EH&S Manual

6151 Pressure and Vacuum Vessels

Thomas Jefferson National Accelerator Facility

6151 Pressure and Vacuum Vessels

Introduction

he hazards associated with pressure vessels and liquefied gas dewars include rupture and explosion. Hazards associated with vacuum vessels such as vacuum chambers in experimental hall equipment include rupture and implosion. Causes of pressure vessel accidents include: inadequate design, failure to properly maintain the vessel for its rated service, exceeding maximum allowable working pressure, failure to provide pressure relief devices, and unauthorized modifications.

Examples of pressure and vacuum vessels used at Jefferson Lab include: Cryomodules, which include both a pressure and a vacuum vessel. Experimental equipment with voluminous vacuum chambers. Small experiment-target vessels sometimes confine as much as 100 atmospheres of pressure. In Jefferson Lab's cryogenic plants, oil-removal and gas-storage systems operate at 15 to 20 atmospheres. Some pressure compressed-air and reservoirs are pressurized to 85 psi and above. Heating and air conditioning systems throughout the site. This chapter sets Jefferson Labs general policy on the design, fabrication, testing, and certification of pressure vessels. This policy shall also be applied to vacuum vessels, which under failure conditions could become pressurized. The chapters pressure vessel requirements are based on the American Society of Mechanical Engineers (ASME) Code. Chapter 6150 Compressed Gases and Chapter 6500 Cryogenic and ODH Safety are to be referred to for additional requirements for specific uses. Appendices: 6151-T1 Vessel Design Documentation 6151-T2 Welding Procedures and Welder Qualifications 6151-T3 Pressure Vessel Testing Procedure 6151-T4 Safety Requirements for Thin Window Design
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Pressure and vacuum vessels in experimental equipment

Users/experimenters planning to incorporate pressure or vacuum vessels in a physics experiment must also comply with Chapter 3120 The CEBAF Experiment Review Process and its appendices or FEL users must comply with Chapter 3130 The FEL Experiment Review Process and its appendices. Although all the provisions of the present chapter apply, users/experimenters must address them within the larger context of the experiment review process.

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Hazard Avoidance
Key hazard avoidance aspects of vessel engineering include the following: Install and use pressure vessels according to the requirements set forth in this chapter. Never exceed the rated capacity of a pressure vessel. Use the pressure vessel only for the purpose it was designed to serve. If you have pressure vessels in your work area, do not tamper with them or their associated piping and fittings. Never apply heat to a pressure vessel except as may be specifically authorized by work procedures which reflect the vessel design criteria. Report knowledge of damage or apparent defects to the appropriate supervisor.

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6151 Pressure and Vacuum Vessels

Key Terms
American Society of Mechanical Engineers (ASME) The professional engineering organization whose Boiler and Pressure Vessel Code is the standard for pressure vessel engineering at Jefferson Lab. This code can also be adapted for certain cases of vacuum vessel engineering design. The most frequently used sections of the Code as applied to pressure vessels used at Jefferson Lab are: Section II: Materials Section VIII: Rules for Construction of Pressure Vessels Section IX: Welding and Brazing Qualifications The Jefferson Lab librarian can help locate one of the copies of the ASME Code maintained on site, or can help acquire relevant portions. A current copy is also kept in the Safety Lab, Trailer 35. The ASME is a world recognized code. Most other national pressure vessel codes will reference ASME. Excluded Vessels Pressurized vessels which do not fall within the scope of the ASME Pressure Vessel Code. The ASME Code specifically excludes: Vessels having an internal or external operating pressure not exceeding 15 psi. Vessels having an inside diameter, width, height, or cross section diagonal not exceeding 6 inches. Machinery such as pumps, compressors, turbines, generators, and engines. Most piping systems or structures whose primary function is the transport of fluids from one location to another within a system of which they are an integral part. Vessels with a nominal water-containing capacity of 120 gal or less for containing water under pressure, including those containing air that is compressed to serve as a cushion. Hot water supply storage tanks heated by steam or any other indirect means, limited to 120 gallons, 210 o F, and a heat input of 200,000 BTU/hr. Department of Transportation (DOT) regulated cylinders and dewars. Lead Mechanical Engineer/Responsible Designer Engineer designated by a Division to be responsible for pressure vessel construction/design.

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6151 Pressure and Vacuum Vessels

Lethal Service Vessels containing poisonous gases or liquids of such a nature that a very small amount of the gas or of the vapor of the liquid, mixed or unmixed with air, is dangerous to life when such gases are inhaled, or when persons come in contact with the liquid. National Board Inspection Code This is a widely adopted Code which sets the criteria and procedures for maintenance, inspection, repair, alteration, and rerating for pressure vessels and boilers. Non-Code Pressure Vessels A pressure vessel whose design cannot meet the intent of the applicable ASME Boiler and Pressure Vessel Code. Non-Stamped Pressure Vessels A pressure vessel whose design meets the intent of the applicable ASME Boiler and Pressure Vessel Code, but which is not stamped in accordance with the Code. Peer Review Documented technical validation of vessel engineering design, to be conducted by at least one pressure vessel design engineer who meets the qualifications in this chapter. Pressure Relief Device An automatic device used to relieve the pressure in a system. Examples include rupture discs and pop-off valves. Pressure Vessel Container for the containment of pressure, either internal or external. R Stamped Pressure Vessel ASME official R stamp marked on a vessel indicates R for repair. U Stamped Pressure Vessel ASME official U symbol marked on a vessel indicates U for unfired. Other pertinent design information is also included with the U stamp. Vacuum Vessel Any vessel operating at less than atmospheric pressure.

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Responsibilities Everyone at Jefferson Lab

Refer vessel engineering matters to properly qualified engineers. Before adding, moving, or modifying pressure vessels associated with the
normal physical plantsuch as HVAC equipment, boilers, etc.consult the Maintenance Services Manager (ext. 7671). Inform the appropriate line manager or the lead mechanical engineer if you know or suspect that a pressure vessel planned for use on site does not conform to the ASME Code, or a vessel, or associated equipment such as a pressure-relief device, is unsafe.

Responsible designers/lead mechanical engineers

Ensure that pressure vessel engineering meets ASME Code requirements
according to the policy set forth in this chapter. In the special cases arising in the accelerator and experimental equipment environment, reinforce your engineering judgment and your use of the ASME Code by consultation with engineers who have done similar or analogous work at Jefferson Lab or other accelerator laboratories. Forward copies of all pressure vessel documentation to Facilities Management. Develop pressure test Standard Operating Procedures. Have non-code vessels peer-reviewed.

Line managers
Ensure that engineers who design pressure and vacuum vessels are qualified per
the requirements of this chapter. Maintain qualifications for welders.

Maintenance Services Manager

Maintain centralized records of all pressure vessels, to include at a minimum
vessel design documentation and pressure test SOPs. Maintain an annual inspection and report system for all pressure vessels

Associate Directors
Assign a lead mechanical engineer for the division as a subject-matter expert for
pressure and vacuum vessel engineering.

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6151 Pressure and Vacuum Vessels

Qualifications
Lead mechanical engineer/pressure vessel design engineers must demonstrate ability to design and construct according to the ASME Boiler and Pressure Vessel Code, Section VIII, Division I, Design and Fabrication of Pressure Vessels. This can be accomplished one of three ways: attend Jefferson Lab-sponsored ASME seminar SAF120, complete interactive SAF120 computer-based training, or attend an off-site ASME sponsored seminar (coordinate with Jefferson Lab Training and Development to ensure that the correct course is taken). Welders must maintain qualifications for the types of fabrication associated with pressure vessel construction.

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Program Summary
The Boiler and Pressure Vessel Code (the Code) of the American Society of Mechanical Engineers (ASME) serves as the standard for pressure vessel engineering at Jefferson Lab. In cases where the Code cannot be met, such as for special materials not referenced by the Code, or unusual vessel structures, engineers responsible for vessel engineering must exercise substantial professional judgment. Although the Code does not apply to vacuum vessels, Jefferson Labs policy is to apply it where practical to vacuum vessel design: If a vacuum vessel can be pressurized under regular or failure conditions, the Code must be applied to its design. In order to ensure that design and use of pressure vessels at Jefferson Lab meet the intent of the ASME Code, several procedural and documentation requirements must be met. These requirements are listed in Table 1. Details are provided in technical appendices. A copy of all documentation must be kept on file in Facilities Management with the Maintenance Services Manager. Table 1: Requirements for Pressure Vessels
Code Stamped Vessels NonModified Stamped Code Vessels that Vessels with comply with no R stamp the Code X X

Requirement

Responsible staff

Non- Code Vessels

Lead engineer

A lead engineer must be designated for each vessel by the Department Head Each lead engineer is responsible for providing inventory to Facilities Management annually, or when changes occur

Inventory of Pressure Vessels Vessel Design Documentation Welding procedure Welder Qualification Vessel Pressure Test Annual Inspection Nameplate Training Peer Review

Lead Engineer

Facilities Management Lead Engineer must ensure that nameplate meets Code Lead Engineer and any design engineer for pressure vessels

X X

X X X X

X X X X

X X X X

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Pressure vessels associated with Facilities Management

The pressure vessels of the normal physical plant, including all unfired and fired pressure vessels such as HVAC equipment and boilers, are maintained under the supervision of the Mechanical/Electrical Maintenance Section Manager (ext. 7671). No addition, movement, or modification of any such vessel is to be made without consulting with the manager.

Pressure Vessels used to support accelerator and R&D efforts

Procured pressure vessels must have the ASME certification stamp, known as the U stamp, unless the vessel is excluded from the Code (see key terms). Fabrication, testing, and certification must be performed by a manufacturer or assembler holding the appropriate certificate. Non-stamped pressure vessels engineered on site must comply with the Code from design through fabrication and testing. For non-code pressure vessels, peer-validated documentation of additional safeguards is required for the engineering requirements that do not meet the Code.

Brittle Components
Brittle components of pressure systems (e.g. thin windows) call for additional controls to prevent exposure to hazards associated with failure of the component. Controls that must be considered include: Barriers Safety glasses Hearing protection Special guidance for vacuum vessel thin window design is given in Appendix 6151-T4 Safety Requirements for Thin Window Design. This guidance is intended specifically for the low-mass materials used in the vacuum chamber windows of experimental equipment.

Pressure-relief devices
Relief devices and their discharge piping must be positioned so that they do not discharge at people, delicate apparatus, or in such a manner as to hinder escape. The Code contains the complete set of requirements for pressure relief. Commercially purchased pressure relief devices must be Code certified. This is usually verified by checking that the required markings are present. When non-Code reliefs must be installed, the vessel is to be considered non-code and a peer review is required.

Refer to the Code for specifics on:

Rupture disk devices, including instructions for deriving the burst pressure, test burst requirements, and instructions for determining the capacity rating Pressure reliefs designed for liquid service

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Installation and the location of the pressure relief valve, prohibition of stop valves between the vessel and the relief device Requirements for vessels with single pressure relief device, multiple devices, and required tolerances Venting requirements for lethal contents

Pressure Vessel Quality Control

This information is essential for the Jefferson Lab Pressure Vessel Quality Control Program. New requirements are effective as of the 2001 release date of this chapter.

Required markings for in-house pressure vessels

Each pressure vessel must be marked with the following: maximum allowable working pressure (MAWP) at specified temperature (there may be more than one), minimum design metal temperature at specified pressure, type of construction, year built, and Jefferson Lab documentation reference number. Notes For vessels having more than one independent pressure chamber the markings may be made in one location on the vessel, or each chamber may be separately marked. Specifications must be in US customary units. Metric units may be shown in parenthesis. The nameplate and pressure test label may be incorporated. For internal vessels, markings are not required. For vessels whose failure pose zero risk to personnel or property, markings are not required.

Repairing or modifying pressure vessels

Repairs/modifications to stamped pressure vessels must be performed by a company that is authorized to use the National Board R stamp. Repair to a vessel by a company that is not authorized must be reviewed as a new non-stamped vessel. The stamp must then be removed and the vessel will require an addendum to the vessel design documentation and a pressure test prior to being placed in service, as will repairs to non-stamped vessels. Changing the service of a vessel is also viewed as a vessel modification. Changing the service can mean any change in the application or change in the location of the vessel if the structural support is affected.

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Inspection requirements
Pressure vessels and pressure-relief devices must be inspected annually according to requirements of the National Board Inspection Code. Make sure that vessels are installed so that any inspection openings are accessible. Carrying out regular internal inspections is imperative to the safety and extended life of the vessel. Not all vessels will have inspection openings; however, since almost all pressure vessels are subject to internal corrosion, most will.

Gauges
Pressure gauges must be calibrated before put into service. Gauges must be visible at a safe distance from the vessel as determined by the vessel engineer. Use specific-use gauges where required: e.g. oxygen, ammonia, acetelyene and hydrogen. Full scale reading of the gauge must equal twice the operating pressure. Gauges should be of the full blow out type with integral sides and front. Gauges that do not have this type of construction must have a tested, approved gauge safety shield installed, minimum thickness 3/8 inch polycarbonate. Valves that can isolate gauges must be clearly visible. Protect gauges that are subject to excessive pressure surges or cyclic pulses by installing a throttling device such as a pulsation dampener.

Pressure vessel testing

Except for unmodified pressure vessels properly stamped as required by the ASME Code, all new and modified pressure vessels at Jefferson Lab must be tested in accordance with Appendix 6151-T3 Pressure Vessel Testing Procedure.

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