CRYOGENIC & GAS SYSTEM

PIPING PRESSURE TESTS

{A collection of PT permits}

D-ZERO ENGINEERING NOTE # 3823.115-EN-566

August 22, 2002

Author: Russell A. Rucinski

Project Engineer

PPDIMSDIDO Operations

This engineering note is a collection of pipe pressure testing documents for varloussections of piping for the D-Zero cryogenic and gas systems.

High pressure piping must conform with FESHM chapter 5031.1. Piping lines with ratings greater than 150 psig have a pressure test done before the line is put into service. These tests require the use of pressure testing permits.

It is my intent that all pressure piping over which my group has responsibility conforms to the chapter. This includes the liquid argon and liquid helium and liquid nitrogen cryogenic systems. It also includes the high pressure air system, and the high pressure gas piping of the W AMUS and MDT gas systems.

This is not an all inclusive compilation of test documentation. Some piping tests have their own engineering note. Other piping section test permits are included in separate safety review documents. So if it isn't here, that doesn't mean that it wasn't tested.

Russ Rucinski, PPDIMDIDO Operations.

Fermilatl

LN2 FILL LINE, WELD REPAIR

Pressure Testing Permit·

Type of Test: [v] Pneumatic - Gas nitrogen ,or argon

Test Pressure: Nitrogen lines = 110% (225 psig) = 248 psid

Maximum Allowable Working Pressure: 225 psig set by ST-569-N

Items to be Tested: LN2 dewar 42 fill line up to PV-540-N

Location of Test: O-Zero Ass'y Building, south parking lot.

Date: August 20,2002

Hazards Involved: Minimal hazards, very little store energy.

PA.6E; i OF- 4

8120/02

Safety Precautions Taken: Will stand to the side of and away from the strainer/till area.

Special Conditions or Requirements: Check valve flapper must be disabled. Pressurize through

MV-568N.

Test Coordinator:-BllSS.Bp!<irulti ____ --:-~-_

Division/Section Safety Officer~R-6l~~P4-J""",""",,w-,,,,,,,,,F-,/­

Division/Section Head ----'''''''is----'-C~_------

DeptlDate PPDlMD/DO 8102/2002 DeptlDate~ fl;J..t 6/2/)/0z. Dep!'Date <ijzl/r> 'Z--

Results P~e&sv,Q..tl.E:'.D fIS'~ "'-d f!o\J,.JJ) ,""v·S'&·,-I IAC.C.IAl6 c.£4jr;. Ac..so 57&1

OE~~1Sf ~ ~"'I.CeSJ"'e "l.Ck CL.fIISIf'J~. WE: C.£.9(.A-~D MV ... S&tt.,.., tJlc"r-tt It. p,~

VA .... "" ftA-rr:o ~ ') 'f.otstv. ~SUJ'l'oe-D Tes"f. S/tIDo/Eb A'-O~' VI~. "'~IJ) l.Sc' PS16

Witne~~~';' '-(S'ifety Officer or DeSIgnee)

C:u .. "0 MaIN-rIrS. No c..e#\t:$ 1)'" ~1t'w(U:;5 O,J sr;;.c;-rcol'J 1tf' fV(.,(,..,

-rES" ('(l.e-sS\l~ (,.)(ce,~ ~,..", Ci4' (4\16,4. sf $V .. Stu· N). $V· St.fl· A.J C"'",v'E;i) AF-r(,.'- -re:-S"1' I SE-r * -rf;S-rEj) ~ ,'lO ,"5&.4 ""Jt) Pe.o--re-c...7 l~(.",,"N.

~

• Must be signed by diviSion/section safety officer and division/section bead prior to conducting test. It is the responsibility of the test coordinator to obtain signatures. Fennilab ESd:H Manual S034TA-l

Rev. 4/92

~ )~------------------------------------------------~--

W515N

11 I I

'1 I

,I "1 :-1-- -"1 • I

I I I I I I I I

~~,,l f\..

95 PSI

PI5SJN

BLOW-DOWN

1 1/2"

w- 1if 5HN A fM561N

. N

1/2'x3' 444LN

PI

PI555N

100 PSI

pSv-5-42N

r-------

PUMP OVERFILL

SHUTOFF DEVICE

A.S.---

TRY-COCK

W-I' 516N r

LN2 DEWAR #42 20,000 GAL.

TANK CENTER-LINE EL. 749'-0'

PIC1409N

JOO PSI

P5V-537N

* -e-

I/A SYSTEI.1 ___ --l W472N

- - -..,

P1565N

TO DPR576N

I' T

C.S.

c:::::::J

PIC501N

I

01 011

....... o->~+-iI~ C. s ffi I ( • wi!

100 PSI ~ .., II>

I

~

Oil Vi I~ 1-1 t 51~

I

D0PIPINGC ONENTS 211 ) ::>2 DEVICE DESCRIPTION MANUfA RER/MODEL SIZE RATING CV549N LN2 FILL CHECK VALVE LADISH 5260 STAINLESS STEEL 1-1/2" MV550N VAPORIZER LIQUID SHUT OFF POWELL 70-102 1/2" 400 psi ,,'

PSV55JN SAFETY RELIEF VALVE. GN2 HEATERS NUPRO SS-4CPA2-150 1/4" 150psl set MV552N RELIEF MANIFOLD TEST VALVE NUPRO B-4JA 1 1/4" 600 psi

FOR NITROGEN DEWAR PI553N RELIEF MANIFOLD PRESSURE ASHCROFT 1/4" 0-160 psi

INDICATOR NITROGEN DEWAR MV554N RELIEF MANIFOLD TEST VALVE NUPRO B-4JAI 1/4" 600 psi

FOR NITROGEN DEWAR PI555N RELIEF MANIFOLD PRESSURE ASHCROFT 1/4" 0-160 psi

INDICATOR NITROGEN DEWAR MV556N GAS SUPPLY SHUT-OFF NITROGEN DEWAR POWELL 70-102 I" 400 psi PSV557N PRESSURE BUILD CIRCUIT INLET RELIEF NUPRO B-4CPA2-150 150 psi FM558N CRYOSTAT CONDENSER OVERFLOW SENSOR DEITERICH STANDARD DNW-l0 1-1/2". SCH. 40

559 NOT ASSIGNED WASmv559N DPS560N SWITCH FOR FM55SN AMERICAN FLUIDPOWER SERIES 20 1/4" 2.5"-45 W.C.

#22TA-K614 FM561N DEWAR CONDENSER OVERFLOW SENSOR FNAL DESIGN. VENTURI TYPE 1" 150 PSI

562 NOT ASSIGNED . . WASmv562N DPS563N SWITCH FOR FM561N AMERICAN FLUIDPOWER SERIES 20 1/4" 2;5"-45 W.C.

#22TA-K614 MV564N SOUTH PRESSURE INDICATOR SHUT OFF VALVE NUPRO B-4HK 1/4" 1000 psi PI565N SOUTH END DEWAR PRESSURE INDICATOR U.S. GAGE 33004 1/4"

MV566N SOUTH END DPI3VALVE MANIFOLD ANDERSON ~EENWOOD MM1VDB-2 1/4" 3000 psi DPI567N SOUTH END DPI (DEWAR LEVEL INDICATOR) BARTON 227 A-B021503 1/4" O-lOO"W.C. MV568N ST569 DRAIN VALVE REGO 9454DA 1/2" ST569N FILL STRAINER MEULLER #351 100 mesh 1-1/2" 225 pslg EV5701 3-WAY AMBIENT HEATER SWITCHING WORCESTER SERIES 75 1275 R1 I"

SOLENOID VALVE HX571N NORTH AMBIENT COLD GAS HEATER THERMAX INC .• ALL ALUMINUM. 3/4" 400 psi design pressure

MODEL #TF041 O-HF-SG I/O Connection 500 psi test pressure HX572N SOUTH AMBIENT COLD GAS HEATER THERMAX INC.; ALL ALUMINUM. 3/4" 400 psI desIgn pressure

MODEL #TF041 O-HF-SG I/O Connection 500 psi test pressure MV573UV W LINE SHUTOFF AT NITROGEN DEWAR NIBCO. I" SOO psI

574 NOT ASSIGNED I . \

MV575N PRV530N SHUT OFF VALVE WORCESTER C466PMSW 1/2" VJ 1500 psi max DPR576N AUTOMATIC LN2 OVERFILL SHUTOFF RELAY FAIRCHILD MODEL 24 1/4" ~ 1-60. 120 pslg max

..... ..... MVJ5001 I/A SHUT"OFF VALVE FOR LN2 DEWAR NIBCOCF-SM 1" I 300psIWOG PI150Jl 1/ A PRESSURE INDICATOR. LN2 DEWAR LINE US GAGE 1/4" ~, 0-2oopsl

MV15021 I/A SHUT-OFF VALVE WORCESTER (STK#1075-OO29) . 1/4" BRASS 250psl

Page 16

/3:j5 t!> !/8"

/3 ~('t 13 '. 'to

f"1: Z. I

-ft4k FO""''() fh v- SIo8·V l.~.,Jl, a. P/f<.tC(~ ..1# /ZfI\ ~~ 5~ ,~; ~ ~....o,~4. . ~ L":+J:: .. <2 &...J(1 c.o~ ~ E~,er- <i! Et-JO LeA-~J,- P5V-S'fl-d . P~SLJtf-e e. 35 PsI,*

f(J.~~I#()· '1"6 ISO PSIt[, ~ B ~ .. 1"1 S' ISj~. 5V-S'fI .. ~ ~1S.,It!I~~ __ NfJ"f (JAtJ ... ~

t a 5 f5 1G. - i:,...,/.? tt::.#~~I?,J." A~ 1Hs'/~

t!){J€f'l811 jIA.I n PtL<Q.sv~ ~ ...,... t4:$ fs,,,. ~. 9C-( Rtr::G 0 V¥f,.1- FO~ '2.S" Ps~

of~~~ ~ sv~~

210 p,;

lSI'· 'l.:J 2. 2.0 fS~' 11~"ttJ \Z."U.:J ($;," _S"tp.$)t.,I'f!~ tJITI'ft \EPr~

J 3"- " J AJC~,.,., E-d """VL..~ <lIIz~"t-r~tf,.. . =- --r""D IJer ~j'4 '* I ~! 2, fh 1.1 ."''' (!::" 2~() '~/'. -IS", _ ~ l.{f ..,J·.ue~(~ 040,

MV--568;N R€:&IO BY1'1''lT ifitj dlJl/;J

BACK UP AIR PIPING

PRESSURE TEST

D-ZERO ENGINEERING NOTE # 3823.115-EN-563

March 12, 2002 iIuiki4 ) ,. ,

Author: Russell A Ruc' ~ Project Engineer "{J'

PPDIMSDIDO Operations

TABLE OF CONTENTS

Pressure Testing Permit - 2 Pages

Handwritten Log of activity during Pressure test - 2 Pages

Historical Trend Chart of PT -744-I, pressure versus time record - 1 Page

Pressure test schematic, drg. 3740.510-MC-295633 - 1 Page

Pressure test procedure - 2 Pages

Pressure ratings of all components in test - 1 Page

Handwritten cales of stored energy and pumping speed during test - 2 Pages

E-mail of recommendations and approval to proceed with test - 3 Pages

Fermilab

HP Air Compressor connection tubing Pressure Testing Permit (Page 1 of 2)*

Type of Test: tV] Pnuematic

Test Pressure: 110%(2200 psi) = 2420 psig

PA6£ 3 OF 4 211212002

Maximum Allowable Working Pressure: 2200 psig (Set by the rating of several ball valves)

Items to be Tested: Short length (12") of flex hose, Approx. 50 feet of 112" OD x 0.049 " wall

tubing run from gas shed to existing piping. Will includes some compression fittings. Will

also test about 300 feet of existing ~" piping and components from tube trailer isolation valve

to final regulator PRV-745-I in utility room. Ref. P&I Drg. 3740.000-ME-273995.

MIVth Location of Test: South side DAB tank farm ___ Date: Pe8R1arv 2002

Hazards Involved: Sudden mechanical release of high pressure gas could cause flying debris,

whipping hoses, loud noise. Equivalent stored energy is 620,(X)() Joules = 460,000 ft-Ibs or the

equivalent of 134 grams of TNT.

Safety Precautions Taken: Test personnel will be excluded from the gas shed and pump room

during the pressurization portion of the test~le§§ beb,iud a harr=ier Ear plugs will be required

for personnel within vicinity of gas shed in case 2500 psig relief goes off. Flex hoses greater

than 24" long are safety chained. Shtd d"", I f!JCI(ui /'f"Uhf'itiVl ps~ttd.

Special Conditions or Requirements: We will control perimeter during the test. We will use

the HP air compressor to achieve test pressure. Pumping rate will be about 100 psi/min. The '.

2500 psig relief on the discharge of the HP compressor will limit ovetpressure during the test.

A 2200 psig relief will be installed on the piping after the test.

* Must be signed by division/section safety officer and division/section head prior to conducting test. It is the responsibility of the test coordinator to obtain signatures.

Fermilab ES&H Manual 5034TA-I Rev. 4192

Fermilab

HP Air Compressor connection tubing

Pressure Testing Permit (page 2 of 2)

P Af<f: 4 of 4-

211212002

Test Coordinator: Russ Rucinski DeptJDate PPDIMD/DO OPs 211112002

DiV"'iODlSectiOnsafetyOffirer~&-~;!oate j)PN eN 3 -1-tJ;;l

Division/Section Head ~. DeptIDare ~~q.4.!q,~...,c.~-=z~ __ _

\..ep..\C.5 A.'1" c...1)~~~e.SStb~ F'"T'--rct-J6S. l.EA!l:.S oe'1"ec:.:r"e;o BY'

SNOOP (SO" ....... -retL) I Pp.E-SSu---,e. R.e:.ouc.E.O ou.e.·.",c. :>

""""~"1'E:N'~u of F,"T'1",/VuS_ No FAI\"Vr..E.~ o~ .:s",(l..S>e., Sf: s. "exT of TC~-r AC.-rI\JI"TV Ai'll> p~£:SSV~ .,..~ e. .... 0 Or rT -/44·1 IS A."'t'-tAc..""G::rO.. ,DO("UME f'l"fA"ftb,.J

5Tb~o Loc:.,. LA .. ", -A-S .D¢> ~'~E.eta,~6 NctTe 3fC7.l.l\S-£Al-5b3.

Witness~,dd~~' IDrS361 DeptJDate wP/MI>!l:9 cPs 3Jrzjoz-(Safety Officer or Designee)

5034TA-2 Rev. 4192

Fermilab ES&H Manual

D0 CRYO INSTRUMENT AIR BACKUP SYSTEM

D0 ENGINEERING NOTE 3740.214--EN-268

JOHN URBIN 20-NOV 90

== Fermilab . EXHIBIT B

Pressure Testing Permit*

Type of Test: 0 Hydrostatic ~eumatic

PA<:xE '2.. O~ 2-Date: /.y' Nt' V flZJ

Test Pressure: 5C)oo psig Maximum Allowable Working Pressure: ...?~()O psig

Items to be Tested: /'l,4/..../{. ...fj.YTEV/ W;W.<:/r ..:;u~~E5 6Nz.- Jj) i3Ac..<~'" 7Uf£'

Z2~ ~ /Np)t~~.vr 1/4 .sp;r~#

Date and Time: --------~--------

Safety Precautions Taken: 7i:;S'7 ~ 1v1'4- a~ ~t!!:J w' f?eJtSo../A!4(... 7£.if Aiof- ivel..L H/M-tf.!6 .

1£ .,I{t:)"~ O~p. ",,1'0.1- S/~N) /bY&.:). 1u. -4V6A:.Il!r ~ elVf7btI'v'GL ;6 /H.£ 74Sr.4Tt£A ~ ~

k~datel:1 81 7i£.rr AiXsO;.PIC,-. AN,t/du.ycbt~iVror- 7kt:r 1lS[,- W?c.c.. & AAd£ tfvJ T4lr 1?4. SJrfM. A-v~ Aw""'duNc~t:Nr W~tA- M ~£ HHd>V 7Hc!f 7;!:V /.r ~,iI~. Speci a 1 Condi tions or Requi rements :_..:.M..LQ.:=:.:w::i~~ ... ______________________ _

~rWGrc2. a (,Of{' prr ~ *:;,} FC~~,.u +. @ S-~k~y ~r ~""e\.AJ (f'0'o r ~

be(), iVl.'cs tL . ~SS u(-t ~S -I- .

Tes t Coordi na tor :-=..J="':_o..;..."""'-.-;;a~· • .:;.:It~~~:;.:;"'~---,q:z..~~-Pr--.;._---...,;DePt/ Da te: If 1r'" 90 7JJ,.;..;~'--m'i-=-~=-__ De.pt/Date: ((p A}t:t{ 90

_,>Division/Section Head: Dept/Date: /B~PIJ

Results: 7?sr ~kS kCCrS51i«f:;tt 4e~/d7OJ ?v/at1«r e{c/4Nr

&Vdl#- :rt~ L.LJIKS ~ "f#AFA£!! H!Nb 7¥ ~.

Witness: Dept/Date: 44~a /j'.../&vftJ afety Off; cen or D g . \ I

*Must be signed by d;q;sion/section ~afetY officer~nd division head prior to conducting test. It is the responsibility of the test coordinator to obtain signatures.

5034TA-6 hlB6

Safety Documentation for review of

D-Zero's Emergency Air Supply High pressure piping

\ oF- 4 R. Rucinski

2113f2002 Rev.3/5f20C12

D-Zero has a back up air supply system to add reliability to air compressor systems. The system includes high pressure piping which requires a review per FESHM 5031.1.

The core system consists of a pressurized tube trailer, supply piping into the building and a pressure reducing regulator tied into the air compressor system discharge piping. Air flows from the trailer if the air compressor discharge pressure drops below the regulator setting. The tube trailer is periodically pumped back up to approximately 2000 psig. A high pressure compressor housed in one of the exterior buildings is used for that purpose.

The system was previously documented, tested and reviewed for Run I, except for the recent addition of piping to and from the high pressure compressor.

The following documents are provided for review of the system:

1.) Instrument air flow schematic, drg. 3740.000~ME-273995 rev. H

2.) Component list for air system

3.) Pressure testing permit for high pressure piping

4.) Documentation from Run I contained in D-Zero Engineering note 3740.214-EN-268, John Urbin 11120/90.

5.) Pressure test procedure

6.) Schematic for pressure test

7.) List of component pressure ratings

The goal of this independent review is to:

A.) Reviewer makes recommendation to the Division/Section Safety Officer to appprove the testing permit.

B.) Reviewer is satisfied the FESHM 5031 is met, and recommends to the division head that approval to operate be granted.

Sincerely submitted,

~~ Russ Rucinski, Project engineer, PPDIMDIDO operations

Russ Rucinski

From: To: Cc: Sent: Subject:

Russ,

"Robert Barger" <barger@fnal.gov> "Russell Rucinski" <rucinski@fnal.gov> "Robert k Barger" <barger@fnal.gov>; "James E. Fagan" <jefagan@fnal.gov> Wednesday, January 30, 2002 11 :31 AM High Pressure Modifications for Emergency Air Backup System

Have completed the relocation of the High Pressure Air Compressor to the new protected location in the Gas Shed Tim has completed the supporting electrical modifications providing a 480 V AC/3ph outlet inside the shed. I have completed the extended piping runs to the shed. Relevant physical data for the changes:

Page 1 of 1

~ oF4

~NI- &IJI~, 3. ~ Ie·,;; - P ~~I<- CItYInt--r_

1) High Pressure extended piping consis~ 112" D.D. x .049 wall 304 S.S. . tubing per ASTM-A269 rated @ 3.06 ksi; connecting fittings are 316 S.S. commercial threaded and compression type fittings rated at 4.5 ksi or S ..... I"6"'("oIt. 'f'tQ) f<:.;6 higher, a Dragon 1/4" NPT 303 S.S. Model 816033KR needle valve rated @ 6.0 ksi, and a braid reinforced corrigated hose section salvaged from high pressure cylinder manifolding. The hose was devoid of identifying marks, but had been in a previously approved high pressure service application, without failure.

2)Low Pressure inlet extended piping consists of 112" D.D. x .049" wall 304 S.S. tubing as above, combined with one section of 112" D.D. x .035" wall rated @ 2.14 ksi; connecting fittings as above.

3)Low pressure dry air source is relieved @ 150 psig via a Circle Seal B 4MP-5159-150 112" NPT relief at a ballast tank fed from a 3/8" instrument air line.

4 )High pressure compressor discharge relief is an Anderson-Greenwood Model 81MS66-3 set @ 2500 psig, rated @ 1137 scfm.

5)High pressure compressor is an Ingersoll-Rand type 30, model 223 with a capacity of 5.0 cfm at rated pressures (up to 3000 psi).

6)As this is not a cyogenic or frred boiler application, no trapped volume reliefs were installed in either line extension. The Dragon valve was installed inside the shed for maintenance safety/control reasons.

At this time, preparations are underway for a hydrotest of the high pressure line segment, pending selection of desired MA WP rating and receipt of testing pennit.

Bob

1130/2002

Flexible Metal Hose Model M1F Scott's Stainless Steel Flexible Metal Hoses are fabricated from corrugated Stainless Steel Type 316l innercore rein­forced with stainless steel braid. Both innercore and double braids are heliarc welded to the end fitting.

FEATURES - Stainless steel construction for excellent corrosion and diffusion resistance.

-Close pitch, high convolution count annular innercore has excellent flexibility, less force to bend and can withstand continual flexing.

-All hoses cleaned for oxygen service.

Tubing

Model No.

Type 304 StainIess'Steei Standard . 58-1TS4-0282· 1/8 58-1TS4-0284 I 1/4 58-1TS4-o356 3/8

I

.028

.028

.035

-Metal 1.0. tags: Product is identified as to pressure rating, part number and date of manufacture.

SPECIFICATIONS Internal Diameter: 1/4" minimum Working Pressure: 3200 psig @ 70°F (20OC), 2500 psig @ 500°F (2600C) Proof Testing of Assemblies: 4800 psig Burst Pressure (minimum): 1 3,000 psig

MATERIALS OF CONSTRUCTION Innercore: 316l Stainless Steel Braid: 321 Stainless Steel End Fittings: 31 6l Stainless Steel

8200 3900 3220

$3.50 4.00 5.50

Type 304 Stainless Steel Tubing Degreased and Passivated 58-1TSP4-0282 I 1/8 .028 58-1TSP4-0284! 1/4 .028 58-1TSP4-0356 I 3/8 .035

Type 316 Stainless'Steei Standard Tubins 58-1TS6-o282 I 1/8 58-1TS6-o284 1/4 58-1TS6-o356· 3/8

I

.028

.028

.035

Type 316 Stainless Steel Tubins Degreased and Passivated 58-1TSP6-o282 I 1/8 .028 58-1TSP6-o284: 1/4 .028 58-1TSP6-0356 I 3/8 .035

i

Standard Copper Tubing (Annealed)

58-1TC-0302 : 1/8 I 58-HC-0496 I 1/4 58-1TC-0656 . 3/8

.030

.049

.065

8200 3900 3220

8200 3900 3220

8200 3900 3220

2500 2200 2412

7.00 8.00

11.00

4.00 4.50 6.00

7.50 9.00

12.00

2.00 2.50 4.50

Steel sold in random lengths 17 to 24 feet. Copper sold in 50 fool coil. Special cuts subject to S 13.00 charge,

Note: Contact the nearest Scott facility for pricing of tubing quantities above 100 feet.

3 of 4 Scott

EQUIPMENT SECTION 6

Delivery System AccesSories

We offer straight lengths of stainless steel tubing (for corrosive service) as well as coils of copper tubing (for non-corrosive service) to allow flexibility in the design of specific industrial and laboratory fluid sys­tems. They are ideal for use in remote ventilation systems so that hazardous gases do not endanger the immediate work area in the event of equipment fail­ure. The option of having the stainless steel tubing degreased and passivated is available. This process removes all traces of oil, grease and dirt and insures optimal corrosion resistant performance. Consid­eration should be given to pressure, flow, and corrosion resistance requirements when selecting the proper tubing.

261

4 OF- 4 Scott

Multi-Purpose Automatic Change-Over Manifold Model 8501 The Scott Multi-Purpose Automatic Change-Over Manifold offers a safe, economical means to deliver an uninterrupted supply of gas. It is designed to maintain a constant delivery pressure during automated cylinder bank change­over. By preventing unscheduled downtime, it reduces Operating costs and increases productivity. Includes pressure regulators for a complete gas handling system.

BENEFITS • Eliminates costly downtime by provid­

ing constant uninterrupted gas flow.

• Enhances safety by consolidating cylin­ders into a centralized location.

• Improves system purity with system vent for purging flexible pigtails.

Automatic cylinder bank change-over reduces operating and labor costs.

• Alerts operator when cylinder changeout is required (with optional annunciator).

Model 8501 Multi­Purpose Automatic

Change-Over Manifold with Optional

Annunciator

MATERIALS OF CONSTRUCTION Panel: 14 Gauge Sheet Steel, Epoxy Painted Pigtails: Rigid Brass with Brass CGA Check Valves: BrasslViton 11.-·---- -I

SPECIFICATIONS Ball Valves: BrasslTeflon ,...~_....8._--""--_~,

Regulators (Model 51-711): @ Inlet Pressure Rating: 3,000 psig Operating Temperature: -50°F to 150°F Delivery Pressure: 2-75 psig, 2-90 psig for O! service (other ranges available) Flow Capacity: 200 SCFH (other ranges available)

Brass/31 6L SS!f efzel!f eflon @

Power Requirement (for optional annunciator): 11 5/60 Vac Connections (Process/Vent): 1/4" NPT - Outlet

OPTIONAL EQUIPMENT • Flow Limit Shut-off Valve • Pressure Relief Valve • Indicating Pressure Switch • Annunciator Panel • Gas Cabinet • Flash Arrester • Regulator Bonnet Venting Weight: 35 Ibs. • Stainless Steel Flexible Pigtails

Model No.

8501-B-XX-2B-o-tJO

1501-5-XX-22-o-BA

• Armored Pigtails

Description

Multi-Purpose Automatic Change-Over Manifold

(Brass) Annunciator Multi-Purpose Automatic Change-Over Manifold (Stainless Steel) with Annunciator, Not Available for Oz Service

$2,087.ocr

3,796.00

3,519.00'

5,228.00

These fXices do nol include options. Refer to Product Datasheel 8S00 for complete model number and pricing information. Add S38S.00 for Oxmen Service.

@

c:J

8501

I-- 4"--1 0 I

12"

1 0

o == 0

0

Betalert (8501)

T 18'

1

EQUIPMENT SECTION 6

Gas Delivery Systems

\-8'-1

T 18'

'--+}--Jl

f.-7.1/2"--j

I 12'

1 251

..... . .. ,.. Fermllab MDT tube trailer connection tubiog

Pressure Testioc Permit*

Type of Test: ["h Hydrostatic

Test Pressure: 1100/0(2500 psi) = 2750 psig

Maximum Allowable Working Pressure: 2500 psig

I

2/15/2001

Items to be Tested: Connection flex hose. tube trailer fill station. and 3/8" OD tubing run to

Scott Manifold in gas shed.

Location of Test: South side DAB tank farm ___ Date: February 2001 or March 2001

Hazards Involved: Minimal hazards. small size tubing. hydrostatic test.

Safety Precautions Taken: Flex hose will be safety chained (as it normally will be).

Special Conditions or Requirements: Test location is in a minimal traffic area. Will control

perimeter during the test. Temperature must be above 32 F.

Test Coordinator: Russ Rucinski DeptIDate PPDlETTIDO 211512001

==~~ st.'&.~~ifW W9/ol

~------------------------------------------------------

• Must be signed by division/section safety officer and division/section head prior to conducting test. It is the responsibility of the test coordinator to obtain signatures. Fermiiab ES&H Manual S034TA-l

Rev. 4/92

., L Fermilab 211412001

Assembly HaD ,to Collision HaU jumpers, internal pipes

Pressure Testing Permit*

Type of Test: [,I] Pneumatic - Gas nitrogen or argon

Test Pressure: Helium lines = 110%(365 psid) = 400 psjd:

Nitrogen lines = 110'/0 (165 pOO) -180 psid

Maximwn AUowable Working Pressure: Helium' 350 psig + vacuum

Nitrogen: 150psig + vacpwn Items to be Tested: VLPC lines (6). Solenoid lines (5) Note: Lead flow lines are EXCLUDED.

These are all small lines. < %" pipe. Location of Test: D-Zero A!;s'y Building Date: Last two weeks of February 2001

Hazards Involved: Minimal hazards, vC!)' little store energy.

Safety Precautions Taken: Reliefvalve on source will ensure no oyerpressurization. Bavonet ends will be pointed in. safe direction. 15 foor radius in yicinity ofeods will be evacuated. Special Conditions or Requirements: Vacuum Jacket will be evacuated to < 5 torr,

Test Coordinator. Russ Rucmski DeptlDate PPD/EITIDO 211512001

DivisioolSectioo SafetyOffi;~ r/.k~4, peptlDate /h~-4J.r/O I Division/Section Head ~ ,.J', ~~te jlJ1;yfi.(.RiZ R~s, ____________ #-____________________________________ _

• Must be signed by division/section safety office- and division/section head prior to conducting test. It is the fesponsibil ity of the test coordinator to obtain aignatures. . Fermilab ES&H ManuoJ 5034T A-I

Rev. 4/92

=c JF Fermil~M~ __ ~ D •• CAA26E P,P,.J6

Type of Test:

EXHIBIT B Pressure Testing Permit·

[] Hydrostatic M Pneumatic 6He..

Test Pressure: 3'70 psig MayjrnumA1lowab1eWmkingPIessure: 350 psig"t-~!~

Items to be Tested 2.. COMP~e:SSOR. D'~H1A$ee PIPE. , GAS H!:'-lUM Cc:oL powtJ •

LIt-lE:,. (0 f"T3 \/OLUME.. 2" PIPE.. MA.-t..,..AUM s.rz . ..E..

D.rl. A \ 'OJ C:a" e. TAoN I(. P, L..L. ~ ~ J t> LocaDoa of Test w -:;'5. ~ B LD6 • Date and TDDC ~L.'- oT'MER. ~ '''5/~'' Hazards Involved 5-r0ft.E:P E."'J£;g6~:: '537, ceo .f'+\"os ~ IS, 6.CAI.o\S TNT p,SiR$U'ffit>

OVE.R 650 F'E&T OF P,PI1'oJ6.

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COM~M:!::~~\..\-z..E. 11-\G 5~~t> EJ..JERE:t."/.4. DMI\PE:r-J Pass IBLc RE:.L'C;f\SE. . 2ATG.

SpecialCooditionsorRequircments PIPlt-J& Vl.JlL.l. BE. OOue,u:: ISOL.~\"E;.p FRO""

ittE. 1E.\J~\ll.otJ Hl60H ~S\JU H~'E:.IZ... t-JEE..b To uSr.. c..L.~ 6#\S ttE.t....uU (4 50 PPM. (..OJo.,)"T'A.lJ ...... _"t"') t='o~ -n:s-r.

Test CoOrdinator Ru 'Os 'Ru Co \IUS K.\ DcptIDatc PPD I E"TT I rx/J #6 J '17

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• Must be signed by cti~ safety officeI' and divisioolsection bead pi« 10 conducting leSt. It is abe teSpOPSibiJity of abe leSt coordiDator to ob1ain signabJres...

S034TA-4 Rev. 4192

R. Rucinski Date: 5/6197

Notes;

COMPRESSOR DISCHARGE & HELIJ!M PIPING

PRESSURE TESTING PBOCEDJ!BE

[Pressure testing pu>ing per ANSIIASME B31.3 Piping code]

A. 350 psig II1lpped volume reliefs are not instaJled for test. B. 400 to 425 psig relief on source is IOquired. C. Walk thru by the engineer before pressurizing to check valve line up and throttle

valves (MV-2005-H, MV-3024-H, MV-4023-H, MV-4024-H. D. Vacuum jackets around pipes shaJI be at full vacuum during test. E. Record vacuum jacket pressure before and after test for indication of leak to vacuum.

Procedure;

J. Pump and backfill to I psig with clean helium to < 50 ppm. To accomplish this do at least;

One pump to 34 microns and a backfill, or Two pump and backfill cycles to 5 TOlT, or Three pump and backfill cycles to 27 Torr, or Four pump and backfill cycles to 62 Torr, or Five pump and backfill cycles to 103 Torr

2. Take care of notes listed above. 3. Meet special conditions and requirements on permit 4. Get a hold of the pressure test "Witness". 5. Pressurize piping to 195 psig and hold. Check accessible gages or transmitters on

system to confirm pressure is in all test sections. 6. Watch 195 psig pressure for at least 3 minutes. !fno or little pressure drop is seen,

proceed. 7. Pressurize in steps of 40 psig uJ? to full test pressure. Holding for at least 3 minutes at each step. Note, full test pressure 15 390 psig. 8. Watch isolated system for 5 to 10 minutes at full test pressure. !f no pressure drop is seen, bleed down piping system to 310 psig. 9. Snoop fittings, flanges, valve stems and threaded fittings for leaks. A helium sniffer

detector can also be used. . 10. After the leak cbeck, bleed down the system. II. Pressure test can be considered complete.

After the tese 12 Remove pipe plugs and install 350 psig trapped volume reliefs. \3. Bring system up to 325 psig and isolate source. 14. Snoop relief threaded coonection and ootlets to be sure they are sealed. IS. After the leak check, bleed down the system. Remove test equipment

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Type of Test:

Fermilab MoeH?1 C,A1',O"...}

Compressor Discharge pipe section EXHIBITB

Pressure Testing Permit*

Dec. 30, 1998

[] Hydrostatic [..J] Pneumatic - Gas Helium

Test Pressure: 390 psig Maximum Allowable Working Pressure: 350 psig

OF- 4

Items to be Tested: Approximately 150 feet of 2" sch. lOs pipe which includes several valves

and fittings. The pipe is the compressor discharge pipe from MV -2005-H on the berm to EVXl

and EVX2 the STAR heat exchanger inlet valves.

Location of Test: D-Zero Ass'y Building ____ Date and Time: January 1999

Hazards Involved: Minimal hazards. 'Vel)' little store energy. . .

Safety Prt?P'clutions Taken: Personnel will be at least 5 feet away from piping at maximum

pressure: 400 to 425 psig relief on Ghe source is required.

SpeCial Conditions or Requirements: This section has been previously tested. only 4 new welds

have been added. Tev system is isolated by three (two locked) valves from this system.

Procedure: Bag new weld joints. Pressurize to 195 psig hold for 3 minutes. pressurize in 50

psig increments holding 3 min. each step. Full pressure is 390 psig. Hold at 390 psig for 5

minutes. Bleed down to 310 psig and sniff bagged weld joints with helium sniffer. Repair

weld and repeat if leaks are detected. After successful1eak check. bleed down and test is

complete.

Test Coordinator: Russ RUC~ lo~a5'

? Dept/Date PPD/ETT/DO 12130/98

Division/Section SafetyOffi~r . ~ Division/Section Head __ -+.......,.'-#-_______ _

/ Dept/Date m/fSH- 15&1199 Dept/Date 2/!('? r

Results ?-tS1'QA He'-O f>ltessCJ£E F~~ EX-rEAJoeO A~&..I) 'fIMBS.

~--=""":::":::';::;::""""=--==--__ -'---_ Dept/Date PPD/~ Ll ... 'CI...qCS

* M st be signed by divis secti6~ safety officer and division/section head prior to conducting test. It is the responsibility of the test coordinator to obtain signatures. Fermilab ES&H Manual 5034TA-l

Rev. 4192

2 of 4

/oo~;

}

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=c» Fermilae=-ur-e,. P,P'o-lc,

EXHmIT B Pressure Testing Pennit*

Type of Test: W Hydrostatic . [ ] Pneumatic

Test Pressure: '2 ec>O psig Maximum Allowable Working Pressure: 2 'joo psig Items to be Tested '-lEL....IUM -rUBe.. -rRAH • ..E:12. EI Lt... S.-rA.'-IO~.

1!...lG.LuDC.cs, Two 12. FooT L-Or..J(:,. +-\ OSlCS too,..) D ""' GAG-Eo.

Location of Test D 1\ B Sou~ LOT Date and Tune 4/, B 7:00 A~ HazardsInvolved Wl::"PPIt-J~ -l-\OSE: J BLOW 1r-.J6 bUST At.JD Cxe..A\JeL

'F PAIt...LJRt::.. oc..c..u~s.) L-QuD ...... OlSE,.

Safety Precautions Taken "DSE..S WILL.,.; BE.. Ar-.lc...HOR-~ AT EAC-H E..,JD.

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Special Conditions or Requirements t-J~E., seE:: ATl"A-c.ttc-i) ~ a:-ou~ .

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5034TA-4 Rev. 4/92

Fermilab ES&H Manual

R. Rucinski . Date: 4114197 '2 oF- (0

BELWM FILL STATION PIPING

HYDROSTATIC PRESSURE TESTING PROCEDURE

Equipment

See Exhibit A for pressure testing equipment set up.

See Exhibit C for scope of piping to be tested.

Procedure

1. Pressurize piping to 25 psig and hold. 2. Inspect fittings, flanges, and threaded fittings for leaks. Fix leaks if necessary. 3. Take pressure up to about 2000 psi.. Isolate the source. 4. Watch gage pressure for five minutes. If no pressure drop is seen, proceed. 5. Take to design pressure, 2500 psig and isolate source. 6. Watch gage for 5 to 10 minutes. If no pressure drop is seen, proceed. 7. Take to full test pressure, 2800 psig and isolate source. 8. Watch gage for 5 to 10 minutes. If no pressure drop is seen, proceed. 9. Bleed down the system. 10 Test is completed. Record results and have witnesses sign test record.

Design Pressure: 2500 psig, max. tube trailer pressure. [Normal maximum tube trailer pressure ... 2300 psig.]

Per par. 345.4.2 (a) Normal hydro test pressure would be 150% design pressure - 3750 psig. Paragraph (c) however allows reducing the test pressure if a component would be subject to itls yield strength. The weakest identifiable component in the system are the 1" VCO fitting connection rated at 2800 psig. This is probably due to the o-ring. Exceeding that pressure could cause the o-ring to fail. Therefore the test pressure will be limited to 2800 psig or 112% design pressure.

Valves have 3000 psi rating, the hoses have 3600 psi rating, some of the elbows are stamped rated at 3000 psi. The piping and some of the pipe elbows are not identifiably rated, but making some assumptions, are probably good to 4300 psig.

Ind~pendent Reyiew

The mechanical subcommittee chair of the D-Zero ES&H review committee has been notified of the pressure test. Harry Carter, chair of the subcommittee, reviewed the pressure testing permit and made a field visit to look over the installation of the gage panel at D-Zero. His comments were appreciated.

J ,HAY/T ~€"Y'1!Ve1J 7}Ie .()()~~'T1I1loIJ ANP II'JSTAtWtT>oAJ Aovt> tfe:-C()!'l"tnV/) 7)(Ar ~I/Ift.. ~E" (Jlt/6JtI ,q~ 7#ts 7/i1ir: >#~ -1/11/97

SCHI~TIC SITU' ;OR ,RESSURE TEST EQUI'"ENT

IhI'C' Idief Val.,.

t. ll!I1If6tlC mi. tlST

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I., Fermilab

EXHIBITB Pressure Testing Permit""

Type of Test []Hydrostatic tJ.Pneumatic

Date: {2/lti/o '2.

'335 Test Pressure Z/;.$"" psig Maximum Allowable Working Pressure

"3S-0 __ ~..::.....)_-__ psig

v-1vf,~..J

~~-+~~~~~~~~~~~~~~~~~-L~ __ ~~~~~~~Q~~~JB~~~

Location of Test P2(?n;J !1I.le6 t Iv hlfi /!Date and Time

i~ ~dIt'b.., <014 //Oh ,J- re/vlf/tr., /6 r:t:... r, V &- r V Hazards Involved

fJ"%wr £a; Ie//'.t< .

Qualified Person and Test Coordinator Dept/Date

DivisionfSection Safety Officer Dept/Date

e f 12 Dept/Date

* Must be signed by division/ section safety officer prior to conducting test. It is the responsibility of the test coordinator to obtain signatures.

FermilabES&H Manual 5034TA-1 Revised 3/2001

Dzero Engine Valve Box and Transfer line High Pressure Side Pressure Test Procedure

R Sanders 12/16/02

The purpose of this his procedure is to pressure test the piping components of the new Dzero dry engine valve box, transfer-line and u-tubes. The new dry engines and previously existing cryogenic system will not be pressurized during this test.

There are two separate piping subsystems being pressure tested. The high pressure piping subsystem will be rated at 350 psig and tested to 110% above that to 71.5 psig. The low pressure piping subsystem will be rated at 65 psig and tested to 110% above that to 385 psig. The stored energy in the high pressure test is 9479 ft-lbf of energy. The energy in the test of the low pressure piping is much lower.

STEP 1) As noted on the attached marked up copy of drawing 3823.115-ME-399556, barricade and rope off areas and post warning signs in the Dzero assembly hall around the piping components being tested.

STEP 2) For the test of the high pressure piping components install the pressure test equipment with a 420 psig set pressure relief valve installed. Remove SV-2174-H and install pressure test line on its port.

STEP 3) setup the following valve line-up which is also shown on the attached marked up copy of the flow schematic 3823. 115-ME-399449 //5 -2{5

MV-2170-H epe". i"seFl H IHbe CJ-t:ret/" J'?p I{ - /./e ~OI-f7U';;;'{ ) /MV-2171-H open V Y MV-2172-H open v1\IiV-2173-H open, insert u-tube YMV-2174-H open, insert u-tube /MV-217S-H open vMV-2176-H open t/SV-2170-H Plug or remove ;/ ~V-2173-H Plug or remove / vi ~. j ~ /" 7 VSV-2174-H romo¥e aAd eOAAeot pressure test lilie 1'(7)" '?T/;.,.p I'fJl1.l'1lqr/ll fR'I~ v MV-2136-H He-212 u-tube not inserted, this valve is not part of cal' rC>l~ / /' pressure test er In pl'.p,.~Y;bt- v/ey/dj]A., ~5r~p.

V MV-2336-H closed, no u-tube inserted ;/ MV -2436-H closed, no u-tube inserted

STEP 4) On each of the u-tubes He-212, He-216, He-218, insert one end into either the engine valve box or transfer line and do not insert the other end. Cap the open ends of

these u-tubes so that they hold pressure. Do not pressure test the dry engines or the satellite refrigerator.

STEP 5) pressurize the piping in steps of 25, 100,300 and 385 psig. Hold for five minutes at each pressure. There should be no leaks. Fill out the following table. If there are leaks or other problems close off the pressure source and vent the system pressure before investigating.

PRESSURIZE TO: time start time finish comments

200 psig

300 psig

385 psig

STEP 6) close off the pressure source and vent the system pressure completely.

STEP 7) Next For the test of the low pressure piping components; replace the pressure relief valve with a 75 psig set pressure relief valve on the pressure test equipment. Remove the pressure test line from the SV-2174-H port.-Remove the vaive S¥-2274 H and connect the test pressure line onto its peR. iJ'7IP"''''~T cgl' ~~~

STEP 8) Setup the following valve line-up which is also shown on the attached marked up copy of the flow schematic 3823.115-ME-399449.

/MV-2270-H /MV-2271-H /MV-2272-H /MV-2273-H YMV-2274-H V'MV-2275-H /MV-2276-H /MV-2277-H I MV-2278-H /MV-2279-H ~V-2280-H ISV-2270-H I SV-2273-H

. open, insert u tube open open open, insert u-tube open, insert u-tube open open closed closed open open Plug or remove Plug or remove

-F SV -227 4-H v"SV -2278-H

MV-2136-H

/MV-2447-H (/ MV-2347-H

,remeve and eonAect pressul"e test line~ ptJj//' Plug or remove . He-213 u-tube not inserted, this valve is not part of pressure test closed, no u-tube inserted closed, no u-tube inserted

STEP 9) On each of the u-tubes He-213, He-217, He-219, insert one end into either the engine valve box or transfer line and do not insert the other end. Cap the open ends of these u-tubes so that they hold pressure. Do not pressure test the dry engines or the satellite refrigerator.

STEP 10) pressurize the piping in steps of 25 and 71.5 psig. Hold for five minutes at each pressure. There should be no leaks. Fill out the following table. If there are leaks or other problems close off the pressure source and vent the system pressure before investigating.

PRESSURIZE TO: time start time finish comments 25 psig

, hc~ ~ ."e..;r...r /f7j'Yl5 t) ?J;;' ~~t?2

71.5 psig .:Pff!) "2- Ore? 7 h ,~.;r~""'~.:r..r. ,

STEP 11) close off the pressure source and vent the system pressure completely. Remove plugs from or reinstall relief valves.

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C Fermilab Date: 08/07/2006

EXHIBIT B Pressure Testing Permit*

Type of Test: []Hydrostatic [x] Pneumatic

Test Pressure _49_5 ___ psig Maximum Allowable Working Pressure

Items to be Tested 1. Dewar # 39 LN2 fill connector brazed joint (recently repaired) 2. Dewar # 42 LN2 fill connector brazed joint

Location of Test

Hazards Involved Brazed joint rupture

Safety Precautions Taken

DAB gas yard Date and Time

_45_0 ____ psig

08/14/2006

Both joints are secured (bolted to posts) to prevent their separation from the pipes. Relief valve cracking pressure set to 499 pSig. Fences/yellow safety tape will be used to prevent unauthorized access .. Vessels (Dewar # 39 and Dewar # 32) will be double isolated from ressure source - see attached test flow dia rams.

, d. ·.har~~ Special Condl ons ~equirements None

Qualified Person and Test Coordinator Dept/Date

Division/Section Safety Officer Dep t/D ate

Witness (Safety Officer or Designee)

Michael Sar chev PPD/MD/DzeroOps 08/07/2

Dept/Date S. /1/ alP

.. Must be signed by division/section safety officer prior to conducting test. It is the responsibility of the test coordinator to obtain signatures.

Fermilab ES&H Manual 5034TA-1 Revised 3/2001

-TO DEWAR 39

DEWAR BRAZED

39 LN2 FILL CONNECTOR JOINT TEST FLOW DIAGRAM

MV-2760-N; MV-2761-N AND PV-2736-N CLOSED

SV-2757-N MV-2760-N 150 PSIG TOP FILL VENT

FILL CONNECTION MV-2761-N

BOTTOM FILL PV-2736-N

TEST SOURCE GAUGE

FROM N2 BOTTLE -

MV-2759-N

VENT TO AIR

SOURCE RELIEF VALVE

SET 499 PSIG TEST GAUGE

TEST JOINT

FILL CONNECTOR DEWAR BRAZED

42 LN2 JOINT TEST FLOW DIAGRAM

NITROGEN TRUCK CONNECTION FILL LINE

ST-569-N

MV-525-N; MV-511-N AND PV-540-N CLOSED

TEST JOINT

TEST SOURCE GAUGE

FROM N2 BOTTLE -

VENT TO AIR

SOURCE RELIEF VALVE

SET 499 PSIG TEST GAUGE

PV-540-N A.T.O.

SPRING CLOSED

CV-522-N

Z I

If) N If) I

> ~

TOP FILL

t

Z I ~

~

If) I

> ~

BOTTOM FILL

TO DEWAR 42