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REQUIREMENTS AND POLICIES MANUAL

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    Title:

    Pressure Safety

    Publication date:

    1/18/2022

    Effective date:

    1/18/2022

    BRIEF

    Policy Summary

    Lawrence Berkeley National Laboratory's (Berkeley Lab's) Pressure Safety Program manages pressure and vacuum systems used at the Laboratory site by:

    • Stating design and build requirements for pressure systems.
    • Identifying required training for those handling and using pressure and vacuum systems.
    • Listing usage and handling requirements for pressure and vacuum systems.

    Who Should Read This Policy

    All Berkeley Lab employees, visitors, affiliates, and subcontractors working with pressure or vacuum systems

    To Read the Full Policy, Go To:

    The POLICY tab on this wiki page

    To Read the ES&H Program Details, Go To:

    ES&H Manual Chapter 7

    Contact Information

    EHS Subject Matter Expert for Pressure Safety
    Environment, Health, and Safety (EHS) Division


    Title:

    Pressure Safety

    Publication date:

    1/18/2022

    Effective date:

    1/18/2022

    POLICY

    A. Purpose

    Lawrence Berkeley National Laboratory's (Berkeley Lab's) Pressure Safety Program manages pressure and vacuum systems used at the Laboratory site by:

    • Stating design and build requirements for pressure systems.
    • Identifying required training for those handling and using pressure and vacuum systems.
    • Listing usage and handling requirements for pressure and vacuum systems.

    B. Persons Affected

    All Berkeley Lab employees, visitors, affiliates, and subcontractors

    C. Exceptions

    None

    D. Policy Statement

    1. Pressure system safety is achieved by careful engineering, hazard controls, assuring structural integrity of the components, regulation of pressures and flow, and provision for pressure relief (Work Process A).
    2. Low-pressure gas systems are pressure systems operating below 1 MPa gauge (150 psig) and consisting only of regulator, tubing, gauges, valves, and fittings. Low-pressure gas systems represent the lowest hazard category of pressure systems at Berkeley Lab (Work Process B).
    3. Low-hazard pressure systems consist of equipment with a low-hazard level involving routine risks that are accepted as such by the general public (Work Process C).
    4. Pressure systems that do not fall into the low-hazard category are high-hazard pressure systems. Specifically, high-hazard pressure systems include:
      1. All pressure vessel systems that contain irritant, toxic, infectious, and/or radioactive fluids at any pressure.
      2. All pressure vessel systems with oxygen or flammable contents.
      3. All pressurized equipment (including ASME-coded vessels that have been structurally modified) that operates at gas pressures over 1 MPa gauge (150 psig) or at liquid pressures over 10 MPa gauge (1,500 psig), or that contains over 100 kJ (75,000 ft-lb) of stored energy (Work Process D).
    5. Vacuum systems that are back-filled from a pressurized supply must be equipped with a pressure-relief valve to assure that the system will not be subjected to pressures in excess of the Maximum Allowable Working Pressure (Work Process E).
    6. The most severe hazard of cryogenic systems is the possible confinement of even small amounts of cryogenic liquid (Work Process F).
    7. Employees who work with pressure systems over 1 MPa (150 psig) or with pressure vessel systems at any pressure must review training requirements with the Environment, Health, and Safety (EHS) Division pressure safety representative (Work Process G).

    E. Roles and Responsibilities

    Role

    Responsibility

    Division Directors

    Responsible for assuring that all pressure systems are designed, assembled, and operated in accordance with the requirements of this chapter.

    Environment, Health, and Safety (EHS) Division

    • Administers and maintains the Laboratory Pressure Safety Program.
    • Arranges the Laboratory Pressure Safety Training Courses.
    • Maintains copies of all Safety Notes.

    Engineering Division

    • Reviews and approves the design, fabrication, installation, and testing of research pressure systems, including vacuum systems, as required by this chapter.

    Engineering Division Director

    • Designates qualified engineers as Designated Pressure Engineers to provide guidance on pressure vessel and pressure system design and to review such designs as prepared by vendors and Laboratory personnel.
    • Approves any Safety Notes for pressure systems.

    Facilities Division

    • Responsible for the design, fabrication, installation, and testing of all plant facility pressure equipment.
    • Maintains a sufficient staff of qualified and certified pressure installers, who are available to all groups at Berkeley Lab.

    Designated Pressure Engineer

    • Experienced mechanical design engineers who have specific knowledge regarding pressure safety and have been designated by the Engineering Division Director.
    • Responsibilities include:
      • Completing required training.
      • Providing advice and guidance to Berkeley Lab staff in matters related to pressure safety.
      • Reviewing and approving pressure-related Safety Notes on behalf of the Engineering Division Director.

    Responsible Designer

    A competent mechanical designer, usually a member of the Engineering Division. Responsibilities include:

    • Completing required training.
    • Developing or selecting a safe design in accordance with all applicable codes and standards.
    • Specifying procurement, fabrication, installation, maintenance, testing, retesting, and labeling requirements.
    • Preparing all required Safety Notes.

    Responsible User

    • Accountable for the safe use and maintenance of the equipment, including retesting of pressure systems in accordance with the requirements of the Safety Note, and for assurance that all training requirements have been met.
    • Typically the principal investigator or researcher with overall responsibility for the work.

    Employees

    • Must complete the Berkeley Lab course Pressure Safety (EHS 0171) if working with compressed gas systems.
    • Must review training requirements with the EHS Division pressure safety representative if working with pressure systems over 1 MPa (150 psig) or with pressure vessel systems at any pressure.

    F. Definitions/Acronyms

    Term

    Definition

    MAWP

    Maximum Allowable Working Pressure: the maximum pressure at which the design of pressure systems is based

    MOP

    Maximum Operating Pressure: the highest pressure at which a system will operate

    Pressure Installer

    Technicians or mechanics, usually in the Facilities Division, who have completed specialized training and have been designated and certified as such by their Department. Head pressure installers may be assigned to work directly for responsible designers.

    Pressure Regulator

    A valve or device designed to cut of flow at a set pressure

    Pressure Relief Devices

    Valves or rupture disks designed to vent pressure above a set point. Their purpose is to ensure the pressure within the vessel does not exceed MAWP.

    Test Pressure

    The pressure at which a vessel is tested to validate it can withstand the MOP. Test pressures vary from 125% to 200% of the MAWP.

    G. Recordkeeping Requirements

    • Pressure Relief Device Certifications: Facilities Division
    • Pressure Vessel and System Test Certifications: Facilities Division

    H. Implementing Documents

    Document Number

    ES&H Manual Reference

    Title

    Type

    07.07.026.001

    Chapter 7

    Pressure Safety

    Program

    07.07.026.002

    Chapter 7, Work Process A

    General Requirements

    Work Process

    07.07.026.003

    Chapter 7, Work Process B

    Low-Pressure Gas Systems

    Work Process

    07.07.026.004

    Chapter 7, Work Process C

    Low-Hazard Pressure Systems

    Work Process

    07.07.026.005

    Chapter 7, Work Process D

    High-Hazard Pressure Systems

    Work Process

    07.07.026.006

    Chapter 7, Work Process E

    Vacuum Systems

    Work Process

    07.07.026.007

    Chapter 7, Work Process F

    Cryogenic Systems

    Work Process

    07.07.026.008

    Chapter 7, Work Process G

    Training Requirements

    Work Process

    07.07.015.001

    Chapter 13

    Gas Safety

    Program

    07.07.009.001

    Chapter 29

    Safe Handling of Cryogenic Liquids

    Program

    I. Contact Information

    EHS Subject Matter Expert for Pressure Safety
    EHS Division

    J. Revision History

    Date

    Revision

    By Whom

    Revision Description

    Section(s) Affected

    Change Type

    1/2/2012

    0

    J. Dionne

    Re-write for wiki (brief)

    All

    Minor

    9/27/2012

    1

    J. Dionne

    Re-write for wiki (policy)

    All

    Minor

    9/10/2013

    1.1

    K. Ettinger

    Reviewed 8/28/13

    SRDs, Next Review date

    Minor

    1/18/2022

    2

    K. Ettinger

    Periodic review: Reference update to Cal/OSHA to reflect 10 CFR 851 variance; separate out Cryogen Safety Program elements (Cryogens is now its own chapter). Policy name changed from Pressure and Cryogenics to Pressure Safety

    All

    Minor

    DOCUMENT INFORMATION

    Title:

    Pressure Safety

    Document number

    07.07.026.000

    Revision number

    2

    Publication date:

    1/18/2022

    Effective date:

    1/18/2022

    Next review date:

    1/18/2025

    Policy Area:

    Industrial Hygiene and Safety

    RPM Section (home)

    ESH

    RPM Section (cross-reference)

    none

    Functional Division

    EHS

    Prior reference information (optional)

    ES&H Manual Chapter 7

    Source Requirements Documents

    Title 8, California Code of Regulations, (CCR) "Industrial Relations," Division 1, "Department of Industrial Relations," Chapter 4, "Division of Industrial Safety"

    • Subchapter 1, "Unfired Pressure Vessel Safety Orders"
    • Subchapter 2, "Boiler and Fired Pressure Vessel Safety Orders"

    National Fire Protection Association (NFPA)

    • NFPA 45-2015, Standard on Fire Protection for Laboratories Using Chemicals
    • NFPA 51-2013, Standard for the Design and Installation of Oxygen–Fuel Gas Systems for Welding, Cutting, and Allied Processes
    • NFPA 54-2012, National Fuel Gas Code
    • NFPA 55-2013, Compressed Gases and Cryogenic Fluids Code

    Title 10, Code of Federal Regulations, (CFR) Part 851, "Worker Safety and Health Program", Appendix A, "Worker Safety and Health Functional Areas," Section 4, "Pressure Safety"

    Other Driving Requirements

    Title 29, CFR, "Labor", Chapter 17, "Occupational Safety and Health Administration, Department of Labor"

    • 8 CCR, Subchapter 7, "General Industry Safety Orders (GISO)"
    • 8 CCR, Subchapter 4, "Construction Safety Orders (CSO)"

    Title 49, CFR, "Transportation," Subtitle B, "Other Regulations Relating to Transportation," Chapter 1, "Pipeline and Hazardous Materials Safety Administration, Department of Transportation Subchapter C, "Hazardous Materials Regulations"

    • Part 173, "Shippers – General Requirements for Shipments and Packagings"
    • Part 178, "Specifications for Packagings"
    • Part 180, "Continuing Qualification and Maintenance of Packagings"

    American National Standards Institute (ANSI)

    • ANSI Z49.1-2012, "Safety in Welding, Cutting and Allied Processes"

    American Petroleum Institute (API)

    • API RP 520 Part I-2014, "Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries, Part I – Sizing and Selection"
    • API RP 520 Part II-2003, "Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries, Part II – Installation"
    • API Standard 620, "Design and Construction of Large, Welded, Low-pressure Storage Tanks"

    American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE)

    • ASHRAE 15-2010, "Safety Standard for Refrigeration Systems"

    ASME Standards

    • ASME A13.1-2007, "Scheme for the Identification of Piping Systems"

    Compressed Gas Association (CGA) Standards

    • CGA S-1.1-2007, "Pressure Relief Device Standards Part 1 – Cylinders for Compressed Gases"
    • CGA S-1.2-2005, "Pressure Relief Device Standards Part 2 – Cargo and Portable Tanks"
    • CGA S-1.3-2008, "Pressure Relief Device Standards Part 3 – Stationary Storage Tanks"
    • CGA C-6-2007, "Standards for Visual Inspection of Compressed Gas Cylinders"
    • CGA C-7-2009, "Standard Method for Determining Cylinder Valve Outlet Connections for Industrial Gas Mixtures"
    • CGA Pamphlet P-1-2015, "Safe Handling of Compressed Gases in Containers"
    • CGA V-1-2013, "Compressed Gas Cylinder Valve Outlet and Inlet Connections"
    • CGA V-7-2009, "Standard Method for Determining Cylinder Valve Outlet Connections for Industrial Gas Mixtures"

    Expansion Joint Manufacture Association (EJMA)

    • Standards of the Expansion Joint Manufacturer's Association, Ninth Edition, 2007

    National Board of Boiler and Pressure Vessel Inspectors

    • NB 23-2013, National Board Inspection Code

    Tubular Exchanger Manufacturers Association

    • Standards of the Tubular Exchanger Manufacturers Association, Ninth Edition, 2007

    Brookhaven National Laboratory

    • BNL-81715-2008-IR, "Vacuum Systems Consensus Guideline for Department of Energy Accelerator Laboratories"

    Lawrence Berkeley National Laboratory (LBNL)

    • Chapter 13, Gas Safety   
    • Chapter 18, Lockout/Tagout
    • Chapter 29, Safe Handling of Cryogenic Liquids 
    • Chapter 45, Chemical Hygiene and Safety Plan
    • LBNL Facilities Division, SOP0008 Lock-out/Tag-out (LOTO) Operating Procedure
    • LBNL Environmental Technologies Area, Safety Alert, Use of Ovens in Lab Areas

    SLAC National Accelerator Laboratory

    • SLAC-I-720-0A29Z-001-R023.4, Chapter 14, "Pressure Systems"

    Implementing Documents

    Document Number

    ES&H Manual Reference

    Title

    Type

    07.07.026.001

    Chapter 7

    Pressure Safety

    Program

    07.07.026.002

    Chapter 7, Work Process A

    General Requirements

    Work Process

    07.07.026.003

    Chapter 7, Work Process B

    Low-Pressure Gas Systems

    Work Process

    07.07.026.004

    Chapter 7, Work Process C

    Low-Hazard Pressure Systems

    Work Process

    07.07.026.005

    Chapter 7, Work Process D

    High-Hazard Pressure Systems

    Work Process

    07.07.026.006

    Chapter 7, Work Process E

    Vacuum Systems

    Work Process

    07.07.026.007

    Chapter 7, Work Process F

    Cryogenic Systems

    Work Process

    07.07.026.008

    Chapter 7, Work Process G

    Training Requirements

    Work Process

    07.07.015.001

    Chapter 13

    Gas Safety

    Program

    07.07.009.001

    Chapter 29

    Safe Handling of Cryogenic Liquids

    Program

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