360-PG-8710.0.2 High Pressure Systems Operator Certification.pdf

DIRECTIVE NO. 360-PG-8710.0.2A APPROVED BY Signature: Original Signed By EFFECTIVE DATE: December 8, 2020 NAME: Bo Lewis EXPIRATION DATE: December 8, 2025 TITLE: Chief, Safety Division

CHECK THE GSFC DIRECTIVES MANAGEMENT SYSTEM AT

http://gdms.gsfc.nasa.gov TO VERIFY THAT THIS IS THE CORRECT VERSION PRIOR TO USE.

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Center-wide

Procedures and Guidelines (PG)

COMPLIANCE IS MANDATORY

Responsible Office: 360/Safety Division

Title: High Pressure Systems Operator Certification

PREFACE

P.1 PURPOSE

The purpose of this document is to ensure that personnel who operate GSFC high-pressure systems are properly trained and certified. This procedure provides steps for certifying personnel as High Pressure

Systems Operators (HPSOs) as required by NASA’s Policy for Pressure Vessels and Pressurized

Systems (NPD 8710.5). The certification process contained herein is intended to satisfy the requirements outlined in Chapter 7 of NPR 8715.3, NASA General Safety Program Requirements.

P.2 APPLICABILITY

This procedure applies to all personnel – including contractors (excluding construction) – that are required to operate Pressure Vessels and Pressurized Systems (PVS) that meet all of the following conditions:

• PVS is ground-based (non-flight) and subject to the requirements of NASA-STD-8719.17

• PVS is owned, operated, or maintained by GSFC, or, contractor/tenant/transients (excluding construction) on GSFC facilities

• PVS is operating at pressures that exceed 150 psig

Notes:

• Pressure systems with regulator and pressure relief device with

150 psig set pressure or lower, installed on DOT compressed gas cylinders (K-Bottles) are considered low-risk systems. Therefore, operators who operate or change out the DOT compressed gas cylinders are not required to be certified under this program. It is the responsibility of the employee’s supervisor to ensure that the employee is adequately trained to operate DOT compressed gas cylinders.

Operating PVS that conveys or contains propellants such as hydrazine, mono-methyl hydrazine, nitrogen tetroxide or other hazardous fluids requires additional specialized training that is not covered by this PG.

Hazardous materials definition can be found in US DOT 49CFR Subpart A, Paragraph 105.5.

a. In this document, all citations are assumed to be the latest version unless otherwise noted.

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EFFECTIVE DATE: December 8. 2020

EXPIRATION DATE: December 8, 2025

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b. In this document, all mandatory actions (i.e., requirements) are denoted by statements containing the term “shall.” The terms “may” or “can” denote discretionary privilege or permission; “should” denotes a good practice and is recommended but not required; “will” denotes expected outcome; and “are/is” denotes descriptive material.

P.3 AUTHORITY

a. NPD 8710.5, Policy for Pressure Vessels and Pressurized Systems

b. NPR 8715.3, NASA General Safety Program Requirements

P.4 APPLICABLE DOCUMENTS AND FORMS

a. NASA-STD-8719.17, NASA Requirements for Ground-Based Pressure Vessels and Pressurized

Systems

b. NPR 1800.1, NASA Occupational Health Program Procedures

c. GSFC Form 17-129, GSFC High Pressure System Operator Certification

P.5 CANCELLATION

360-PG-8710.0.2-, High Pressure Systems Operator Certification

P.6 SAFETY

N/A

P.7 TRAINING

Training requirements are specified in Section 1.2.

P.8 RECORDS

Record Title Record Custodian Retention

Record of Certification Pressure Systems Manager

NRRS 3/33G

DESTROY 5 YEARS

AFTER SEPARATION OF

EMPLOYEE OR WHEN

NO LONGER NEEDED

SATERN Training Certificates SATERN Database 2 years

* NRRS – NASA Records Retention Schedule (NRRS 1441.1)

P.9 MEASUREMENT/VERIFICATION

The GSFC Pressure Systems Manager (PSM) will verify the number of high pressure systems operators certified against available high pressure systems operators who are not certified.

http://nodis3.gsfc.nasa.gov/

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PROCEDURES

1 CERTIFICATION REQUIREMENTS

No person shall operate a high pressure system at GSFC without being certified in accordance with the following process.

1.1 PROCESS

Personnel are certified by the following process:

a. Complete general training

b. Pass medical exam

c. Complete on-the-job training (OJT)

d. Pass written exam

e. Fill out and submit the HPSO Certification Request Form GSFC 17-129 (located in https://nef.nasa.gov/) to the PSM for review.

The general training and medical exam shall be taken before starting the on-the-job training.

HPSO certification is achieved upon PSM approval of the HPSO Certification Request Form and the issuance of a certification to the operator.

1.2 GENERAL TRAINING

The following courses are required for certification and may be provided by the NASA Safety Training

Center. Registration is available through SATERN:

a. High Pressure Systems Operations and Flexible Hose Safety (SMA-HQ-WBT-301) and, Safety of

Compressed Gas Trailers and Compressed Gas Cylinders Seminar, (SMA-HQ-WBT-302); Or:

b. GSFC-Basic High Pressure Systems Training, (GSFC-SH-HPST); Or;

c. Equivalent training may be accepted pending the review and approval of the PSM.

1.3 MEDICAL EXAM

The candidate shall demonstrate “fitness for duty” by showing they have passed a medical exam within the last two years. The scope of the medical exam shall at a minimum cover:

a. Audiogram: Hearing loss in better ear <40 dB at 500, 1,000, 2,000 Hz with or without hearing aid

b. Visual Acuity: 20/40 with or without corrective lenses

c. Visual Fields: at least 70 degrees in each eye

The operator must pass this exam no less frequently than every two (2) years to maintain their HPSO certification.

https://nef.nasa.gov/

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1.4 ON-THE-JOB TRAINING

An HPSO candidate’s On-the-Job Training (OJT) is provided by the OJT Trainer. The OJT trainer, who is approved by the PSM, may be the Lab Manager, Lab/System Owner, Branch Head, HPSO Senior

Technical Expert, and/or Supervisor. Training continues until the trainer is satisfied that the candidate is proficient at operating high pressure systems. Proof of OJT is provided by the trainer’s signature on the

HPSO Certification Request Form. There is no time limit on completing OJT.

OJT should cover at a minimum the following activities:

a. Assembling high pressure systems (e.g. k-bottle → pressure panel → pressure vessel)

b. Inspecting pressure systems (physical condition, design conformance, calibration and certification dates etc.)

c. Operating high pressure systems (e.g. pressurizing and venting vessels using pressure panels)

d. Troubleshooting (e.g. finding leaks at mechanical fittings and through valves)

e. Rendering a system “safe” when work stops

f. Disassembling high pressure systems

g. Emergency shutdown/safeing procedures and awareness of system hazards

h. Awareness of system-unique parameters/requirements (environmental, contamination, cleanliness, etc.)

1.5 WRITTEN EXAM

a. The candidate shall pass a PSM-approved written exam which should be administered by the pressure system owner. The PSM can help the owner by supplying sample questions and a guide as to what is expected to be included in a written examination.

b. The exam shall test the candidate’s knowledge of how to operate pressure systems safely.

c. The exam shall consist of at least 10 questions, and the candidate must obtain a minimum score of

70% to pass.

d. The PSM shall verify the candidate has passed this written exam before signing the candidate’s

HPSO Certification Request Form.

e. Graded exams shall be retained with the HPSO Certification Request Form.

1.6 HPSO CERTIFICATION REQUEST FORM

The candidate and the OJT Trainer should fill out the HPSO Certification Request Form GSFC 17-129 when all training, medical exams, and written exams are complete. The HPSO Certification Request

Form – along with supporting documentation – shall be submitted to the PSM for review and signature.

1.7 RECORD OF CERTIFICATION

A record of an individual’s certification is identified through the issuance of a card, license, or badge (to be immediately available) or a listing on a personnel certification roster or database. Personnel certification rosters indicate the name, date, materials or operations for which certification is valid, name of certifying official, and date of expiration. (See Appendix C for sample HPSO Certification Card.)

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1.8 RECERTIFICATION

a. Unless approved by the PSM for extenuating circumstances, recertification shall be every four years or sooner.

b. The HPSO shall show proof of having passed the medical exam.

c. The HPSO shall repeat the general training defined in Section 1.2.

The same HPSO Certification Request Form shall be submitted to the PSM with the “recertification” box (□) checked.

1.9 CANCELLATION OF CERTIFICATION

The PSM may revoke certification at any time if it is believed the operator cannot safely perform their duties or is not operating high pressure systems safely. If an operator’s certification is revoked, recertification requirements will be determined by the PSM.

1.10 ALTERNATE PROGRAM FOR TENANT AND/OR TRANSIENT

CONTRACTORS/ORGANIZATIONS

A tenant and/or transient contractors/organizations, who have their own high pressure certification program, may submit such program documentation to the PSM for equivalency determination and approval. If approved, the contractor shall utilize their program in lieu of the requirements in this document. In this case, the PSM may issue a GSFC HPSO individual licenses to assist uniformity of

Validation of the contractors’ approved program is required annually and the contractor must meet with and submit their certification program to the PSM. Due to noncompliance with NASA/GSFC requirements or the contractors own program requirements; the PSM may revoke the contractor’s high pressure systems operator license at any time. In an event of changes made on contractors’ HPSO program, the contractor shall submit their program document for review and approval by the PSM.

Transient contractors/organizations, such as university experimenters, scientists or grant recipients, who plan to operate their high pressure systems at GSFC for less than 180 days, can meet the intent of this program by providing a certification letter that:

a. is signed by their management certifying that specific employees, students or scientists are properly trained, skilled and qualified to operate their pressure systems safely

b. the training program meets the intent of applicable OSHA requirements

c. lists and attaches details of the pressure systems that they plan to operate at GSFC

The certification letter and list of high pressure systems will be reviewed and approved by the PSM.

When approved, the PSM may issue a GSFC HPSO individual license to assist uniformity of

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Appendix A- Definitions

A1. High Pressure System – systems that operate at pressures greater than 150 psig

A2. Tenant – A non-NASA entity or organization that has obtained GSFC’s permission to reside on the Center.

A3. Transient – an individual/organization that is on-center for less than 180 days.

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Appendix B - Acronyms

AETD Applied Engineering and Technology Directorate

DOT Department of Transportation

GSFC Goddard Space Flight Center

HPSO High Pressure Systems Operator

N/A Not Applicable

NPD NASA Policy Directive

NPR NASA Procedural Requirement

NRRS NASA Records Retention Schedules

OJT On the Job Training

PG Procedures and Guidelines

PSM Pressure Systems Manager or designee

PVS Pressure Vessels and Pressurized Systems

SATERN System for Administration, Training, and Educational Resources for NASA

STD Standard

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Appendix C - Sample HPSO Certification Card

GSFC

HIGH PRESSURE SYSTEMS OPERATOR

John Doe

EXPIRES: Jan 1, 2017

Certifying Official:

Joe Smith, PSM, GSFC

This card verifies the person named above has been certified as an operator of GSFC’s PVS per 360-PG-8710.0.1

SAMPLE

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CHANGE HISTORY LOG

Revision Effective Date Description of Changes

Baseline 10/16/2015

Initial release. Administrative change to cancel and replace 500-

PG-8710.3.1 due to change of Responsible Office from Code 500/

Applied Engineering and Technology Directorate (AETD) to Code

360/Safety Division. And to add clarity to training options.

Baseline 11/21/2019

Administratively extended for 1 year and administratively changed to update PG template and correct formatting, updated training titles and removed GSFC Form 17-129 from document and referenced the NASA Electronics Forms (NEF) database.

A

12/08/2020 Revalidated with Administrative Change removing reference to 500-PG-

8710.3.1 in Section P5