SOO_Appendix C_AEDC Standards.pdf

SOO # 16879-26-001

ATTACHMENT 1

APPENDIX C

28 July 2026

Statement of Objectives (SOO) Attachment 1 – Performance Parameters

Appendix C – AEDC Standards AEDC-Arnold AFB: H-1 Heater Modernization

Standards

1. AAFB-ENGR-STD-T-1 Mechanical Systems

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

3. AEDC-SHE-STD-A09 Hazard Communication

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

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

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

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

8. AEDC-SHE-STD-B05 Confined Spaces

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

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

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

12. AEDC-SHE-STD-D05 Hoisting Devices

13. AEDC-SHE-STD-D05HBK Hoisting and Rigging Handbook

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

15. AEDC-SHE-STD-D11 Ionizing Radiation

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

17. AEDC-SHE-STD-E04 Pyrophoric Fuels

18. AEDC-SHE-STD-E07 Asbestos

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

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SOO # 16879-26-001

ATTACHMENT 1

APPENDIX C

28 July 2026

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

21. AEDC-SHE-STD-F04 Respiratory Protection

22. AEDC-SHE-STD-F06 Fall Protection

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

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Department of the Air Force

HQ AEDC (AFMC)

Arnold AFB, TN 37389

AAFB ENGINEERING STANDARD

TITLE: AAFB ENGINEERING STANDARD FOR MECHANICAL SYSTEM

DESIGN

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

EFFECTIVE DATE: May 15, 2026

The provisions and requirements of this Standard are mandatory for use by all contractors performing work for AAFB and all AEDC personnel engaged in work tasks necessary to fulfill the AAFB mission. This Standard is not sensitive.

APPROVED:

ED TUCKER

AEDC Senior Technical Director

AEDC Engineering Panel Chair

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DESCRIPTION OF REVISION

This Arnold Air Force Base (AAFB) Engineering Standard, AAFB-ENGR-STD-T-1, replaces AEDC- ENGR-STD-T-1 with effective date December 5, 2012. This revision is a major rewrite, and the user is cautioned to evaluate the requirements of this document based on the entire content. The major components of this rewrite are as follows:

Revision Date

Description of Change

August 2025 Renamed document to “AAFB” August 2025 Eliminated statements that are already Code requirements and removed redundant statements throughout this Standard August 2025 The Applicable Codes section includes the full table of applicable codes in the document August 2025 The Applicable Codes section includes AAFB specific exceptions and/or additional requirements August 2025 Role and Responsibilities section added August 2025 Technical content:

• Ducting definition added and requirements for design clarified

• Low pressure vessel defined with specific requirements and acceptance criteria

• Vacuum vessel defined with specific requirements and acceptance criteria

• Removed on-site pressure testing requirements; referenced D-2 for those requirements

• Consolidated all pressure relief device requirements into Appendix B

May 2026 Integrate piping requirements into this Standard to create one Mechanical System Design Standard due to significant overlap in T-1 and T-2

May 2026 Updated High Pressure definition; previous definition was >150 psig; piping codes have special rules for high pressure, which would not apply until much higher pressures than 150 psig. Defined per industry accepted best practice

May 2026 Added severe cyclic service requirements May 2026 Added standard piping specs

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TABLE OF CONTENTS

1 PURPOSE

2 SCOPE

3 ROLES AND RESPONSIBILITIES

3.1 Definition of Roles

4 DEVIATIONS AND WAIVERS

5 APPLICABLE CODES

Table 1: Application of National Consensus Codes, Standards, & Laws

6 DEFINITIONS

Table 2: Vessel Types

7 GENERAL REQUIREMENTS

7.1 Operation Limitations

7.2 Design Procedures Outside the Scope of Codes/Standards

7.3 Design Pressure and Temperature

7.4 Minimum and Maximum Design Temperature

7.5 Operating Pressure

7.6 Overpressure Protection

7.7 Pressure Testing

7.8 Fabrication and Erection

7.9 Repairs and Alterations

8 VESSELS AND DUCTING REQUIREMENTS

8.1 Pressure Vessels

8.2 Low Pressure Vessels

8.3 Vacuum Vessels

8.4 Ducting

8.5 Rapid Depressurization

8.6 Tank Mounted Air Compressors (TMAC)

8.7 Corrosion Control

8.8 Materials and Allowable Stresses

8.9 Welded Attachments

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8.10 Installation

8.11 Repairs and Alterations

8.12 Acceptance Inspection and Testing

Table 3: Pressure Testing Requirements

8.13 Marking and Identification

9 PIPING SYSTEM REQUIREMENTS

9.1 Exceptions

9.2 General Piping Design Requirements

9.3 Materials and Allowable Stresses

9.4 Piping Systems

9.5 Straight Pipe and Tube

9.6 Pipe and Tube Bends

Table 5: Pipe Thickness Required for Bend Radius

9.7 Miter Bends

9.8 Branch Connections

9.9 Joints

9.10 Valves

9.11 Control Valves and Pressure Regulators

9.12 Gauges

9.13 Thermocouples

9.14 Hose

9.15 Welded Attachments

9.16 Corrosion Control

9.17 Fabrication/Erection and Routing

9.18 Repairs and Alterations

9.19 Acceptance Inspection and Testing

9.20 Marking and Identification

10 EXTERNAL LOAD AND SUPPORT REQUIREMENTS

10.1 External Loads

10.2 Supports

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10.3 Metal Support Structures

10.4 Concrete Support Structures

10.5 Concrete Structures

10.6 Anchorage

10.7 Steel Connections

10.8 Differential Displacement

11 RELOCATION/REACTIVATION OF EXISTING VESSELS/SYSTEMS

11.1 Relocation

11.2 Reactivation

11.3 Rerating

11.4 Evaluation and Analysis

11.5 Deficiencies

12 DESIGN DOCUMENT REQUIREMENTS (PROJECT TURNOVER)

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APPENDICES

APPENDIX A – CODES, STANDARDS, & LAWS BY NUMBER AND TITLE

Table 6: National Codes, Standards, & Laws by Number and Title

Table 7: AEDC Standards by Number and Title

Table 8: Acronym List

APPENDIX B – RELIEF DEVICE REQUIREMENTS

APPENDIX C – VESSEL IDENTIFICATION

APPENDIX D – FLUID CLASSIFICATION FLOW CHART

APPENDIX E – FLANGED JOINTS

Table 9: Torque Requirements for Required Bolt Stress

APPENDIX F – CORROSION CONTROL FOR BURIED OR SUBMERGED PIPING

APPENDIX G – GUIDANCE FOR PIPE AND COMPONENT SPECIFICATION

Table 10: Class 150 Carbon Steel System (285 psig at 100 F)

Table 11: Class 300 Carbon Steel System – AEDC Low Pressure Steam (225 psig at 400 F)

Table 12: Class 150 304/304L Stainless Steel (275 psig at 100 F)

Table 13: Class 900 316H Stainless Steel (3600 psig at 100 F) – High Temperature Service

Table 14: PIP Piping Specs by System Service

APPENDIX H – HOSE (METAL, RUBBER, & THERMOPLASTIC)

Table 15: Straight Tangent at Fitting for Rubber and Thermoplastic Hose

Table 16: Gase Hoses – Pressure/Length Thresholds

Table 17: Liquid/Hydraulic Hoses – Pressure/Length Thresholds

Table 18: Temperature Correction Factors

Table 19: Hose Temperature Limitations by Material

Table 20: Maximum Flow Velocities

Table 21: Material/Fluid Compatibility

APPENDIX I – AAFB ENGINEERING STANDARD REVIEW PROCESS (AAFB-ENGR-

STD-T-1)

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1 PURPOSE

This Standard establishes minimum requirements for design, materials, fabrication, assembly, erection, inspection and testing of vessels, piping, ducting, and other types of industrial processing containers and systems at Arnold Air Force Base (AAFB) intended for the purpose of storing, conveying, or processing fluids.

2 SCOPE

A wide range of industrial process applications are used at AAFB. The broad scope of this document establishes minimum requirements for vessels, piping, ducting, and other types of industrial processing containers and systems, including some media specific applications, per Section 5, Applicable Codes, Table 1.

Subsequent sections of this Standard establish exceptions and/or additional mandatory requirements for vessels and piping systems for use at AAFB. In addition, ducting is widely used at AAFB, therefore, specific requirements for ducting design, fabrication, and acceptance inspection and testing are included in the scope of this Standard. The criteria in this Standard also form the basis for evaluation, repair, alteration, and defining limits of safe operation for relocation or reactivation of all previously used vessels at AAFB.

The test cell hazard analysis shall govern the safety factors and design approach for piping within the boundaries of the test cell hazard analysis.

Revisions to this Standard will follow the process in Appendix I.

3 ROLES AND RESPONSIBLITIES

For vessels/systems designed, fabricated, and installed for service at AAFB by outside firms working under contract to Arnold Engineering Development Complex (AEDC) or any government agency, hereinafter referred to as the Government, the Test Operations and Sustainment (TOS) Operating Contractor's responsibilities and the interfaces between AAFB and the outside firm, shall be clearly defined in the contract.

Any new vessel/system must be designed to integrate well with existing systems to ensure a successful start-up and seamless transition to operation. Identifying appropriate qualified TOS Operating Contractor personnel to support development of technical requirements, perform design and technical reviews, and support safety reviews and pre-start-up activities is critical to ensuring this objective.

The TOS Operating Contractor is responsible for providing technical expertise to assist the Government in making decisions related to work performed within the scope of this Standard. The recommendations of the TOS Operating Contractor will consider adequacy of design, impact to other systems, personnel safety, and maintainability. In addition, the TOS Operating Contractor shall execute the

NOT SENSITIVE Page C9 requirements of AEDC-STD-CM-1, Configuration Management, AFI 91-202, AEDC Supplement, The US Air Force Mishap Prevention Program, and AFTCI 91-202- AEDC, AEDC Supplement to Air Force Test Center Test Safety Review Policy, AEDC Supplement for all new vessels/systems for use at AAFB and shall manage the retention of all engineering analyses and records of inspection, testing and certification for all vessels/systems within the scope of this Standard.

The TOS Operating Contractor is responsible for identifying personnel within its organization who are qualified and understand the risks associated with the applicable System Safety Hazards Analysis (SSHA) to fulfil the technical requirements as described herein. Final approval authority shall rest with the Designated Government Authority.

3.1 Definition of Roles: The following roles are defined for specific requirements defined in this Standard. This Section does not define all roles that may be applicable to fulfill the above requirements as they could vary depending on the specific project. Additional roles and/or responsibilities may need to be identified as part of the contract and/or project plan.

3.1.1 Designated Design Authority – TOS Operating Contractor representative qualified to review design analyses/drawings associated with a specific project and determine acceptability of said design and who has been identified to the Designated Government Authority as such.

3.1.2 Designated Government Authority – Government representative who has the qualifications and authority based on government organization and procedures to give final approval of the design.

3.1.3 Technical Inspection Authority – TOS Operating Contractor personnel qualified through training and experience who possess the technical acumen to perform the required inspections and documentation review to establish that materials, processes, and products meet established regulatory criteria or industry standards.

4 DEVIATIONS AND WAIVERS

Where compliance with all the requirements of this Standard may be impractical, a request for a deviation or waiver can be made. A justification supporting the request, applicable drawings, specification and/or statement of work, and engineering analysis, shall be provided along with a reasonable assessment of risk and/or mitigation over the recommended range of operating parameters.

Deviations and waivers shall be reviewed and dispositioned by the Designated Design Authority and approved by the Designated Government Authority. A record of the Deviation or Waiver shall be maintained with the asset record.

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5 APPLICABLE CODES

Systems for service at AAFB shall be designed, operated, and maintained in accordance with Table 1, Application of National Consensus Codes, Standards & Laws, and the additional requirements and exceptions included in subsequent sections of this Standard. See Appendix A for a complete list of Codes, Standards, & Laws by title and number.

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Table 1: Application of National Consensus Codes, Standards, & Laws

Vessel Type or System by Media

Design, Fabrication, Installation, Inspection, &

Testing (1)

Operation & Maintenance (1)

Repair & Alteration, ISI (1,2)

Pressure Vessels (including Multi-layer or

Banded Vessels) ASME B&PVC Section VIII

AAFB-ENGR-STD-T-1 AEDC Standards (1)

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

AAFB-ENGR-STD-T-1,

API STD 510,

API RP (572, 580, 581),

API 579/ASME FFS-1

AAFB-ENGR-STD-T-1

Low Pressure Vessels ASME B&PVC Section VIII AAFB-ENGR-STD-T-1 AEDC Standards (1)

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

AAFB-ENGR-STD-T-1,

API STD 510,

API RP (572, 580, 581),

API 579/ASME FFS-1

AAFB-ENGR-STD-T-1

Vacuum Vessels ASME B&PVC Section VIII AAFB-ENGR-STD-T-1 AEDC Standards (1)

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

AAFB-ENGR-STD-T-1,

API STD 510,

API RP (572, 580, 581),

API 579/ASME FFS-1

AAFB-ENGR-STD-T-1

Compressed Air Receivers ASME B&PVC VIII, 29CFR1910.169

29CFR1910.169

AEDC Standards (1)

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

API RP (580, 581),

API 579/ASME FFS-1

Power Boilers ASME B&PVC Section I ASME B&PV Section VIII AEDC Standards (1)

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

API RP 573

Heating Boilers ASME B&PVC Section IV ASME B&PV Section VIII AEDCS Standards (1)

ASME PCC-2,

ASME PCC-3,

ANSI/NB-23

Acetylene Cylinders

29CFR1910.102 &

1910.253, 49CFR100-180,

CGA G-1

29CFR1910.102 &

1910.253, 49CFR100-180, CGA (G-

1, P-1)

AEDC Standards (1)

CGA (C-1, C-6, C-8, G-

1, P-1), 49CFR100-180

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Table 1: Continued

Media

Design, Fabrication, Installation, Inspection, &

Testing (1)

Operation & Maintenance (1)

Repair & Alteration, ISI (1,2)

DOT Cylinders & Tanks (mobile)

29CFR1910.101, 1910.106,

1910.110, 49CFR100-180,

CGA C-1

29CFR1910.101,

49CFR100-180, CGA P-1,

AEDC Standards (1)

29CFR1910.101,

49CFR100-180,

CGA (C-1, C-6, C-8, P-1,

S-1.1, S- 1.2, S-1.3), ANSI/NB-23

Storage Tanks (fixed)

29CFR1910.106, 1910.110,

API SPEC (12B, 12D, 12F),

API STD (620, 650)

AEDC Standards (1)

API STD 2000

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

API 579/ASME FFS-1,

API RP (575, 580, 581),

API STD 653, SP001-03

Hazardous Liquid Propellant Fuels and

Oxidizers:

Vessels/Systems

• Alcohols

• Alkyl Boranes

• Anhydrous Ammonia

• Aniline

• Chlorine Trifluoride

• Ethylene Oxide

• Fluorine

• Hydrazine

• Hydrogen Peroxide

• Monomethylhydradazine

• Fuming Nitric Acids

• Nitrogen Tetroxide

• Pentaborane

• Perchloryl Fluoride

• Normal Propyl Nitrate

• Unsymmetrical

Dimethylhydrazine

• Oxygen Difluoride

ASME BPVC Section VIII Div. 1 Part UW-2 “Service

Restrictions,”

AFM 160-39,

AFTO 00-25-223,

ASME B31.3 – Category M

AAFB-ENGR-STD-T-1

AEDC SHE Standard D02

ASME PCC-2,

ASME PCC-3,

API (570, 576, 574),

ASME FFS-1/API579,

API RP (580, 581)

ANSI/NB-23

AAFB-ENGR-STD-T-1

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Media

Design, Fabrication, Installation, Inspection, &

Testing (1)

Operation & Maintenance (1)

Repair & Alteration, ISI (1,2)

Power Piping Systems

• Steam (NBEP)

• Condensate (NBEP)

• Liquid Fuel to Boilers

• Water at Steam Generating

Station

• Compressed air at Steam

Generating Station

• Central or District Heating

• Steam generating station

Hot water supply for central or district heating system and condensate

ASME B31.1

AAFB-ENGR-STD-T-1

ASME B31.1

AEDC Standards (1)

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

API 579/ASME FFS-1,

API RP (574, 576, 580,

581), API STD 570

AAFB-ENGR-STD-T-1

Process Piping Systems

• Cryogenic Fluids (except

CO2, H2, and O2)

• Potable Water (except plumbing)

• Chilled Water

• Brine

• Air Supply or Exhaust

System

• Vacuum System

• Hydraulic Actuator System

• Liquid Propane Gas

• Gasoline & Kerosene

Hydrocarbon Jet Propulsion (JP) Fuels

• Hydrocarbon Rocket Propulsion (RP Fuels)

• Refrigerants Cryogenics

• Radioactive Fluids

• Nitrogen

• Helium Gas

• Water Containing Solids in

Suspension

• Chemicals

• Fluidized Solids

• Compressed air

• Raw water

ASME B31.3

AAFB-ENGR-STD-T-1 AEDC Standards (1)

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

API 579/ASME FFS-1,

API RP (574, 576, 580

581), API STD 570

AAFB-ENGR-STD-T-1

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Media

Design, Fabrication, Installation, Inspection, &

Testing (1)

Operation & Maintenance (1)

Repair & Alteration, ISI (1,2)

Carbon Dioxide (CO2) Systems

Design & Testing per NFPA- 12 Fabrication, Installation & Inspection per

ASME B31.1

NFPA 12

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

API 579/ASME FFS-1,

API RP (574, 576, 580,

581), API STD 570

Hydraulic Systems AAFB-ENGR-STD-T-1 AEDC Standards (1)

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

API 579/ASME FFS-1,

API RP (574, 576, 580

581), API STD 570

Hydrogen Systems - Liquid

ASME B31.12 (4)

CGA G-5.4,

NFPA 55,

ANSI/AIAA G-095-2004,

29CFR1910.103 (3)

NFPA 50B, 55,

ANSI/AIAA G-095- 2004 ASME PCC-2, API 570

Hydrogen Systems - Gaseous

ASME B31.12 (4),

CGA G-5.4,

NFPA 55,

ANSI/AIAA G-095-2004,

29CFR1910.103 (3)

NFPA 55 (50B),

ANSI/AIAA G-095- 2004 ASME PCC-2, API 570

Natural Gas Systems

Case 1: Commercial Utilities Supply to AAFB service interface (custody transfer point)

Design & Testing per ICC International Fuel Gas Code Fabrication, Installation, &

Inspection per ASME B31.8 Case 2: AAFB service/Boiler

Piping ASME B31.1 Case 3: AAFB service/Process Heating

ASME B31.3

AEDC SHE Standard D02

ASME PCC-2,

ASME PCC-3,

API 570, 576, 574,

ASME FFS-1/API 579,

API RP (580, 581),

ANSI/NB-23

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Table 1: Concluded

Media

Design, Fabrication, Installation, Inspection, &

Testing (1)

Operation & Maintenance (1)

Repair & Alteration, ISI (1,2)

Oxygen Systems - Liquid

29 CFR1910.104,

ASME B31.3,

NFPA (53,55),

ASTM G88,

ASTM MNL 36,

NASA GPR 8710.7,

NASA STD 8719.12,

NASA KSC-C-123J,

NASA GLM-QS-1700.1

ASTM MNL 36, and 29

CFR1910.104

29 CFR1910.104,

ASME PCC-2,

ASME PCC-3,

API STD 570,

ASTM MNL 36,

NFPA 50,

NASA NSS 1740.15

Oxygen Systems - Gaseous

ASME B31.3

NFPA 53, 55,

ASTM G88,

ASTM MNL 36,

29 CFR1910.104,

NASA NSS 1740.15,

NASA KSC-C-123H,

NASA GLM-QS-1700.1

ASTM MNL 36,

29 CFR1910.104

ASME PCC-2,

ASME PCC-3,

API 570,

ASTM MNL 36,

29 CFR1910.104

Oxygen and Fuel Gas Systems for Welding, Cutting and Allied Processes

AWS/ANSI Z49.1,

ASME B31.3,

NFPA 51 NFPA 55

ANSI/NB-23,

ASME PCC-2,

ASME PCC-3,

API 579/ASME FFS-1,

API RP (574, 576,

580,581), API STD 570

Risk Based Inspection N/A N/A

ASME PCC-3,

API STD (510, 570),

API RP (580,581)

Notes:

1. All vessels and systems at AAFB shall be operated, maintained, and inspected in compliance with applicable AAFB and AEDC Standards and the TOS Operating Contractor’s procedures and work instructions.

2. Original Code of Construction may be used for initial evaluation criteria.

3. OSHA 1910.103(b)(1)(iii)(b) calls for the use of ASME B31.1-1967with addenda ASME

B31.1-1969 for hydrogen piping and tubing. AAFB requires the use of ASME B31.12 for new systems which is generally applied in industry.

4. Systems installed prior to FY10 were designed, fabricated, installed, and tested in accordance with ASME B31.3

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6 DEFINITIONS

6.1 Alteration – Any change in the item described in the original Manufacturer’s Data Report or other relevant design documentation which affects the pressure containing capability of the pressure-retaining item.

6.2 Certification – The process for ensuring, through configuration verification/validation, non-destructive examination, engineering analysis and test, the integrity of a pressure vessel/piping system.

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.

6.4 Design Temperature – The temperature used to determine the vessel’s thickness and other design parameters, typically calculated by adding a safety margin to the maximum expected operating temperature.

6.5 Deviation – A request for approval of non-compliance to this Standard initiated before fabrication or installation has begun.

6.6 Double Block and Bleed – Closure of a line, duct, or pipe by closing and locking and tagging two in-line valves and opening and locking a drawing or vent valve in between the two closed valves.

6.7 Ducting – Pressure boundary used to convey media constructed from unlisted piping components not designed in accordance with piping codes and used in industrial process applications that are outside the scope of the ASHRAE Standards

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

6.9 High Pressure – Pressure in excess of that allowed by ASME B16.5 PN 420 (Class 2500) rating for the specified design temperature and material group.

6.10 Maximum Allowable Working Pressure (MAWP) – The maximum gauge pressure permissible at the top of a completed vessel in its normal operating position at the designated coincident temperature for that pressure.

6.11 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

NOT SENSITIVE Page C17 or welds to assess and evaluate defects or flaws without damaging or rendering the article useless under examination.

6.12 Observation Ports – Ports used at AAFB in pressurized systems to provide a means of viewing, photographing, inducing lasers, and performing other test processes.

6.13 Operating Pressure – The pressure at which a pressurized vessel normally operates when in service.

6.14 Operating Temperature – The temperature at which a pressurized vessel normally operates when in service.

6.15 Pressure Piping – Piping and tubing used for the transportation of gases or liquids fabricated from industry standard pipe and tube designed in accordance with the ASME Piping Codes.

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

6.17 Pressure System Devices – Valves, regulators, gauges, relief devices, filters, flow meters, flexible hoses, instruments, and other such devices used to make up a pressure piping system.

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

6.19 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.

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

6.21 Vessels – A specialized container designed to hold process materials within a larger industrial process. For the purpose of this Standard, vessels for use at AAFB are defined per Table 2.

Table 2: Vessel Types

Types Operation/Description Design Pressure

Pressure Vessel Industrial Process Applications greater than15 psig

Low Pressure Vessel Industrial Process Applications 0 psig to 15 psig

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Vacuum Vessel Industrial Process

Applications, operating primarily under vacuum

-15 psig to15 psig

6.22 Waiver – A request for approval of non-compliance to this Standard initiated after fabrication or installation has begun.

7 GENERAL REQUIREMENTS

7.1 Operational Limitations – This Standard does not establish upper limits based on pressure, temperature, size, or other pertinent factors. However, it must be recognized that certain vessels/piping systems 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 this document does not eliminate the need for competent engineering judgment.

7.2 Design Procedures Outside the Scope of Codes/Standards – When it becomes necessary to use design procedures not covered in the applicable codes, every effort shall be made to meet the intent of the code using rational engineering analysis and the design approach shall be reviewed and dispositioned by the Designated Design Authority with final approval by the Designated Government Authority.

7.3 Design Pressure and Temperature shall be determined in accordance with the applicable code, except when this Standard dictates a different requirement

7.4 Minimum and Maximum Design Temperature shall take into consideration the environmental temperatures experienced, particularly during downtimes. Table 3 includes values to be used as a rule of thumb for AAFB.

Table 3: Minimum and Maximum Environmental Temperatures

AAFB Piping Systems Minimum Temperature

Maximum Temperature

Outside/Uninsulated 5 °F (Note 1) 110 °F Inside 30 °F N/A

Note 1: Per ASCE7.

7.5 Operating Pressure – Operating pressure for vessels shall not exceed the Design Pressure of the system or the MAWP of the pressure vessel(s).

7.6 Overpressure Protection – All vessels/ducting/piping systems installed at AAFB (code stamped or otherwise) shall be provided with overpressure protection in

NOT SENSITIVE Page C19 accordance with this Standard and the applicable code. If a relief device is to be used for overpressure protection, then that device shall be designed and installed as specified by the applicable codes. Specific requirements for relief devices are discussed in Mandatory Appendix B, Pressure Relief Device (PRD) Requirements

7.7 All pressure testing performed on-site at AAFB shall also meet the requirements of AEDC-SHE-STD-D2 Paragraph 4.2.4.

7.8 Fabrication and Erection

7.8.1 All fabrication, assembly and erection shall be in accordance with the applicable code per this Standard and Table 1, Application of National Consensus Codes, Standards & Laws.

7.8.2 Welding shall be in accordance with AEDC-ENGR-STD-T-5.

7.8.3 Compliance with safety requirements and verification that all material substitutions and design deviations have been approved in accordance with Section 4 Deviations and Waivers shall be ensured prior to pressurizing a system after installation, repairs, or alteration.

7.9 Repairs and Alterations – Non-physical changes such as an increase in the MAWP (internal or external), an increase in design temperature, or a reduction in minimum temperature of a pressure retaining item shall be considered an alteration.

8 VESSELS AND DUCTING REQUIREMENTS

This Section includes specific requirements for vessels and ducting for use at

AAFB.

8.1 Pressure Vessels

8.1.1 Exceptions

A. Pressure vessels fabricated from standard pipe, standard pipe fittings, and standard flanges of 6-inch nominal pipe size (NPS) or less shall be designed, fabricated, erected, inspected, and tested in accordance with Section 9.

B. Test cells, vacuum chambers, ballistic range launch tubes, or other unique AAFB pressure vessel configurations may be beyond the scope of industry standards. Any unique to AAFB design approach shall be documented and approved in accordance with Section 4, Deviations and Waivers.

C. Vessels furnished as part of a test article. These shall be documented and approved via the SSHA in accordance with

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AFTCI 91-202 AEDC Supplement.

8.1.2 Pressure Vessels for use at AAFB shall also comply with the following:

A. The application of Division 1 for the design of new pressure vessels above 3,000 psig shall require a deviation in accordance with Section 4, Deviations and Waivers.

B. ASME BPVC Section VIII Division 2 vessels shall be Class 1, except Class 2 vessels may be used if a waiver is obtained per Section 4, Deviations and Waivers.

C. Pressure Vessels with a design pressure above 10,000 psig shall be designed to ASME BPVC Section VIII Division 3.

D. Pressure Vessels to be newly procured shall be Code-stamped.

E. All new pressure vessels shall be designed with thermal sleeves unless thermal analysis shows that the thermal sleeve is not needed.

F. Pressure Vessel (“U”) Stamps and Repair Code (“R”) Stamps shall be affixed only by companies holding the applicable certifications in accordance with the latest edition of ASME BPVC and ANSI/NB- 23 Codes.

G. Existing Pressure Vessels in service and being relocated or out-of-service and being reactivated shall be evaluated in accordance with Section 11, Relocation/Reactivation/Rerating of Existing Vessels/Systems.

8.2 Low Pressure Vessels shall be designed in accordance with ASME BPVC Section VIII except they do not require a code stamp.

8.3 Vacuum Vessels

8.3.1 Vessels under external pressure, axial compression, or bending with an external diameter greater than 1000 times the wall thickness shall be designed to ASME BPVC Section VIII Division 2 unless stiffening rings and axial supports can meet the requirements of ASME BPVC Section VIII Division 1. In addition, lateral-torsional buckling of stiffening rings shall be evaluated for vessels and ducting that fall under these design conditions.

8.3.2 Vessels intended for vacuum service only are permitted to have an internal pressure rating of 15 psig and remain as vacuum only vessels.

A. Vacuum vessels intended for vacuum service only shall be

NOT SENSITIVE Page C21 designed in accordance with ASME BPVC Section VIII except they do not require a code stamp.

B. Vacuum only vessels shall be tagged in accordance with Appendix C, Vessel Identification, and identified as such.

8.4 Ducting

8.4.1 Ducting, as defined in this Standard, shall be designed, fabricated, inspected, and tested in accordance with ASME B31.3 Process Piping, with unlisted materials and components meeting the design requirements of ASME B31.3 para 302.2.3, except that ducting design per 8.4.2 below satisfies ASME B31.3 requirements for unlisted components.

8.4.2 Sections of ducting requiring fabrication from multiple segments of formed plate or sheet shall be designed, fabricated, inspected and tested in accordance with ASME BPVC Section VIII, Division 1 and shall address the design conditions listed in ASME B31.3 para. 301 (e.g. dynamic effects and flexibility analysis).

A. ASME BPVC Section VIII Division 2 may be used in accordance with Mandatory Appendix 46 in ASME BPVC Section VIII Division 1 to establish thicknesses and design details, while the fabrication, inspection, and testing of the ducting remains in accordance with Division 1.

B. Design, fabrication, inspection, and testing of ducting in accordance with ASME BPVC Section VIII Division 2, except as allowed by 8.5.4(A), shall require a deviation in accordance with Section 4, Deviations and Waivers. Furthermore, documentation shall be provided explaining the reason for constructing the ducting to Division 2, and the system shall be labeled as a Division 2 construction within the Asset Management System

8.4.3 ASME BPVC Section VIII Division 3 shall not be used for design of ducting

8.4.4 Design and construction methods shall be fully documented and shall be reviewed and dispositioned by the Designated Design Authority with final approval by the Designated Government Authority.

8.5 Rapid Depressurization – For procurement, modification, or rerating of pressure vessels, the operating conditions for design shall specify how the vessel will be used including, but not limited to, whether the vessel may experience rapid depressurization (e.g. wind tunnel blowdown service) that would warrant evaluation of the need for a thermal sleeve.

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8.6 Tank Mounted Air Compressors (TMAC) - 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.

8.7 Corrosion Control

8.7.1 Carbon steel vessel design shall include a corrosion allowance.

8.7.2 Optimum corrosion allowance shall be determined on a case-by-case basis taking into consideration fluid type, design requirements, external environmental conditions, and service history. However, a minimum corrosion allowance of 10% of wall thickness or 1/16", whichever is less, is required.

8.8 Materials and Allowable Stresses

8.8.1 All materials used in the construction of new vessels shall be selected in accordance with the ASME BPVC.

8.8.2 Allowable stresses shall be taken from the applicable section of the ASME

BPVC.

8.8.3 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.

8.8.4 For existing vessels constructed using ASTM materials, allowable stresses for materials shall be determined in accordance with the methods outlined in the applicable code therein.

8.9 Welded Attachments

8.9.1 Attachments to Pressure Vessels - Process piping, conduits, or other supports and attachments not included as part of the original vessel design 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. NOTE: Welding to Code Stamped vessels must be performed by a company holding a repair code stamp certification ("R" stamp).

A. Integral attachments shall be of materials which are compatible for welding to the vessel.

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B. Preheating, welding, and post heat treatment shall be in accordance with the applicable section of the ASME BPVC.

8.9.2 Design temperatures for components or hangers in direct contact with the vessel shall, at a minimum, be the design temperature of the vessel walls.

8.10 Installation

8.10.1 All pressure vessel installations shall allow sufficient clearance for normal operation, maintenance, and inspection (internal and external).

8.10.2 Orientation of nozzles, manways, and attachments shall ensure that clearance between nozzles, manways, attachments, and surrounding structures is sufficient to facilitate installation of associated devices and piping components and performance of maintenance activities.

8.11 Repairs and Alterations

8.11.1 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 Table 1- Application of National Consensus Code, Standards & Laws.

8.11.2 Code-Stamped Vessels – Repairs or alterations shall be performed by a company holding a repair code stamp certification ("R" stamp) in accordance with the latest edition of the National Board of Boiler and Pressure Vessel Inspections (ANSI/NB-23), National Board Inspection Code (NBIC)

8.11.3 Vessels Without a Code Stamp – Repairs or alterations are not required to be performed by a company possessing an "R" Code Stamp. However, they shall be performed in accordance with the latest edition of the National Board of Boiler and Pressure Vessel Inspections (ANSI/NB-23), National Board Inspection Code (NBIC) and applicable codes listed in Table 1- Application of National Consensus Codes, Standards & Law.

8.12 Acceptance Inspection and Testing

8.12.1 All vessels for service at AAFB shall have acceptance inspection and testing performed in accordance with this Standard and the applicable code(s) in Table 1- Application of National Consensus Code, Standards & Laws.

8.12.2 Non-Code Stamped Vessels/Ducting - fabrication, alterations, and repairs shall be reviewed, inspected, and dispositioned by the Technical Inspection Authority and approved by the Designated Government Authority.

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8.12.3 Pressure Testing for vessels and ducting in service at AAFB shall be performed in accordance with Table 4.

Table 4: Pressure Testing Requirements

Description Acceptance Testing

Pressure Vessels ASME BPVC Section VIII

Low Pressure Vessels Exempt from pressure test and RT if leak test performed

Vacuum Vessels ASME BPVC Section VIII UG-99(f)

Ducting for Internal Pressure (designed to ASME BPVC Section VIII)

Initial service leak test with hazards analysis reflecting acceptable low risk and approved by Air Force; otherwise, ASME BPVC Section VIII.

Ducting for External Pressure (vacuum)

(designed to ASME BPVC Section VIII) Initial Service Leak Test

8.13 Marking and Identification

8.13.1 Pressure Vessels that are newly procured shall comply with the ASME BPVC Section VIII Required Marking.

8.13.2 The following vessels shall be identified by attachment of a metal tag as illustrated in in Appendix C, Vessel Identification

A. Pressure Vessels certified in accordance with this Standard.

B. Low Pressure Vessels and Vacuum vessels designed and fabricated with an internal pressure less than 15 psig.

8.13.3 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.

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

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

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8.13.6 All vessels and associated devices shall be assigned a device identifier and tagged in accordance with AEDC-ENGR-STD-T-3.

9 PIPING SYSTEM REQUIREMENTS

This Section includes specific requirements for ASME B31.1 and ASME B31.3 piping systems designed for use at AAFB. When this Standard specifies a different requirement than the applicable Code, the requirement in this Standard shall prevail.

9.1 Exceptions

9.1.1 Test Articles. Piping integral to a test article is not covered by this Standard. However, an engineering evaluation considering pressure piping integral with the test article must be made of any proposed test installation to ensure adequate protection for personnel and equipment.

These shall be documented and approved via the SSHA in accordance with AFTCI 91-202 AEDC Supplement.

9.2 General Piping Design Requirements

9.2.1 For ASME B31.3 applications, Appendix D provides a guide for classifying fluid service and may be used to determine the proper classification for a piping system.

A. Category M fluid service classification shall include, but is not limited to, systems identified as Hazardous Liquid Propellant Fuels and Oxidizers per Table 1.

B. The Code makes no provisions for Category M fluid service also designated as high pressure or severe cyclic service. These must be specified per ASME B31.3 paragraph 300(c )(5). When these conditions apply, the design approach shall be reviewed by the Designated Design Authority and approved by the Designated Government Authority.

C. Piping systems meeting the definition of high pressure per this Standard shall be designed and constructed per ASME B31.3 Chapter IX.

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D. Severe Cyclic Service –

1 For Normal and Category D fluid service, piping considered severe cyclic service and constructed to ASME B31.3 shall meet the design criteria in paragraph 302 and be evaluated using ASME B31.3 Appendix W – High Cycle Fatigue Assessment of Piping Systems.

2 Alternatively, fatigue analysis may be exempt if the Likelihood of Failure (LOF) is less than 0.3 using the methodology found in Guidelines for the Avoidance of Vibration Induced Fatigue Failure in Process Pipework by the Energy Institute.

3 New construction piping systems subjected to the following operating conditions shall be identified as severe cyclic service and require additional vibration assessment and fatigue analysis.

• Kinetic energy (ρv2) greater than 5,000 kg/m*s2

• Choked or sonic flow

• Connected to rotating or reciprocating machinery without isolation

• Pulsation from positive displacement pumps or compressors without adequately designed pulsation dampener

• Centrifugal or axial compressors with the potential for rotating stalls.

• Flashing or cavitation

• Fast acting valves as defined by the Guidelines for the Avoidance of Vibration Induced Fatigue Failure in Process Pipework by the Energy Institute

• Intrusive elements in the process stream that could introduce a source of vortex induced vibration

• Multiphase flow with the potential for slugs

• Piping with historical vibration issues

9.2.2 For ASME B31.3 applications, the design pressure shall be at least 10% above the operating pressure.

9.2.3 All pressure piping systems shall have drawings or schematic diagrams in accordance with AEDC-ENGR-STD-T-3 and SHE Standard D03. These shall be reviewed and dispositioned by the Designated Design Authority and approved by the Designated Government Authority prior to operation.

9.2.4 Systems in service before the date of the latest revision of this Standard may be uprated for use at more severe conditions provided compliance with Section 11 is demonstrated.

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9.2.5 The impact of extended downtimes for systems in service at AAFB shall be considered in the design.

9.2.6 Butt-welded joints with a misalignment of more than 3 degrees shall be considered miter bends.

9.2.7 Alignment of bolt holes and flange bolt tension on flanged assemblies shall be in accordance with Appendix E.

9.2.8 Standard factory-made butt-weld fittings such as integrally reinforced fittings, tees and crosses, made to ASME B16.9 of ASTM A234 or A403 material, are superior to fabricated branches, threaded fittings, socket weld fittings, or flanged fittings (which are castings) and are preferred.

While this Standard does not prohibit non-standard fabricated fittings, engineering analysis must show that fabricated fittings meet design requirements for the system.

9.2.9 Underground piping – All underground piping installations shall be reviewed and dispositioned by the Designated Design Authority and approved by the Designated Government Authority. General requirements are included in Appendix F of this Standard and shall be included in the piping design and installation

9.2.10 Branches off potable water shall be made downstream of backflow preventor.

9.3 Materials and Allowable Stresses

9.3.1 Piping systems shall be designed and constructed of materials compatible with the service fluid and service conditions to include corrosion, oxidation, abrasion, pressure, temperature, shock, and other factors as applicable

A. Guidance for pipe and related components is included in Appendix G Tables 9-12.

B. Alternatively, Process Industry Practices (PIP) piping specifications may be used per Appendix G Table 13.

C. If materials deviate from those in Appendix G or a PIP spec is not used, refer to applicable code.

9.3.2 All materials shall be positively identified on design drawings and sketches by reference to ASTM or other material specifications in accordance with

AEDC-ENGR-STD-T-3.

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9.3.3 Materials not identified with an ASME or ASTM approved specification may be used in non-code applications.

9.3.4 Allowable stresses for materials not listed in the ASME B31 Piping Codes shall be determined in accordance with the methods outlined in the applicable code therein.

9.3.5 Aluminum, brass, or cast iron fittings shall not be used in systems where design pressure is 150 psig or greater. For pressures less than 150 psig, the limits of the applicable code shall apply.

9.4 Piping Systems

All piping systems for use of AAFB shall be comprised of components and devices designed in accordance with applicable codes from Table 1 and the following paragraphs based on design pressure and design temperature requirements for the system.

9.4.1 Uninsulated Piping Systems may be designed to a temperature other than the fluid temperature if service experience based on measurements supports this. This is in addition to other allowances already defined in the applicable section of ASME B31.

9.4.2 Hydraulic Systems do not require strict compliance with the piping codes, particularly with respect to ASME Section VIII relief valves. To align with industry practice, the following rules will be used to modify the design requirements for hydraulic power systems. Full compliance with ASME B31.3 is also acceptable. Minimum requirements include the following:

A. Except for determining the design pressure and pressure relief device requirements, hydraulic piping systems shall fully comply with ASME 31.3.

B. Design pressure shall be determined by the maximum pump pressure without regard to motor horsepower or design flow rate.

Note that for some designs this will exceed the rating. The preferred approach is for the entire system to be designed for the entire pump rating. To protect against pump shutoff, either an ASME Section VIII or hydraulic style relief valve can be used.

C. For systems that cannot be designed for the maximum pump pressure, the design must incorporate two protective elements such that a single failure will not compromise system safety. One of the devices must be locked or safety wired into position to prevent inadvertent operation or tampering. One example would be a pump with an integral pressure compensator and a secondary relief valve. Another example would be a vane pump with an

NOT SENSITIVE Page C29 unloading valve and secondary relief valve.

D. For systems where there are multiple pressure zones, each zone will require redundant protection. An example would be a pressure reducing valve and a secondary relief valve.

E. Relief valve sizing shall follow an approach similar to ASME B31.3 and ASME Section VIII in that the relief valve must have adequate capacity to pass the entire flow of the system without exceeding 10% over the design pressure. Where there is an upstream restriction or regulator, the flow can be estimated based on the upstream design pressure through the devices using the failed open or rated flow capacity (C ).

9.4.3 Gas Welding and Cutting Systems – piping shall be designed, fabricated, installed, and tested in accordance with AWS/ANSI Z49.1 Safety in Welding, Cutting, and Applied Processes Piping and NFPA 51 Standard for Design and Installation of Oxygen – Fuel Gas Systems for Welding, Cutting, and Allied Processes.

9.5 Straight Pipe and Tube

9.5.1 Only pressure tubing shall be used for pressure systems. Mechanical (structural) tubing shall never be used for pressure tubing.

9.6 Pipe and Tube Bends

9.6.1 For tubing with nominal diameter of one inch (1") and below wall thickness measurements may be impractical; therefore, straight tubing thicknesses from Table 5 shall be used and the tubing considered acceptable after bending provided good bending practices were used and all other Code requirements, including the pressure test, are satisfied.

Table 5: Pipe Thickness Required for Bend Radius Radius of Bends Thickness Prior to Bending

6 pipe diameters or greater 5 pipe diameters 4 pipe diameters 3 pipe diameters

1.06 tm

1.08 tm

1.14 tm

1.25 tm

Notes:

1) Interpolation is permissible for bending to intermediate radii.

2) tm is minimum thickness required to meet design conditions.

3) Pipe diameter is nominal diameter per ASME B31 applicable specification.

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9.6.2 Final wall thickness after bending shall be measured to ensure the code required thickness after bending is satisfied when possible.

9.7 Miter Bends

9.7.1 Full penetration welds shall be used on all miter joints.

9.8 Branch Connections

9.8.1 Standard factory-made butt-weld fittings such as integrally reinforced fittings, tees and crosses, made to ASME B16.9 of ASTM A234 or A403 material, are superior to fabricated branches, threaded fittings, socket weld fittings, or flanged fittings (which are castings) and are preferred.

While this Standard does not prohibit non-standard fabricated fittings, engineering analysis must show that fabricated fittings meet design requirements for the system.

9.8.2 Minimum length and spacing for welded branch connections shall be in accordance with Pipe Fabrication Institute (PFI) Standard ES-07.

9.8.3 Modified AN fitting branch connection per Figure 1 below is acceptable for use at AAFB.

Figure 1: Modified AN Fitting

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9.9 Joints

9.9.1 Threaded Joints

A. Pipe with wall thickness less than standard wall shall not be threaded, regardless of service.

B. For all new construction in flammable or toxic gas service (in either the gaseous or liquified state), carbon steel threaded pipe 2 inches or smaller shall be at least Schedule 80 except as permitted by NFPA 54 that allows usage of ASTM-A106 carbon steel SCH 40 threaded pipe for low pressure natural gas service.

C. Threaded joints shall not be used in service where severe corrosion, erosion, cyclic loading, shock, vibration, or other extreme operating conditions may occur.

D. Threaded joints shall not be used at temperatures greater than 925 °F.

E. Threaded fittings shall not be welded to each other or to tubing to form joints for pressures 150 psig and over unless documented on approved drawings.

F. Except as excluded by 9.9.1(K) below or where alternate safety measures are provided, threaded joints shall be seal-welded in piping handling flammable or toxic fluids (except hydraulic fluids) when indoors or in confined spaces outdoors. While not mandatory in other areas, it is recommended that all threaded joints in service with flammable or toxic fluids be seal welded.

G. Threaded joints shall also be seal welded in piping handling abrasive solids suspended in gas or liquid.

H. Backing off to permit alignment of threaded joints shall not be permitted.

I. Aluminum pipe of annealed temper shall not be threaded.

J. All external pipe threads shall be NPT threads in accordance with ANSI B1.20.1 or line pipe threads in accordance with API 5B.