure vessels and pressurized piping systems used at the Laboratory or in conjunction with Laboratory business to ensure that (1) pressure systems receive required approvals and certification, (2) that correct engineering design, fabrication, and quality control procedures are followed, and (3) that required operation and maintenance/inspection procedures are implemented. specialized pressure systemA pressure system that does not meet the requirements of national (industrial) codes and standards that may include small, one-of-a-kind, experimental systems. The Pressure Safety Committee reviews and approves all specialized pressure systems. stored energyA property of a system that is a function of pressure, the material pressurized (liquid or gas), and the volume of that material. It is proportional to the product of that pressure and volume.
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Inspection and Testing of Pressure Systems

Los Alamos National Laboratory Laboratory Implementation Guidance LIG 402-1200-02.1 Original Issue Date: May 15, 2001. Revision Date: August 14,2003 Nonmandatory Document

Note: Stored energy may be expressed in units of foot-pounds, joules, or TNT equivalence (4.6 kJ/gm). A large volume of low-pressure gas could have a significant amount of stored energy, as might one with high pressure and low volume. A pressurized liquid system can have a significant amount of elastic stored energy in the vessel itself as well as in the liquid. stored/storage When placed in an inoperative state for a certain future purpose. use To bring or put into service and make available. workerAny contract employee, subcontract employee, or visitor who performs work at the Laboratory. 5.0 PRECAUTIONS AND LIMITATIONS

The guidance contained in this document cannot address all conceivable situations. The recommendations should not be interpreted as mandatory requirements but as suggestions to improve the safety of pressure systems over their lifetime. Contact the Pressure Safety Committee (665-6936) for additional guidance. 6.0 6.1 GUIDANCE Inspections

The purpose of a pressure system inspection is to determine if the system is safe for continued use. The method and frequency of inspection depend on the hazards of the system and the consequences of failure. Inspections include the following: visually examining the equipment to evaluate the systems internal and external integrity, measuring critical thicknesses, measuring corrosion or erosion rates, testing and calibrating pressure relief devices, and reviewing current and planned applications.

Regularly scheduled inspections are suggested for all pressure systems, including compressed gas systems. See LIR 402-1200-01 "Pressure, Vacuum, and Cryogenic Systems" for maximum allowable inspection intervals. Inspection guidance is given below. 6.1.1 Compressed Gas Systems

Storage facilities for compressed gases should be inspected before initial use to assure they are in a safe location away from traffic, shaded if outdoors, and are well ventilated. See LIG 402-1200-01 Compressed Gases. Equipment for compressed gases, including gas cylinders, transportable containers, Dewars, or bulk storage containers, should be inspected for defects when received and periodically thereafter. Defects should be reported to the PSC. 6.1.2 Pressure Piping Systems

Problem areas in piping systems are often discovered while the system is in service. These typically occur at elbows, high and low points, pump inlets and discharge points, and in piping sections that are buried or otherwise hidden from view. If the piping system cannot be inspected while in service, it may require removal from service for inspection. Purging, drying, detoxifying, and decontaminating the system may be required beforehand. 6.1.3 Pressure Vessels
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Inspection and Testing of Pressure Systems

Los Alamos National Laboratory Laboratory Implementation Guidance LIG 402-1200-02.1 Original Issue Date: May 15, 2001. Revision Date: August 14,2003 Nonmandatory Document

External visual inspections of pressure vessels, including PT and UT, may be performed while the vessel remains in service. However, it is unsafe to tighten bolts or fittings while pressurized. Internal inspections obviously require depressurizing and, if needed, purging, drying, cooling, warming, detoxifying, or decontaminating. Small pressure vessels, including many air receivers, which may not allow entry, may be inspected through nozzles and inspection openings. Entry into larger vessels for inspection will probably be considered a confined space and require a confined space entry permit. Before entering, contact the Industrial Hygiene and Safety Group (HSR-5) or other HSR representative. See LIR 402-810-01 Confined Spaces. 6.1.4 Pressure Relief Systems

Pressure relief systems are periodically inspected for deterioration, including leaks and corrosion. Relief valves may require recalibration and fusible and rupture disks may require replacement. 6.2 Pressure Tests

Pressure tests can be hydrostatic, using a compatible liquid (such as water or oil) or pneumatic using a dry gas (such as air or nitrogen). In a typical pressure test, the liquid or gas is admitted to the vessel and, if required, the rest of the pressure system. It is slowly pressurized to a level that assures the integrity of the system. The test pressure is stated in national codes and test standards (see LIR 402-1200-01). Because the test pressure usually exceeds the set pressure (see below) of the relief device, the device will have to be removed and its fitting capped. However, safety is enhanced if another relief device, set to 10-15% above the test pressure, is installed anywhere in the circuit during the test. Before a pressure test, preparation of a hazard control plan (HCP) or a detailed test procedure is recommended. See LIR 300-00-02, Documentation for Safe Work Practices. The pressure used in these tests depends on the test fluid, liquid or gas, and the MAWP of the system and its components. Pressure vessels are removed from the rest of the system and tested separately. Afterwards, the entire system is reconnected and tested. The piping system may also be pressure tested separately. After a pressure system has been modified or repaired, or its configuration changed, it is considered to be a new system subject to another pressure test. 6.2.1 Hydrostatic vs. Pneumatic Tests

A hydrostatic test is less hazardous than pneumatic, and is therefore preferred. Typical tests liquids are clean water and mineral oil. The system should be filled completely with the test liquid. A highpoint vent is used to remove all the air. If some gas remains trapped and cannot be removed, the test is considered "hydro-pneumatic" and requires the same safety precautions as pneumatic tests. A low-point vent is required to drain the liquid after the test. If required, clean air may be circulated through the vessel to evaporate the remaining water. Pneumatic tests are more hazardous than hydrostatic tests because of the much higher stored energy in the test gas. Pneumatic tests on modified or repaired pressure systems are discouraged. 6.2.2 Testing Area

The pressure test area should be restricted to prevent unauthorized entry. Pneumatic tests should be done remotely with personnel shielding. When possible, the vessel being pressure-tested should be oriented so that bolts, flanges, and other possible projectiles point away from people and other equipment.
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Inspection and Testing of Pressure Systems

Los Alamos National Laboratory Laboratory Implementation Guidance LIG 402-1200-02.1 Original Issue Date: May 15, 2001. Revision Date: August 14,2003 Nonmandatory Document

6.2.3

Pressure Piping Systems

Additional high-point vents or low-point drains may be required to hydrostatically test piping systems. The test liquid should be flowing out of the high-point vents before they are closed to ensure a true hydrostatic test since the order in which multiple vents are closed may be important. It may require necessary to flushing the system with dry gas to remove all of the test liquid afterwards. 6.2.4 Pressure Vessels

Pressure vessels ought to be pressure-tested separate from the rest of the system but with all attached accessories in place that are not typically isolated by valves. This may include instrument connections, sight and level glasses, liquid level gauges, and view windows. 6.2.5 Pressure Relief Systems

All pressure relief devices should have tags or stampings showing date of manufacture and set pressure. After installation, calibrations should be regularly scheduled for all pressure relief valves, but not rupture (or fusible) disks. See LIR 402-1200-01. Pressure relief devices, no matter how massive, are delicate instruments and should be treated as such. Safety relief valves that are dropped or bumped should be sent back to the manufacturer for re-calibration. Rupture and fusible disks should be kept in their original shipping boxes until installed. 6.2.6 Proof Tests

A proof test is a pressure test to verify that a pressure system can operate at a specified MAWP with required safety factors. It is accomplished for specialized pressure systems when the MAWP cannot be verified by accepted design calculations or previous operating and/or test history. This is a potentially dangerous procedure and should be performed only as a last resort, and only behind barricades. It is to be performed only on vessels made of ductile materials. The vessel to be prooftested is to be instrumented with strain gauges and the pressure increased until incipient yielding is observed. The MAWP is 2/3 of that pressure. 6.2.7 Leak Tests

Leak tests are performed to determine the integrity of connections within a pressure system. Types of connections include flanged, threaded, compression, flared, expanded, and welded. Soap solutions and helium leak detectors are often used. Leak tests should be performed in stages beginning with relatively low pressures increasing in moderate steps up to the MOP of the system. Detected leaks should be marked. It should be considered unsafe to repair the leak while the system is pressurized.

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Inspection and Testing of Pressure Systems

Los Alamos National Laboratory Laboratory Implementation Guidance LIG 402-1200-02.1 Original Issue Date: May 15, 2001. Revision Date: August 14,2003 Nonmandatory Document

7.0 7.1

DOCUMENTATION Inspection and Test Results

The operating groups should maintain records of pressure system inspection and tests. 7.2 Document Ownership

HSR-5 is responsible for this document. 8.0 REFERRALS

Compressed Gas Processing Center (TA-3-170), 667-4406 Pressure Safety Committee, 665-6936 Industrial Hygiene and Safety Group (ESH-5), 667-5231 Operational Safety Section of the Industrial Hygiene and Safety Group, 665-8503 Compressed and Liquefied Gas Safety Committee, 667-4240

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