Appendix C_AEDC Standards_NOT SENSITIVE.pdf

SOO # 16904-26-001

ATTACHMENT 1

APPENDIX C

2 March 2026

Statement of Objectives (SOO) Attachment 1 – Performance Parameters

Appendix C – AEDC Standards

Standards

1. AEDC-ENGR-STD-T-1 Pressure Vessels

2. AEDC-ENGR-STD-T-2 Pressure Piping

3. AEDC-ENGR-STD-T-5 Welding Practices

4. AEDC-SHE-STD-A09 Hazard Communication

5. AEDC-SHE-STD-B01 Master Work Permit

6. AEDC-SHE-STD-B02 Lockout/Tagout

7. AEDC-SHE-STD-B03 Control of Hazardous Areas

8. AEDC-SHE-STD-B04 High Voltage Electrical Work

9. AEDC-SHE-STD-B05 Confined Spaces

10. AEDC-SHE-STD-C03 Local Exhaust Ventilation

11. AEDC-SHE-STD-C06 Excavations, Trenching, and Shoring

12. AEDC-SHE-STD-D02 Pressure Vessels and Systems

13. AEDC-SHE-STD-D 5 Hoisting Devices

14. AEDC-SHE-STD-C05HBK Hoisting and Rigging Handbook

15. AEDC-SHE-STD-D08 Portable Power Tools

16. AEDC-SHE-STD-D11 Ionizing Radiation

17. AEDC-SHE-STD-D14 Cross Connection and Backflow Prevention

18. AEDC-SHE-STD-E04 Pyrophoric Fuels

19. AEDC-SHE-STD-E07 Asbestos

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SOO # 16904-26-001

ATTACHMENT 1

APPENDIX C

2 March 2026

20. AEDC-SHE-STD-E09 Wastewater Discharge Management

21. AEDC-SHE-STD-E11 Oil Pollution Prevention

22. AEDC-SHE-STD-F04 Respiratory Protection

23. AEDC-SHE-STD-F06 Fall Protection

24. AEDC-CCP-100 Protective Coatings and Corrosion Control Program

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AEDC ENGINEERING STANDARD

TITLE: AEDC Standard Pressure Vessels

STANDARD NO.: AEDC-ENGR-STD-T-1

EFFECTIVE DATE: December 5, 2012

The provisions and requirements of this standard are mandatory for use by all AEDC personnel engaged in work tasks necessary to fulfill the AEDC mission. This AEDC Standard is not sensitive. Please contact AEDC/EN for clarification or questions regarding this standard.

APPROVED:

AEDC/EN

Department of the Air Force

HQ AEDC (AFMC)

Arnold AFB, TN 37389

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AEDC-ENGR-STD-T-1

CONTENTS

PARAGRAPH PAGE

1.0 INTRODUCTION 1-1

1.1 Purpose 1-1

1.2 Scope 1-1

1.3 Deviations/Waivers 1-2

1.4 General Requirements 1-2

1.5 Applicable Codes 1-3

1.6 Definitions 1-4

2.0 DESIGN 2-1

2.1 General Requirements 2-1

2.2 Materials 2-1

2.3 Allowable Stresses 2-1

2.4 Supports and Welded Attachments 2-2

2.5 Windows 2-2

3.0 FABRICATION AND ERECTION 3-1

3.1 By AEDC Operating Contractor 3-1

3.2 By Outside Contractor 3-1

4.0 INSPECTION AND TESTING 4-1

4.1 Acceptance Inspection 4-1

4.2 Testing 4-1

5.0 CERTIFICATION REQUIREMENTS 5-1

5.1 Introduction 5-1

5.2 Certification Report 5-1

5.3 In-service Inspection/Testing (ISI/T) 5-3

6.0 IDENTIFICATION 6-1

6.1 Vessel Tags 6-1

6.2 Pressure System Components 6-1

7.0 TANK-MOUNTED AIR COMPRESSORS 7-1

7.1 Specifications 7-1

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APPENDICES PAGE

A. APPLICATION OF NATIONAL CONSENSUS CODES, STANDARDS, AND LAWS A-1

B. GUIDANCE FOR DESIGN AND CONSTRUCTION OF DUCTING B-1

C. RELIEF DEVICE REQUIREMENTS C-1

D. GUIDANCE FOR DESIGN AND INSPECTION OF WINDOWS D-1

E. IDENTIFICATION TAG E-1

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DATE AFFECTED PAGES

Vertical lines are not used in this revision to identify changes with respect to the previous issue due to the extensive changes. Users of AEDC-ENGR-STD-T-1 are cautioned to evaluate the requirements of this document based on the entire content.

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1-1

1.0 INTRODUCTION

1.1 PURPOSE

This standard establishes minimum requirements for design, materials, fabrication, assembly, erection, inspection, and testing of all new pressure vessels for operation at AEDC. The criteria in this standard also form the basis for evaluation, repair, alteration, defining limits of safe operation, and certification of all previously used vessels for return to service at AEDC.

The Operating Contractor shall define specific roles, responsibilities, and other information processes to ensure the retention of engineering analysis and records of inspection, testing, and certification for all pressure vessels at AEDC.

1.2 SCOPE

For this standard, a pressure vessel is any container for media under pressure, either internal or external, as defined by the American Society of Mechanical Engineers Boiler and Pressure

Vessel Code (ASME BPVC). This standard shall also include all carbon and alloy steel ducting not constructed per ASME B31 piping codes and these, hereinafter, shall be referred to collectively as pressure vessels when not specifically addressed. This standard applies to all pressure vessels for use at AEDC except:

1.2.1 Pressure vessels fabricated from standard pipe, standard pipe fittings, and standard pipe flanges of 6 inch nominal pipe size (NPS) or less. These shall be designed, fabricated, erected, inspected and tested in accordance with AEDC-ENGR-STD-T-2.

1.2.2 Shells, ducting, and piping fabricated from standard pipe, standard pipe fittings, and standard pipe flanges whose primary purpose is to convey gases or liquids. These shall be designed, fabricated, erected, inspected and tested in accordance with

AEDC-ENGR-STD-T-2.

1.2.3 Portable commercial compressed gas cylinders designed in accordance with

Department of Transportation (DOT) standards. These vessels shall be identified, inspected, tested, handled, and stored in accordance with AEDC-SHE-STD-D4

Compressed Gas Cylinders. Note: If a compressed gas cylinder has been repaired, altered or is installed for permanent use in a system at AEDC then that vessel shall be regarded as non-DOT compliant and is subject to the requirements of this standard.

1.2.4 Test cells, vacuum chambers, ballistic range launch tubes, or other unique AEDC pressure vessel configurations may be beyond the scope of industry standards. Any unique to AEDC design approach shall be documented and approved by the

Operating Contractor’s design group.

1.2.5 Vessels furnished as part of a test article.

1.2.6 HVAC ducting. Heating, ventilating and air conditioning ducting shall be designed in accordance with ASHRAE.

1.2.7 Additional exclusions listed in the ASME BPVC section entitled “Scope”.

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1.3 DEVIATIONS/WAIVERS

Under certain circumstances, compliance with all requirements of this standard may be impractical, perhaps impossible. In such cases, the AEDC Operating Contractor shall provide an engineering analysis or statement assessing risk and recommend a reasonable acceptance of risk and/or mitigation over the range of operation. Details of any deviation request for a non-compliance with this standard initiated before fabrication or installation has begun or waiver request for a non-compliance after fabrication or installation has begun shall be prepared and approved in accordance with AEDC-STD-CM-1 Configuration Management, AEDC Safety Standard A4 System Safety, and AEDC Operating Contractor procedures prior to operation.

1.4 GENERAL REQUIREMENTS

1.4.1 Governing Codes. Pressure vessels shall meet the requirements of the governing code as cited in paragraph 1.5 Applicable Codes unless code requirements are modified by this standard. Modified code requirements established by this standard are more restrictive than those contained in the code to provide a greater degree of safety over the operating range of the vessel based upon experience at AEDC.

1.4.2 Operational Limitations. This Standard does not set upper limits based on pressure, temperature, size, or other pertinent factors. However, it must be recognized that certain vessels subjected to ultra-high pressures, high temperatures, low temperatures, severe transient loads, and other unusual conditions may have to be evaluated on an individual basis requiring information that is not contained in this standard or the referenced codes. Therefore, this standard and the governing codes referenced herein should be considered as containing basic reference data and formulas and should not be considered as design handbooks covering all situations.

Use of these documents does not eliminate the need for competent engineering judgment.

1.4.3 Vacuum or External Pressure Service. All vacuum vessels and ducting designed for vacuum or external pressures are within the scope of this standard as defined in paragraph 1.5. The factors in the following warning shall be considered in the design of these vessels.

WARNING

The requirements of the ASME Code, Section VIII for vessels designed for external pressure service may not be adequate. Experience at AEDC during structural evaluation of a large vacuum chamber revealed a size regime wherein a code-designed vessel could collapse under design load conditions. It is recommended that vessels for external pressure service be carefully evaluated to substantiate structural integrity. Axial compressive loading (from external pressure) and out-of-plane (torsional) buckling of stiffening rings must be considered.

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1.4.4 Relocation or Reactivation of Pressure Vessels. Pressure vessels now in service that are to be relocated or vessels currently out of service that are to be reactivated shall be evaluated in accordance with paragraph 5.0 Certification.

1.4.5 Overpressure Protection. All vessels installed at AEDC shall be provided with overpressure protection in accordance with the applicable code. If a relief device is to be used for overpressure protection then that device shall be as specified and installed by the appropriate code. Specific requirements for relief devices are discussed in Appendix C.

1.5 APPLICABLE CODES

The selection of codes applicable for service at AEDC shall be in accordance with Appendix

A and as follows:

1.5.1 ASME Boiler and Pressure Vessel Code Section VIII Divisions 1, 2, & 3. All pressure vessels covered by this AEDC standard shall be designed, fabricated, erected, inspected and tested in accordance with the applicable Division (1, 2, or 3) of

Section VIII of the ASME BPVC. Use Division 1 which employs conservative

“design by rule” methodology for vessels with design pressures less than or equal to the following: the lesser of 1) 3000 psig, 2) five percent of the material tensile strength at room temperature, and 3) five percent of the material tensile strength at design temperature. Division 1 shall be given preference over Division 2. However, Division 2 may be used in lieu of Division 1 when more rigorous analysis is justified.

Divisions 1 and 2 both state that design pressures (internal and/or external) less than or equal to 15 psi are not within their scope. However, Section VIII shall be used for this pressure range unless excluded elsewhere in this standard. Design for external pressure shall be supplemented with sound engineering judgment and analysis. See paragraph 1.4.3. Division 3 is applicable to vessels with design pressure generally above 10,000 psi.

1.5.2 Modified Code Requirements for AEDC Service. Modified code requirements established specifically for AEDC service are noted in the table below:

Service/Feature Standard Section

Hazardous Liquid Propellant Fuels and Oxidizers Appendix A

Vacuum/external pressure service 1.4.3

Ducting not constructed per ASME B31 codes Appendix B

Evaluation of used vessels 5.1

Vessels with unknown history 5.1

Impact test requirements 4.2.8

Multi-layer/banded vessels Appendix A

Metal support structures 2.5.4

Concrete supports 2.5.5

Supports, anchors & attachments 2.5

Vessel identification 6.1

Pressure component identification 6.2

Air compressors 7.0

Windows Appendix D

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1.5.3 Pressure Vessels.

a. All newly procured pressure vessels for AEDC service shall be Code-stamped unless particular requirements preclude Code design or fabrication. When there is an application requiring pressure vessels, heat exchangers, or pressure containing devices, such as accumulators or filters, where a determination of

Code Stamp applicability is needed, then that decision shall be documented and approved by the Operating Contractor’s responsible engineering group.

b. Existing Code Stamped vessels at AEDC with a Code Stamp are to be repaired or altered in strict compliance with NB-23 and shall require the work to be performed by a company possessing “R” Code Stamp. All repairs and alterations of pressure vessels shall be governed by the latest edition of the National Board of Boiler and Pressure Vessel Inspectors ANSI/NB-23, National Board

Inspection Code (NBIC) as noted in Appendix A.

c. Existing vessels at AEDC without a Code Stamp may be repaired or altered in accordance with this standard and do not require the work to be performed by a company possessing “R” Code Stamp. All repairs and alterations of pressure vessels shall be governed by the latest edition of the National Board of Boiler and

Pressure Vessel Inspectors ANSI/NB-23, National Board Inspection Code

(NBIC) as noted in Appendix A.

d. The Government and the Operating Contractor do not have the authority to affix

ASME “U” and “R” Code Stamps to pressure vessels.

e. An ASME Code stamp is not applicable for ducting designed using this standard.

1.5.4 Welding. All welding shall be in accordance with AEDC-ENGR-STD-T-5 for welding, fabrication, etc.

1.6 DEFINITIONS

1.6.1 Alteration- Any change in the item described on the original Manufacturer’s Data report which affects the pressure containing capability of the pressure-retaining item.

Nonphysical changes such as an increase in the maximum allowable working pressure (internal or external) increase in design temperature, or a reduction in minimum temperature of a pressure retaining item shall be considered an alteration.

1.6.2 Certification – The process for ensuring through configuration verification/validation, non-destructive examination, engineering analysis and test, the integrity of a pressure vessel. Once certified, an in-service inspection and configuration management are required to sustain certification.

1.6.3 Design Pressure - The pressure used in the design of a vessel component together with the coincident design metal temperature, for the purpose of determining the minimum permissible thickness or physical characteristics of the different zones of the vessel. When applicable, static head shall be added to the design pressure to determine the minimum required thickness of any specific zone of the vessel. It is

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1-5 recommended that a suitable margin be provided above the pressure at which the vessel will be normally operated to allow for probable pressure surges in the vessel up to the relief set pressure of the pressure relieving devices.

1.6.4 Design Temperature:

a. Maximum - The maximum temperature used in design shall not be less than the mean metal temperature (through the thickness) expected under operating conditions for the part considered. If necessary, the metal temperature shall be determined by computation or by measurement from equipment in service under equivalent operating conditions.

b. Minimum – The minimum mean metal temperature shall be determined by consideration of the lowest operating temperature, operational upsets, auto refrigeration, atmospheric temperature, and any other sources of cooling. The

Minimum Design Metal Temperature (MDMT) marked on the nameplate shall correspond to a coincident pressure equal to the Maximum Allowable Working

Pressure (MAWP). When there are multiple MAWP’s, the largest value shall be used to establish the MDMT marked on the nameplate. Additional MDMT’s corresponding with other MAWP’s may also be marked on the nameplate.

MDMT is the lowest temperature at which a significant load can be applied to a pressure vessel as defined in the applicable construction code.

1.6.5 Ducting – Shells fabricated using rolled plate with longitudinal seam welds not constructed per ASME B31 piping codes and used as a conduit for fluids.

1.6.6 Fluid – A substance, as a liquid or gas, that is capable of flowing and that changes its shape at a steady rate when acted upon by a force tending to change its shape.

1.6.7 In-Service Inspection/Test (ISI/T) – Inspection of an operational (may also include pressure vessel in mothballed or sustainment status) pressure vessel as part of the

Center’s maintenance program as a preventive maintenance action to ensure continued safe, reliable and effective operation as well as to maintain the certification of the vessel. The ISI/T may be performed in conjunction with CIVR. Reference:

AEDC-SHE-STD-D2 pressure vessels and systems.

1.6.8 Maximum Allowable Working Pressure (MAWP) – The maximum gage pressure permissible at the top of a completed vessel in its normal operating position at the designated coincident temperature for that pressure. This pressure is the least of the values for the internal or external pressure to be determined by the rules of ASME

BPVC Section VIII for any of the pressure boundary parts, including the static head thereon, using nominal thicknesses exclusive of allowances for corrosion and considering the effects of any combination of loadings listed in the code that are likely to occur at the designated coincident temperature. It is the basis for the relief set pressure of the pressure relieving devices protecting the vessel. The design pressure may be used in all cases in which calculations are not made to determine the value of the maximum allowable working pressure.

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1.6.9 Nondestructive Examination (NDE) – A process involving the use of nondestructive tests (NDT) or nondestructive inspections (NDI) such as visual, liquid penetrant, magnetic particle, ultrasonic, eddy current, radiography, etc. to examine materials or welds to assess and evaluate defects or flaws without damaging or rendering the article useless under examination. Reference: American Society of

Nondestructive Testing (ASNT).

1.6.10 Operating Pressure – The pressure at which a pressurized vessel normally operates when in service. At AEDC, the operating pressure shall be equal to or less than the design pressure.

1.6.11 PSI - Units of pressure, pounds per square inch. In this standard, PSI refers to either gauge pressure (PSIG) or differential pressure (PSID) in the context where it is used.

Absolute units (PSIA) are not used in this document or the ASME Code.

1.6.12 Pressure System Components – Mechanical elements suitable for joining or assembly into pressure-tight fluid-containing piping systems. Components include pipe, tubing, fittings, flanges, gaskets, and bolting.

1.6.13 Pressure Vessel – A pressure vessel is a container for media under pressure, either internal or external. For the purposes of this document, ducting and non-standard piping are included in references to “pressure vessel” as stated in paragraph 1.2.

1.6.14 Recertification – The renewal process for a pressure vessel that has reached the end of its certification period or lost its previous certification because of ineffective maintenance, configuration management, improper disposal, abandonment or similar situations.

1.6.15 Relief Set Pressure – The pressure at which the pressure relief device(s) is set to protect the pressure vessel from over-pressurization. The relief set pressure for a relief valve shall not exceed the vessel MAWP. If the pressure relief device(s) is also intended to protect the balance of a piping system associated with the pressure vessel, then relief set pressure will need to be specified to not exceed the lower design pressure of either and have adequate capacity at that lower pressure. Note: The burst pressure for a rupture disk or relief valve/rupture disk combination shall be selected per the applicable code.

1.6.16 Repair – The work necessary to restore pressure-retaining items to a safe and satisfactory operating condition.

1.6.17 Standard Pipe, Fittings, and Flanges – Pipe, fittings, and flanges designed to the appropriate standard as listed in ASME B31.3 Table 326.1 Standard Components.

1.6.18 Test Pressure – The pressure at which a system is tested based upon the design pressure, test method, and the applicable code.

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1.6.19 Window - Ports used at AEDC in pressure system (vessel) applications to provide a means of photographing, inducing lasers, and performing other test processes.

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2.0 DESIGN

2.1 GENERAL REQUIREMENTS

2.1.1 New Pressure Vessels. All new pressure vessels shall be designed in accordance with the applicable code as designated by paragraph 1.5 Applicable Codes insofar as possible.

2.1.2 Used Pressure Vessels. All previously used vessels shall be certified in accordance with paragraph 5.0 Certification Requirements prior to use.

2.1.3 Repair and Alteration of Pressure Vessels. The design of all repairs and alterations to existing vessel shells, heads, or other components shall comply with the requirements of this standard and the applicable standard(s) listed in Appendix A. This shall include portable DOT cylinder/vessel systems modified from the original DOT configuration or installed for permanent use within a system at AEDC.

2.1.4 Ducting and Piping not constructed in accordance with ASME B31 Specifications.

Appendix B provides guidance for the design of ducting and piping not constructed in accordance with specifications of the ASME B31 Piping Codes.

2.2 MATERIALS

2.2.1 ASME Code Materials. All materials used in the construction of new vessels should be selected from those allowed by the ASME BPVC. Code stamped vessels shall use

ASME Code materials.

2.2.2 ASTM Code Materials. ASTM materials may be substituted for ASME BPVC materials if after an engineering evaluation in accordance with the ASME BPVC has been performed to demonstrate ASME BPVC requirements have been met.

2.3 ALLOWABLE STRESSES

2.3.1 Allowable stresses shall be taken from the applicable section of the ASME BPVC whenever possible.

2.3.2 Allowable stresses for materials not listed in the ASME BPVC shall be determined in accordance with the methods outlined in the applicable code therein. In addition, every effort shall be made to learn of any unusual characteristics which might influence the establishment of allowable stress levels for the material.

2.3.3 The higher allowable stress intensities of the ASME BPVC Section VIII, Division 2 shall be used only if all other requirements (e.g. design, materials, fabrication and inspection) of the division are met.

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2.4 SUPPORTS AND WELDED ATTACHMENTS.

2.4.1 External Loads. External loads shall be considered in the design of all vessels. In the case where existing vessels are reused, these loads must be considered to determine if the vessel and its supports are adequate for the intended service. The latest edition of the International Building Code (IBC) shall be used to establish wind, ice, snow, and earthquake loads. For AEDC service, the design Wind Speed of 90 mph, Snow Load of 10 psf and Seismic Zone 1 shall be used unless otherwise specified.

2.4.2 Supports. Supports shall be designed as to cause no excessive localized bending or flattening of the vessel or harmful thermal gradients as determined by satisfying the requirements of the applicable ASME BPVC.

2.4.3 Attachments to Pressure Vessels. Process piping, conduits or other supports and attachments shall not be welded directly to the vessel if it can be avoided. If it cannot be avoided then stresses resulting from these attachments under both operating and hydrostatic test conditions shall be included in the combined stresses and considered in establishing the integrity of the vessel in accordance with the applicable ASME BPVC.

a. Integral attachments shall be of materials which are compatible for welding to the vessel. Preheating, welding and post heat treatment shall be in accordance with the applicable ASME BPVC.

b. Design temperatures for components or hangers in direct contact with the vessel shall be the design temperature of the vessel wall.

2.4.4 Metal Support Structures. All metal support structures shall be designed in accordance with the latest editions of the AISC Specifications and AISC Manual of

Steel Construction (Allowable Strength Design).

2.4.5 Concrete Supports or Footings. Concrete supports or footings for metal support structures shall be designed in accordance with the latest edition of ACI Standard 318, Building Code Requirements for Structural Concrete.

2.5 Windows. The design of windows used in pressure vessels is not specifically addressed in the ASME BPVC. Appendix D contains considerations for the design and inspection of windows for service in test cells and vacuum chambers at AEDC.

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3.0 FABRICATION AND ERECTION

3.1 BY AEDC OPERATING CONTRACTOR

3.1.1 General. All fabrication, assembly and erection shall be in accordance with the applicable code as designated by paragraph 1.5 Applicable Codes.

3.1.2 Welding. All welders, welding operators, and welding procedures shall be qualified in accordance with the applicable code.

3.1.3 Heat Treatment. All heat treatment shall be performed in accordance with the applicable code.

3.2 BY OUTSIDE CONTRACTORS

3.2.1 For pressure vessels fabricated or erected for service at AEDC by outside firms working under contract to AEDC or to any governmental agency, the relationships and design engineering responsibilities between AEDC and the vessel fabricator or erector shall be clearly defined in the contract and shall include all requirements of paragraph 3.1.

3.2.2 Pressure vessels shall be code stamped and registered with the National Board.

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4.0 INSPECTION AND TESTING

4.1 ACCEPTANCE INSPECTION

All inspections shall be performed in accordance with the applicable section of the ASME

BPVC. Certification requirements are listed in Section 5 of this Standard.

4.2 TESTING

4.2.1 Pressure Testing (Hydrostatic & Pneumatic). All pressure testing shall be performed in accordance with the applicable code per Paragraph 1.5 and AEDC SHE

Standard D2. A system safety hazard analysis shall be performed to assess risk and shall be documented on an approved pressure test certificate in accordance with

AEDC SHE Standard D2 prior to performing the test.

4.2.2 Hydrostatic Testing. The vessel support system shall be evaluated to ensure that vessel buckling will not occur during the hydrostatic test. The floor-loading conditions also shall be evaluated so as to safely transfer the vessel's weight and contents to the floor slab and the supporting grade. This evaluation shall be documented in the pressure test hazard analysis.

4.2.3 Pneumatic Testing. Due to the large amount of energy stored in compressed gas and the potential hazard of a sudden release of this energy, pneumatic testing should be avoided if at all possible. A pneumatic pressure test is permitted only when one of the following prevails:

a. Pressure Vessel cannot be safely filled with water or liquid due to the design of the vessel and support system

b. Pressure Vessel in which traces of testing liquid cannot be tolerated (i.e. the hydrostatic test would damage linings or internal insulation, or contaminate a process which would be hazardous, corrosive, or inoperative in the presence of moisture, or would present the danger of brittle fracture due to low metal temperature during the test)

4.2.4 General Guidance on Pressure Testing Separation Distance. The method as outlined in the AEDC-SHE-STD-D2 provides a conservative approach to estimate the minimum safe distance from an article undergoing a pneumatic test to any personnel.

4.2.5 New Vessels. All new pressure vessels that were designed and fabricated in accordance with ASME BPVC requirements shall satisfy the requirements for pressure tests as given in the applicable section of the ASME Code. (Reference:

AEDC-SHE-STD-D2)

4.2.6 Used Vessels. Vessels which are certified using the procedure given in paragraph 5.0 shall satisfy the pressure tests requirements of the certification program.

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4.2.7 Vessels subject to External Pressure (vacuum service). Vessels designed for external pressure only are outside the scope of the ASME BPVC and thus, there is no code requirement to perform a pressure test. A positive pressure leak test, negative pressure leak test, or a vacuum test may be performed to confirm vessel integrity.

4.2.8 Impact Testing. Materials for all vessel components which are subject to stress due to pressure shall meet the impact test requirements of the ASME BPVC Section VIII unless governed by another code per Appendix A.

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5.0 CERTIFICATION REQUIREMENTS

5.1 INTRODUCTION

A pressure vessel is certified when inspection, analysis, and testing are performed and documented in accordance with the requirements of this section. Certification of a new vessel may be performed by outside contractors who design, fabricate, inspect, test and place the vessel into an in-service inspection/test program prior to operation. Certification of a used vessel, whose history is not well documented, may be accomplished through reverse engineering/analysis, inspection, and test. Certification documentation for all pressure vessels, provided in a Certification Report, shall be retained by the AEDC Operating

Contractor. The latest revision of API 510 and 579 can be used as a guide for maintenance inspection, repair, alteration, and rerating procedures for pressure vessels.

5.2 CERTIFICATION REPORT

The Certification Report includes documentation verifying that a pressure vessel has been designed, manufactured, inspected, and tested in accordance with this Standard and is safe for operation at AEDC. The format and content of the Certification Report are as follows:

5.2.1 Section 1. Introduction. System Description. This section shall include a description of the vessel, the system of which it is a component, and the design and operating conditions of the vessel and system for both new and used vessels. In addition, it should include any documentation of the history of the vessel, such as its point of origin, operational history, repairs, and alterations since original manufacture. A system specification, purchase description, schematic, preventive maintenance record (AEDC CMMS), or other records may be used to fulfill the requirement.

5.2.2 Section 2. Identification. This section shall include Manufacturer's fabrication drawings, Mill Test Reports, records of heat treatments, mechanical test records, Welding Procedure Specifications and Welding Procedure Qualification Records, and

Manufacturer’s Data Reports for new vessels. For used vessels, the documentation may not be available and will require additional information specified in 5.2.3.

Required data for new vessels includes:

a. Designer, manufacturer, inspector, and tester's name and address.

b. Procuring specification or contract.

c. Revision of drawings for which the vessel was designed and fabricated.

d. Drawing numbers.

e. Dimensions and details of fabrication sufficient to determine component thicknesses.

f. Design code (including section, division, revision date, and applicable addenda), or design basis.

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g. Corrosion allowance

h. Identification of materials and their yield and ultimate tensile strength values.

i. Efficiency of welded joints

j. Method and extent of non-destructive examinations performed including acceptance and rejection criteria.

k. Types of pressure tests (e.g., pneumatic, hydrostatic) performed including location and date of test(s).

l. National Board Forms U-1, U-2, etc.: When a new, ASME Code stamped pressure vessel is purchased, the AEDC Operating Contractor shall retain (file records in AEDC CMMS) ASME Code Stamp information and design or other technical information that establishes certification for safe operation.

5.2.3 Section 3. Evaluation and Analysis. This section shall include calculations performed to develop new vessel design or verify used vessel design. When certification of a used vessel is required, cyclic conditions and operating environments shall be included in the evaluation and analysis. A combination of fatigue, fracture mechanics and finite element analyses may be used to analyze indications identified during nondestructive evaluation (NDE).

5.2.4 Section 4. Inspection and NDE. This section shall include inspection and NDE

Plans and Reports prepared by the manufacturer or inspector. It shall also include radiographic film to be retained by the user for the life of the vessel or as specified in the system/vessel ISI/T Plan. New vessels shall meet inspection and NDE requirements identified in the ASME Code Section V and Section VIII. Used vessels shall meet those required for a new vessel plus:

a. Visual Inspection (VT). Detailed internal and external visual inspection. May require equipment such as bore scopes, flashlights, pit gauges, etc. to perform inspection.

b. Magnetic Particle Test (MT). All nozzle and support welds and areas that are suspect due to repairs, alterations, and anomalies detected during visual inspection. Liquid penetrate test (PT) shall be substituted if the vessel is manufactured of a nonferrous material.

c. Radiographic Test (RT). All circumferential and longitudinal welds and nozzle welds designed such that radiographic testing is feasible. For multi-layered vessels, radiography of circumferential and nozzle welds is required however;

radiography of the longitudinal welds is not required.

d. Ultrasonic Thickness Test (UTT). At least 12 areas per head and 20 areas on the shell sections for documentation and verification. The extent necessary for dented areas and areas of suspect thinning will be determined on a case-by-case basis.

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e. Ultrasonic Shear Wave Test (UT). Although radiography is the preferred volumetric examination method, in some cases ultrasonic shear wave may be substituted or used to augment radiography.

5.2.5 Section 5. Deficiency Correction. Documentation of repairs made as a result of inspection or analysis in 5.2.2, 5.2.3, and 5.2.4. Documents shall include repair procedures used, NDE reports (including weld maps identifying repair locations and linking NDE reports to current weld configurations), revised drawings, and additional calculations as necessary.

5.2.6 Section 6. Final Certification Tests. Pressure vessel test certificates shall be completed for the appropriate test. This section shall include documentation verifying pressure vessel relief devices/pressure gauges have been pressure tested or calibrated for the intended service. Relief device certificates shall specify model number, serial number, set points, orifice size, flow capacity detected, and signature of test technician. Gauge certificates shall specify gauge number (or identification number), date calibrated, and signature of calibration technician.

5.2.7 Section 7. In-Service Inspection/Test Plan. This section shall include the ISI/T Plan developed for each pressure vessel certified. The format of the ISI/T report shall be in accordance with the requirements of AEDC-SHE-STD-D2.

5.2.8 Section 8. Summary of Conclusions and Recommendations. This section consists of any other additional data necessary to document the certification, such as a

Physical Configuration Audit/Functional Configuration Audit (PCA/FCA) certificate.

5.3 IN-SERVICE INSPECTION/TEST (ISI/T)

To maintain confidence in the safety of certified pressure vessels, an in-service inspection test program shall be established and executed. The comprehensive ISI/T program will include certification based on and design or projected operating requirements, combined with the monitoring of defects permitted to remain in the vessels. Routine monitoring of known flaws, which were deemed to be acceptable with ISI monitoring, shall be performed to assure that the discontinuity has not progressed to an unacceptable condition. ISI/T program requirements and frequencies shall be based on the failure mechanisms (pressure, thermal, vibration, fatigue, corrosion, etc.), vessel configuration, and performance requirements. For more detailed information on ISI, refer to AEDC-SHE-STD-D2.

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6.0 IDENTIFICATION

6.1 VESSEL TAGS

The following pressure vessels shall be identified by attachment of a metal tag as illustrated in Appendix E:

6.1.1 All new pressure vessels that are procured without Code stamps.

6.1.2 All pressure vessels which have been certified in accordance with this standard.

6.1.3 The requirement for identification is not retroactive and does not apply to vessels installed before the date of issuance of this revision of this standard if used under service conditions originally established by the contract operators.

6.1.4 Tags shall not be attached to the pressure shell. They may be installed on the skirt, supports, jacket, or other permanent attachment to the vessel.

6.1.5 No paint, tape, or decals shall be used for marking directly on stainless steel and aluminum vessels.

6.2 PRESSURE SYSTEM COMPONENTS

All pressure system components associated with a pressure vessel shall be tagged in accordance with AEDC-ENGR-STD-T-3.

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7.0 TANK-MOUNTED AIR COMPRESSORS (TMACS)

7.1 SPECIFICATIONS

When practical, specify an air compressor unit with the compressor and air receiver mounted separately, such as on a skid, so fatigue cycling is minimized. When portability, space limitations, or other restrictions dictate a tank-mounted air compressor unit, use the following statement to assure ASME BPVC requirements are included:

The TMAC shall meet the requirements of the ASME BPVC as outlined in the California

Code of regulations, Title 8, Chapter 4, Subchapter 1, Article 3, dated 1990. All documentation pertaining to Title 8 shall be provided with the TMAC at the time of delivery.

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