This document is no longer a CPR. This document implements the requirements of Corporate Procedure ESH100.2.PS.1, Control Pressure Safety Hazards.

IMPORTANT NOTICE: A printed copy of this document may not be the document currently in effect. The official version is the online version located on the Sandia Restricted Network (SRN).

2. THE PRESSURE SAFETY PROGRAM

Subject Matter Experts: Shane Page, and David Paoletta
Contributor: Pressure Safety Committee
MN471000, Issue U
Revision Date: November 17, 2008; Replaces Document Dated: October 31, 2008
Administrative Changes: May 26, 2011, and January 19, 2012

• ELEMENTS OF THE PRESSURE SAFETY PROGRAM
  • Introduction
  • Policies and Procedures
  • Advice and Assistance
  • Individual Knowledge
  • Documentation and Accountability
  • Hardware Control
• ORGANIZATION OF SANDIA'S PRESSURE SAFETY PROGRAM
  • Introduction
  • Managers
  • Pressure Advisors
  • Pressure Installers
  • Pressure Operators
• PRESSURE SAFETY PROGRAM SUPPORT ORGANIZATIONS
  • Pressure Safety Committee
  • Safety Engineering Department
  • Support Organizations
  • Hardware Procurement Support Organizations
• PRESSURE SAFETY TRAINING PROGRAM
  • Training Requirements
  • Commercial Hardware Training

ELEMENTS OF THE PRESSURE SAFETY PROGRAM

Introduction

The Pressure Safety Program consists of five elements:

1. Providing required pressure safety policies and procedures through MN471000, Pressure Safety Manual (PSM).
2. Providing knowledgeable people as members of the Pressure Safety Committee (PSC) and designating consultants to furnish advice and assistance in pressure safety.
3. Developing individual knowledge of a safe pressure environment at Sandia through personnel who are trained and qualified.
4. Providing for the documentation and accountability for each pressure vessel and system.
5. Providing for the control of the selection and the use of pressure hardware.

Policies and Procedures

The PSM states the policies and procedures established by the PSC as part of the SNL Pressure Safety Program.

Advice and Assistance

The PSC provides oversight at SNL for the safety of pressure systems and is responsible for administering the Pressure Safety Program. The PSC:

• Establishes pressure safety requirements.
• Addresses unusual problems and occurrences.
• Provides advice and assistance in pressure safety. Other people and organizations are available to consult about pressure safety requirements and issues. The Pressure Safety Assistance Index contains a pressure safety assistance index arranged alphabetically by subject.

Pressure Safety Program support organizations are further discussed later in this chapter.

Individual Knowledge

The manager provides oversight for the implementation requirements of the PSM and ensures that all Members of the Workforce who work with pressure systems develop an individual awareness of pressure hazards. The following measures are taken to promote this awareness.

• Members of the Workforce are responsible for implementing appropriate safeguards to require safe performance of pressure systems.
• Managers must consider the training and experience of Members of the Workforce, the complexity of tasks to be performed and equipment to be used, and whether the task is routine or unusual.
• Training is provided for personnel who design, fabricate, install, operate, or maintain pressure systems.
• At least one Pressure Advisor (PA) is assigned to each center that deals with pressure systems.
Adequate PA coverage and involvement in their areas of responsibility enhance individual awareness.
• Qualification of various levels of pressure users is based on required training, knowledge, assignments, and experience.

Documentation and Accountability

• The design meets the requirements of the appropriate standards (see Ch. 4).
• Pressure systems have proper documentation (see Ch. 7 and Ch. 9).
• Procedures for safe operations will be documented in technical work documents (TWDs) (see Ch. 7).
• Periodic assessments will be conducted by line organizations, ES&H organizations, and self-assessment groups.

Hardware Control

• Oversight of the just-in-time suppliers (JIT) of pressure hardware and industrial and specialty gases by the purchasing contracting representative and the SNL Pressure Safety Committee.
• Guidance for and review of purchases of pressure equipment by each organization’s assigned PA.
• Periodic site visits to commercial vendor facilities.
• Review of the JIT contracts for types and quality of pressure hardware.

ORGANIZATION OF SANDIA’S PRESSURE SAFETY PROGRAM

Introduction

The following individuals and groups are key elements of the Pressure Safety Program at SNL:

• Managers
• Pressure Advisors
• Pressure Installers
• Pressure Operators
• Hardware procurement support organizations
• Pressure Safety Committee (PSC)
• Self-appraisal groups
• ES&H Organizations
• Technical Consulting groups

Managers

1. Each identified pressure system is represented by a responsible Member of the Workforce (e.g., Pressure Advisor, Pressure Installer, or Pressure Operator) as defined in the Applicability section in Chapter 1 of this document. Note: This is required even in cases in which equipment suppliers or offsite contractors participate in the installation of pressure equipment.
2. All pressure systems comply with the PSM.
3. Equipment operators and maintenance personnel in the organization are properly trained and qualified. Training requirements for pressure system personnel are listed in the Training section of this Manual and on the Pressure Advisor Qualification Form [Word file/Acrobat file], the Pressure System Operator Qualification Form [Word file/Acrobat file], and the Pressure Installer Qualification Form [Word file/Acrobat file].
4. Copies of all pressure system documentation are maintained by the organization traceable to the applicable pressure system.

Pressure Advisors

Pressure Advisors are the first point of contact for questions or guidance regarding any aspect of pressure system safety (e.g., configuration, ratings, procurement, and documentation). Every research and development or service organization working with pressure systems should have its own PA. Facilities engineering also appoints one or more PA. As a minimum, each center that deals with pressure systems must have at least one PA.

PAs are responsible for (based on the types of system applications they are assigned to oversee):

• Developing and maintaining knowledge of:
  • Pressure systems – proper assembly and setup
  • Typical pressure safety hazards
  • Standard practices as set forth in the Sandia PSM
  • Basic pressure system design.
• Providing guidance in the purchase of pressure equipment.
• Reviewing new pressure systems and initial reviews of Data Packages and other ES&H Technical Work Documents (TWDs) dealing with pressure systems.
• Consulting with end users and serving as liaison between the end user and the PSC, Safety Engineering, or any other expert consultant (e.g., nondestructive testing, materials, stress analysis).
• Maintaining visibility: Make themselves known to the personnel in their area of responsibility as a reminder for the personnel to use their services. Participate in organization safety meetings.
• Advising on pressure-related issues.
• Serving as conscience: Create an awareness of the intent of the Pressure Safety Program. Recognize and eliminate unsafe practices.

Qualifications for PAs include:

1. Recommendation by the Senior Manager. (See Pressure Advisor Designation Form [Word file/Acrobat file], SF 2001-PAD.)
2. Prior experience with pressure systems.
   Note: Managers validate that qualified personnel are designated to the job task. The Pressure Advisor Qualification Form (Word file/Acrobat file) is supplied for the convenience of the Manager for validation. A copy should be maintained by the organization.
3. Having completed the following classroom training courses:
   • PRS150, Pressure Safety Orientation
   • PRS160, Pressure Advisor Training
   • PRS250, Advanced Pressure Safety
   • PRS115, Cryogen Safety (if applicable)
   • Commercial Hardware Training, or equivalent

Pressure Installers

Note: Pressure Installers (PIs) act as the lead point of contact for issues related to the pressure system.

Pressure Installers (PIs) are responsible for:

• Installing and modifying pressure systems without supervision.
• Procuring pressure hardware.
• Supervising activities of non-PIs performing installation and modification tasks.
• Performing maintenance and other non-routine tasks to the pressure system.

Qualifications for PIs include:

1. Be designated by their manager based on job tasks.
2. Qualification to be determined by the line manager.
3. Complete the following classroom training courses:
   • PRS150, Pressure Safety Orientation
   • PRS250, Advanced Pressure Safety
   • PRS115, Cryogen Safety (if applicable)
   • Commercial Hardware Training, or equivalent
4. Complete local and on-the-job training as specified by the organization.

Note: Managers validate that qualified personnel are designated to the job task. The Pressure Installer Qualification Form (SF 2001-PIQ [Word file/Acrobat file]) is supplied for the convenience of the Manager for validation. A copy should be maintained by the organization.

Pressure Operators

Pressure Operators are responsible for:

• Being aware of the hazards of pressure systems.
• Operating the system safely and within its designed operating parameters.
• Seeking advice from a PA on questions of compliance and safety.
• Verifying that the pressure system has been assembled to the satisfaction of a PI.
• Verifying that the pressure safety requirements regarding operation and documentation for the system(s) have been met.

Qualifications for pressure operators include:

1. Be designated by their manager based on a job task.
2. Complete the following classroom training courses:
   • PRS150, Pressure Safety Orientation
   • PRS115, Cryogen Safety (if applicable)
3. Complete local and on-the-job training as specified by the organization.

Note: Managers validate that qualified personnel are designated to the job task. The Pressure System Operator Qualification Form (SF 2001-PQF [Word file/Acrobat file]) is supplied for the convenience of the Manager for validation. A copy should be maintained by the organization.

PRESSURE SAFETY PROGRAM SUPPORT ORGANIZATIONS

Pressure Safety Committee

Note: The PSC is governed by a charter approved by the ES&H and Emergency Management Center Director.

Committee membership includes:

• A Chairman who is appointed by the Director, ES&H and Emergency Management Center.
• A Secretary who is appointed by the PSC Chairman.
• A representative from each division who is knowledgeable in applicable pressure safety disciplines.
• Additional members appointed by the Chairman to ensure that the committee has at least one expert in each of the following disciplines:
  • Applied Mechanics
  • Materials
  • Safety Engineering
  • Facilities Engineering
  • Other disciplines as deemed appropriate by the Chairman.

The PSC is responsible for:

• Establishing and documenting pressure safety requirements in the Pressure Safety Manual (MN 471000) and Safe Handling of Cryogenic Fluids (GN 470100).
• Regularly reviewing and, when necessary, revising these documents.
• Assisting SNL organizations by interpreting the pressure safety requirements of DOE orders, criteria, guides, and other codes, standards, and practices.
• Reviewing the adequacy and availability of SNL pressure testing capabilities.
• Developing, reviewing, approving, and mandating pressure safety awareness training.
• Periodically monitoring the effectiveness of the Pressure Safety Program and establishing criteria to assess the effectiveness of the Pressure Safety Program and its implementation by SNL organizations.
• Communicating pressure-related safety issues and concerns to affected Members of the Workforce and management.
• Staying aware of relevant industry standard codes, standards, hardware, and procedures related to pressure safety issues.
• Maintaining communication with the DOE Pressure Safety Committee and implementing its initiatives.
• Interfacing with the Purchasing Department on matters applicable to pressure safety, including, but not restricted to, JIT contracts.
• Advising management on resources needed to develop and maintain a viable Pressure Safety Program.
• Publishing pressure safety bulletins.
• Maintaining a Pressure Safety web page on the Sandia Internal Restricted Network.

Safety Engineering Department

Safety Engineering Department pressure safety personnel are responsible for:

1. Interpreting laws, codes, standards, and regulations that apply to pressure safety and providing updates to the PSM as necessary.
2. Providing consultation on pressure safety issues.

Support Organizations

Other support functions include, but are not limited to:

1. Materials Mechanics.
2. Materials Application Engineering.
3. Nondestructive Evaluation (NDE).
4. Solid Mechanics Engineering.
5. Design Definition (Pressure Drawing Review).
6. Welding.
7. Facilities Engineering.
8. Component Development.
9. Purchasing.
10. Training.
11. Quality.

Hardware Procurement Support Organizations

• The SNL/NM Safety Engineering Department and the SNL/CA Health & Safety Department.
• Quality assurance functions.
• Buyers supporting Center purchasing operations.
• Feedback from users and PAs.

Responsibilities of the support organizations are to provide:

• Supplier qualification.
• Pressure hardware (including JIT) procurement.
• Investigation of pressure hardware quality and support issues as needed.

PRESSURE SAFETY TRAINING PROGRAM

Training Requirements

Managers shall ensure that Members of the Workforce complete the required training identified below prior to performing the indicated work activity or fulfilling the indicated role. Untrained Members of the Workforce may temporarily work under the direct supervision of an appropriately qualified Member of the Workforce if the conditions/limitations of such work are documented (e.g., specific activities and duration) prior to performing the work.

Managers shall verify that individuals responsible for developing and conducting job-specific pressure systems training and pressure safety training have the appropriate education, training, and skills to discharge this responsibility. See ESH100.2.GEN.2, Determine, Complete, and Document Required ES&H Training, for instructor qualification requirements.

Training requirements for pressure system personnel are listed in Table 2-1 and on the qualification forms SF 2001-PAQ [Word file/Acrobat file], SF 2001-PQF [Word file/Acrobat file], and SF 2001-PIQ [Word file/Acrobat file]. All personnel involved with pressure systems are required to take the course PRS150, Pressure Safety Orientation. Those designated to perform the duties of PI shall also receive instruction on the particular type of hardware being used by the organization, either from a commercial vendor or as on-the-job training within the organization. New personnel shall demonstrate the skills and abilities necessary to perform the duties of a PI, while under direct supervision of an Installer, prior to meeting the qualification requirements.

Refresher training for SNL courses is required at intervals not to exceed three years to provide updates on new requirements and pressure safety criteria.

Note: Web-based refresher training courses are available in TEDS for PRS150, PRS250 and PRS115, and are intended as the path to satisfy the refresher requirement.

See HR100.2.1, Identify and Complete Sandia Required Training for all Members of the Workforce, for the corporate Sandia Required Training Policy.

Commercial Hardware Training

Shane Page, srpage@sandia.gov
Al Bendure, aobendu@sandia.gov

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