RPM

Title:	Pressure and Cryogenics
Publication date:	9/10/2013
Effective date:	6/17/2010

BRIEF

Policy Summary

Berkeley Lab's Pressure and Cryogenics Program manages gases and cryogenic liquids used at the Laboratory site by:

Stating design and build requirements for gas and cryogenic delivery systems
Identifying required training for those handling and using gases and cryogenic liquids
Mandating the use of process safety documentation
Listing usage and handling requirements for gases and cryogenic liquids

Who Should Read This Policy

All Berkeley Lab employees, visitors, affiliates, and subcontractors

To Read the Full Policy, Go To:

The POLICY tab on this wiki page

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

http://www.lbl.gov/ehs/pub3000/CH7.html

Contact Information

Pressure and Cryogenics Subject Matter Expert
EHSS Division

Title:	Pressure Hazard Assessment and Control
Publication date:	9/10/2013
Effective date:	6/17/2010

POLICY

A. Purpose

Berkeley Lab's Pressure and Cryogenics Program manages gases and cryogenic liquids used at the Laboratory site by:

Stating design and build requirements for gas and cryogenic delivery systems
Identifying required training for those handling and using gases and cryogenic liquids
Mandating the use of process safety documentation
Listing usage and handling requirements for gases and cryogenic liquids

B. Persons Affected

All Berkeley Lab employees, visitors, affiliates, and subcontractors

C. Exceptions

None

D. Policy Statement

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)
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)
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)
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 operate 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)
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)
The most severe hazard of cryogenic systems is the possible confinement of even small amounts of cryogenic liquid. (Work Process F)
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 EHSS 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, Safety, and Security (EHSS) Division	Administers and maintains the Laboratory Pressure Safety Program Arranges the Laboratory Pressure Safety Training Courses Maintains copies of all AHDs and 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. Reviews and approves pressure-system Activity Hazard Documents (AHDs), which are written to assure that pressure operations are within the design limitations of such systems. This is in addition to the normal review process for AHDs, and it does not cover AHDs required for other reasons.
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; and for all requisite AHD's 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 and AHDs 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 or AHD; 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 EHSS 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	PUB-3000 Reference	Title	Type
07.07.026.001	Chapter 7	Pressure Safety and Cryogenics	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	Gases	Program
07.07.009.001	Chapter 29	Safe Handling of Cryogenic Liquids	Program

I. Contact Information