OPERATION AND MAINTENANCE: UNMANNED PRESSURE TEST FACILITIES SAFETY CERTIFICATION MANUAL
Record of Changes - 4_390_010002
FOREWORD - 4_390_010003
CONTENTS - 4_390_010004
CHAPTER 1. INTRODUCTION - 4_390_010005
APPENDIX A. MILITARY HANDBOOK 1039/2 UNMANNED PRESSURE TEST FACILITIES SAFETY CERTIFICATION MANUAL
CONTENTS - 4_390_010007
CONTENTS-continued - 4_390_010008
CONTENTS-continued - 4_390_010009
TABLES - 4_390_010010
Section 1: INTRODUCTION - 4_390_010011
Standard DOD Syntax Summary
Scope and Applicability
System Certification Procedures
New System
Existing System-continued
Section 2: THE SYSTEM CERTIFICATION PROCESS
Figure 1. Certification Sequence of Events
Figure 2. Hazard Category Identification
Hazard Category Criteria
HAZCAT Guidelines
Submission of Supporting Documentation
Review and Approval of Supporting Documentation
Objective Quality Evidence (OQE)-continued
Figure 3. System Certification Milestone Event Schedule
Survey Coverage
System Certification Survey Cards
Category 2
All Category 1A and 1B deficiencies
Figure 4. Sample System Certification Survey Card
Operational Demonstration
Termination or Suspension of System Certification
Sustaining System Certification
Continuation of System Certification
Transfer of System Custody
Recipient Command-continued
Section 3: INITIAL CERTIFICATION
Summary Description of the System
Design Analysis - 4_390_010039
System Drawings
Operability and Maintainability
Justification of Materials
Fabrication And Assembly
Fabrication/Assembly Procedures
Welding Procedures
Assembly Procedures
Quality Assurance Program
Configuration Management and Drawing Control
Cleanliness Control
System Testing Program
General Requirements for Test Procedures
Operating And Emergency Procedures (OPs and EPs)
Maintenance Program - 4_390_010053
Operating And Maintenance Manual
Granting Initial Certification
Granting Initial Certification-continued
Section 4: RESPONSIBILITIES OF THE ACQUISITION MANAGER
Document Control
Technical Design Reviews
Associated Documents
Section 5: REPAIR AND OVERHAUL
Pre-Overhaul Requirements
Overhaul
HAZCAT II Systems
Procedures - 4_390_010065
Technical Requirements - 4_390_010066
Section 6: NOTES
APPENDIX A. CATEGORIZATION OF SCOPE OF CERTIFICATION MATERIALS AND COMPONENTS
CATEGORY 1 - MATERIALS AND COMPONENTS
CATEGORY 3 - MATERIALS AND COMPONENTS
CATEGORY 3 - MATERIALS AND COMPONENTS-continued
APPENDIX B. DESIGN PARAMETERS FOR UNMANNED PRESSURE TEST FACILITIES
Fatigue
Fracture Toughness
DESIGN STRENGTH PARAMETERS OF INTERNALLY-LOADED PRESSURE VESSELS
Verification of System Design Pressure-contnued
DESIGN OF PRESSURE VESSELS TO COMMERCIAL CODES
Manufacturer's Documentation
NDT Records
Ultrasonic (UT) Inspection
MATERIAL SELECTION - 4_390_010081
Protective Finishes
DESIGN OF PENETRATIONS INTO AND THROUGH THE PRESSURE VESSEL
Piping Penetrations
FABRICATION DESIGN CRITERIA
Locking Devices for Critical Mechanical Fasteners
Piping - 4_390_010087
Piping Flexibility
Materials - 4_390_010089
Welded Pipe Joints
Flexible Hoses/Flexible Pipe
Piping Components
Components of Gas Pressurized Systems
Receivers and Volume Tanks
System Pressure Gages
Special Considerations for Oxygen Systems
Components of Fluids Pressurized Systems
General Considerations for Piping Systems
Cleaning and Testing
DESIGN OF ELECTRICAL SYSTEMS
Lighting Systems
Remote Control Power Supply
APPENDIX C. REQUIRED DOCUMENTATION
Figure C.1. Maintenance Log Outline
Re-Entry Control (REC)
Supporting Documentation/Objective Quality Evidence
Re-Entry Control Log Instructions-continued
Figure C.2. Re-Entry Manned Pressure Test Facility Control Log
Re-Entry Control Form Instructions for Figure C.3
Test Line-Up Instructions (FIG C.4)
Figure C.3. Unmanned Pressure Test Facility Re-Entry Control Form
Figure C.4. Unmanned Pressure Test Facility Test Line-Up Sheet
Joint Tightness Test
System Tightness Test
Leak detecting solution method
Figure C.5. Unmanned Pressure Test Facility Joint Tightness Test
System Tightness Test Instructions (FIG C.6)
Figure C.6. Unmanned Pressure Test Facility System Tightness Test
Hydrostatic/Pneumatic Test Instructions (FIG C.7)
Operation Log-continued
Figure C.7. Unmanned Pressure Test Facility hydrostatic/Pneumatic Test
Figure C.8. Unmanned Pressure Test Facility Hose Log
Figure C.9. Unmanned Pressure Test Facility Sample Operating Procedure Form XXXXX LINE UP
BIBLIOGRAPHY - 4_390_010124
BIBLIOGRAPHY-continued - 4_390_010125
BIBLIOGRAPHY-continued - 4_390_010126
REFERENCES - 4_390_010127
REFERENCES-continued - 4_390_010128
GLOSSARY - 4_390_010129
GLOSSARY-continued - 4_390_010130
GLOSSARY-continued - 4_390_010131
GLOSSARY-continued - 4_390_010132
GLOSSARY-continued - 4_390_010133
4_390_01
Record of Changes - 4_390_010002
FOREWORD - 4_390_010003
CONTENTS - 4_390_010004
CHAPTER 1. INTRODUCTION - 4_390_010005
APPENDIX A. MILITARY HANDBOOK 1039/2 UNMANNED PRESSURE TEST FACILITIES SAFETY CERTIFICATION MANUAL
CONTENTS - 4_390_010007
CONTENTS-continued - 4_390_010008
CONTENTS-continued - 4_390_010009
TABLES - 4_390_010010
Section 1: INTRODUCTION - 4_390_010011
Standard DOD Syntax Summary
Scope and Applicability
System Certification Procedures
New System
Existing System-continued
Section 2: THE SYSTEM CERTIFICATION PROCESS
Figure 1. Certification Sequence of Events
Figure 2. Hazard Category Identification
Hazard Category Criteria
HAZCAT Guidelines
Submission of Supporting Documentation
Review and Approval of Supporting Documentation
Objective Quality Evidence (OQE)-continued
Figure 3. System Certification Milestone Event Schedule
Survey Coverage
System Certification Survey Cards
Category 2
All Category 1A and 1B deficiencies
Figure 4. Sample System Certification Survey Card
Operational Demonstration
Termination or Suspension of System Certification
Sustaining System Certification
Continuation of System Certification
Transfer of System Custody
Recipient Command-continued
Section 3: INITIAL CERTIFICATION
Summary Description of the System
Design Analysis - 4_390_010039
System Drawings
Operability and Maintainability
Justification of Materials
Fabrication And Assembly
Fabrication/Assembly Procedures
Welding Procedures
Assembly Procedures
Quality Assurance Program
Configuration Management and Drawing Control
Cleanliness Control
System Testing Program
General Requirements for Test Procedures
Operating And Emergency Procedures (OPs and EPs)
Maintenance Program - 4_390_010053
Operating And Maintenance Manual
Granting Initial Certification
Granting Initial Certification-continued
Section 4: RESPONSIBILITIES OF THE ACQUISITION MANAGER
Document Control
Technical Design Reviews
Associated Documents
Section 5: REPAIR AND OVERHAUL
Pre-Overhaul Requirements
Overhaul
HAZCAT II Systems
Procedures - 4_390_010065
Technical Requirements - 4_390_010066
Section 6: NOTES
APPENDIX A. CATEGORIZATION OF SCOPE OF CERTIFICATION MATERIALS AND COMPONENTS
CATEGORY 1 - MATERIALS AND COMPONENTS
CATEGORY 3 - MATERIALS AND COMPONENTS
CATEGORY 3 - MATERIALS AND COMPONENTS-continued
APPENDIX B. DESIGN PARAMETERS FOR UNMANNED PRESSURE TEST FACILITIES
Fatigue
Fracture Toughness
DESIGN STRENGTH PARAMETERS OF INTERNALLY-LOADED PRESSURE VESSELS
Verification of System Design Pressure-contnued
DESIGN OF PRESSURE VESSELS TO COMMERCIAL CODES
Manufacturer's Documentation
NDT Records
Ultrasonic (UT) Inspection
MATERIAL SELECTION - 4_390_010081
Protective Finishes
DESIGN OF PENETRATIONS INTO AND THROUGH THE PRESSURE VESSEL
Piping Penetrations
FABRICATION DESIGN CRITERIA
Locking Devices for Critical Mechanical Fasteners
Piping - 4_390_010087
Piping Flexibility
Materials - 4_390_010089
Welded Pipe Joints
Flexible Hoses/Flexible Pipe
Piping Components
Components of Gas Pressurized Systems
Receivers and Volume Tanks
System Pressure Gages
Special Considerations for Oxygen Systems
Components of Fluids Pressurized Systems
General Considerations for Piping Systems
Cleaning and Testing
DESIGN OF ELECTRICAL SYSTEMS
Lighting Systems
Remote Control Power Supply
APPENDIX C. REQUIRED DOCUMENTATION
Figure C.1. Maintenance Log Outline
Re-Entry Control (REC)
Supporting Documentation/Objective Quality Evidence
Re-Entry Control Log Instructions-continued
Figure C.2. Re-Entry Manned Pressure Test Facility Control Log
Re-Entry Control Form Instructions for Figure C.3
Test Line-Up Instructions (FIG C.4)
Figure C.3. Unmanned Pressure Test Facility Re-Entry Control Form
Figure C.4. Unmanned Pressure Test Facility Test Line-Up Sheet
Joint Tightness Test
System Tightness Test
Leak detecting solution method
Figure C.5. Unmanned Pressure Test Facility Joint Tightness Test
System Tightness Test Instructions (FIG C.6)
Figure C.6. Unmanned Pressure Test Facility System Tightness Test
Hydrostatic/Pneumatic Test Instructions (FIG C.7)
Operation Log-continued
Figure C.7. Unmanned Pressure Test Facility hydrostatic/Pneumatic Test
Figure C.8. Unmanned Pressure Test Facility Hose Log
Figure C.9. Unmanned Pressure Test Facility Sample Operating Procedure Form XXXXX LINE UP
BIBLIOGRAPHY - 4_390_010124
BIBLIOGRAPHY-continued - 4_390_010125
BIBLIOGRAPHY-continued - 4_390_010126
REFERENCES - 4_390_010127
REFERENCES-continued - 4_390_010128
GLOSSARY - 4_390_010129
GLOSSARY-continued - 4_390_010130
GLOSSARY-continued - 4_390_010131
GLOSSARY-continued - 4_390_010132
GLOSSARY-continued - 4_390_010133
4_390_01
