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).

9. DOCUMENTING THE OPERATIONAL SAFETY OF PRESSURE SYSTEMS

Subject Matter Experts: Shane Page, and David Paoletta
Contributor: Pressure Safety Committee
MN471000, Issue T
Revision Date: November 2, 2009; Replaces Document Dated: March 31, 2008
Administrative Changes: November 5, 2009, February 11, 2010, June 8, 2010, June 10, 2010, and May 26, 2011, and January 19, 2012

• DOCUMENTATION CRITERIA
• DATA PACKAGE

DOCUMENTATION CRITERIA

Requirements

Managers shall ensure that:

• All pressure systems are documented according to the requirements of this chapter.

Guidance

Managers should use a graded approach to documentation depending on the:

• hazards and complexity of the system.
• applicable codes or standards
• method of procurement, design, and fabrication.

DATA PACKAGE

The Data Package serves as a tool for design review of the pressure system. The amount of information contained in the Data Package varies with the complexity of the system. The Data Package contains all the facts and evaluations that have been made and are needed for:

• Documenting compliance with this manual (this implies compliance with applicable codes, standards, and practices).
• Summarizing hazards and controls.
• Formally evaluating the system (to include reevaluation criteria for vessels or components).
• Use as a training tool for pressure operators.

General Data Package Requirements

Data Packages shall be:

• maintained for the life of the pressure system
• revised to reflect the modification of the system, vessel(s), or other components

• on file, retrievable and traceable to the system it documents

• approved by the manager and reviewed and signed by the individuals responsible for the system, including:

• Pressure Installer, who typically authors the data package
• Pressure Advisor, who serves as the required peer reviewer
• Line Manager
• *Pressure Operators.

*The Pressure Operator’s signature is typically included in the Data Package. This signature is optional and at the discretion of the approving manager—with consideration given to the hazards and complexity of the system.

The SNL Pressure Safety Committee has determined that an alternate peer review and signature are acceptable if one of the following conditions exists:

• The Pressure Advisor is also acting as the Pressure Installer for the system. Another individual trained and qualified to at least the level of pressure installer may review and concur on the system.
• The Pressure Advisor lacks specific knowledge to conduct a review of the pressure system. The Pressure Advisor can solicit assistance from other Members of the Workforce (e.g., ES&H team members, qualified co-workers). The Pressure Advisor would still participate in the review and sign the data package.
• The Center Pressure Advisor is not available. A pressure safety SME, or another pressure advisor, can provide review and concurrence on an interim basis.

Specific Data Package Requirements

The Data Package shall contain the following information:

• Identity of the pressure sources.
• Maximum allowable working pressure (MAWP) for the system or segments of the system.
• Description of overpressure protection. Where applicable, address pressure relief valve set pressure and flow capacity.
• Criteria for and results of any applicable testing. Examples may include an overpressure test, leak test or functional test.
• Criteria for any applicable re-evaluation, re-test, maintenance or inspection for vessels or components, including re-testing or re-placement intervals for pressure relief valves.
• Any applicable service life calculations. Service life examples may include fatigue, corrosion, aging mechanisms, and manufacturer’s recommendations.
• For used vessels or components, the applicable analysis or testing required for re-application of the vessel or component.
• For custom-designed vessels or components that do not have supplier-established pressure ratings, all the applicable design criteria to evaluate the structural integrity of the item must be included. Examples of design criteria include the following:
  • design calculations with MAWP, safety factor
  • applicable design code or equivalent safety
  • fabrication drawings and assembly criteria, such as specific weld joint designs and bolt torques
  • testing requirements, such as overpressure or leak test and test results.

Additional Data Package Guidance

Members of the Workforce who prepare Data Packages should consider the following content:

• Cover sheet with system identification and location, and required signatures.
• Abstract - summarizes the hazards and controls and highlights any special requirements or analyses.
• Drawings (system configuration, and vessel or unique component drawings when applicable).
• Materials and process callouts (vessels and unique components).
• The rated MAWP for each component (e.g., tubing, fitting, valves, vessels) or categories of components.
• Operating parameters (e.g., pressure and temperature ranges, cycles, restrictions).
• Date placed into service.
• The Manufacturer's Data Report (Form U-1) for ASME Code pressure vessels.

Note: Form U-1 is available for vessels carrying the ASME Code stamp and registered with the National Board of Boiler and Pressure Vessel Inspectors (called the National Board) of Columbus, Ohio. However, the forms lack supplementary procurement notes essential for material and process definition. Include this information in the Data Package when it is necessary because of requirements unique to that vessel.

• Reference should be made to other technical work documents (TWDs) pertinent to the system such as ES&H SOPs, Service Logs, Operating Procedures, or manufacturers' manuals.
• Memos and reports supporting original evaluation and all subsequent evaluations.
• Brittle material concerns, shielding or containment issues
• For chemical hazard gases (such as toxic, oxidizer, flammable, pyrophoric, corrosive), list applicable controls, such as volume limits, flow restriction, local exhaust ventilation, and gas detection issues
• Personal protective equipment (PPE) selection.
• Data Package templates exist on the Pressure Safety homepage.

The SNL Pressure Safety Committee has determined that documentation requirements for the following items, when used according to the manufacturer’s documentation, are satisfied by the manufacturer’s published literature (equipment manuals, labels, etc.) and do not require that a formal data package be created for:

• Standard, commercially available shop tools.
• SNL facilities-installed compressed air hose reels (Figure 1) used for dusting operations (with standard OSHA compliant air guns) or connections for tire-filling operations.

Figure 1. Compressed Air Hose Reels

• Cryogen containers such as:
  • Open top and non-pressurized, hand-pour Dewars (commonly referred to as lab Dewars) (Figure 2).

Figure 2. Dewars

 

• Pressurized Dewars such (Dura-Cyl or Cryo-Cyl) used for filling of lab Dewars and not connected to a piping and cryogen liquid distribution system.

Note: Oxygen deficiency evaluations are performed according to ESH100.2.IH.19, Evaluate and Control Asphyxiant Hazards.

• Desiccator jars (Figure 3.)

Figure 3. Desiccator Jars

 

• Vacuum chucks and tweezers (Figure 4).

Figure 4. Vacuum Chucks and Tweezers

 

• Pressurized spray cans and dusters.
• Closed-loop, self-contained, water-cooling systems (Figure 5).

Figure 5. Water-Cooling System

 

• Commercial self-contained (single cylinder) torches (Figure 6).

Note: Oxy and flammable torches (Figure 7) with regulators, check valves, and flash arrestors, etc., require a data package; a template exists on the homepage.

• Commercial butane lighters and soldering irons (Figure 8).

• Paintball and air rifles.
• Fire extinguishers and sprinklers.
• Eyewash stations and safety showers (includes portable and fixed stations).
• Non-pressurized and non-purged sealed drums.
• Vacuum cleaners.
• Forklifts and their associated propane fuel systems.
• DOT gas or liquid supply cylinders and tanks. These items are stamped and tested at the required intervals by the vendor. They should be documented in the system "Data Package" to indicate the pressure source and maximum pressure available.
• Hydraulic lifts and jacks (all hand-operated hydraulic tools) (Figure 9).

Figure 9. Hydraulic Lifts and Jacks

Note: For heating, ventilating, and air conditioning (HVAC) systems, and Facilities-supplied “house” gases (such as compressed dry air or nitrogen), the informational intent of the Data Package is satisfied through the Facilities design specifications that are maintained online at the Facilities Architectural and Engineering Standards website. Operating and maintenance instructions, specifications, and records are maintained in the appropriate Building Mechanic’s office and are tracked through the MAXIMO database. Where industry practices require documentation, such as U-1 Forms on ASME Code registered and stamped air receiver tanks, Facilities Operations will maintain these documents for all like systems. Lab equipment not referenced above and connected to house gases will require a data package

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

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