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Maintenance of DOT Regulated Valves

Maintenance of DOT Regulated Valves. ABC Company ABC Chemical Complex Engineering Specification. Maintenance for DOT Regulated Valves. SCOPE

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Maintenance of DOT Regulated Valves

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  1. Maintenance of DOT Regulated Valves ABC Company ABC Chemical Complex Engineering Specification

  2. Maintenance for DOT Regulated Valves • SCOPE • Covers emergency response, manual update requirements, and general pipeline patrolling in addition to general pipeline patrolling, maintenance, and repair. • Does not cover valve repair • Valve maintenance intervals • Gas transmission: Annually with a max. of 15 mos. • Liquid: Semiannually with a maximum of 7.5 mos.

  3. Maintenance for DOT Regulated Valves • INTENT • The intent of this procedure is to ensure that valves in DOT regulated pipelines will function as designed while the pipeline is in operation. • Summarizes general requirements for valve maintenance. • Supplements information provided by the valve manufacturers.

  4. Maintenance for DOT Regulated Valves • REFERENCES • ASME/ANSI B31.4, Liquid Transmission • ASME/ANSI B31.8, Gas Transmission • API 6D, Specification for Pipeline Valves • DOT 49CFR192, Transmission of Natural and Other Gas by Pipeline • DOT 49CFR195, Transportation of Hazardous Liquids by Pipeline

  5. Maintenance for DOT Regulated Valves • DEFINITIONS • CGI: Combustible Gas Indicator • DOT: Department of Transportation • ESD: Emergency Shutdown System • MSDS: Material Safety Data Sheet • Valve Maintenance: On-stream work • Valve Repairs: Shop work necessary • VCM: Vinyl Chlorinated Monomer

  6. Maintenance for DOT Regulated Valves • PERSONNEL REQUIREMENTS • Company and control personnel performing maintenance on pipeline valves shall possess the following credentials: • Southern Louisiana Safety Council Training • Plant Specific Training by Company Safety Training • Trained in emergency response procedures • Trained for repair of valve type and size

  7. Maintenance for DOT Regulated Valves • SAFETY • Review MSDS and determine required personal protective equipment. • Determine maximum exposure limits and tests to insure safe exposure limit is not exceeded. • Locate wind direction indicator upstream of work.

  8. Material or Chemical Ethylene Hydrogen VCM Vapors VCM Liquids Kerosene Ethylene Dichloride Natural Gas Safety Equipment Fire Extinguisher Combustible Gas Ind. Fire Retarding Clothing Eye Goggles Ear Plugs Full Face Mask with Egress Bottle Slicker Suits & Boots Non-Sparking Tools Maintenance for DOT Regulated Valves

  9. Maintenance for DOT Regulated Valves • PROCEDURE • PLANNING • Review equipment file to establish history. • Write maintenance plan based on past experience and valve manufacturer’s recommended maintenance procedures. • Obtain tools, materials, and safety equipment • Obtain a Work Permit through Operations • Gain approval for partial valve closure if necessary • Give a copy of your plan to your supervisor

  10. Maintenance for DOT Regulated Valves • PROCEDURE (Continued) • Site Preparation • Determine that work site is safe. • Clear work site of vegetation and soil accumulation. • Check “DANGER” and “WARNING” signs for proper location and replace if necessary. • Verify valve wheels, handles, or wrenches are in place or available. • Insure protective devices to prevent unauthorized use are adequate and install correctly.

  11. Maintenance for DOT Regulated Valves • Clean and Lubricate • Perform maintenance in accordance with manufacturer’s recommendations. As mini-mum requirements perform the following: • Clean dirt and corrosion from the valve. • Lubricate as specified by the manufacturer. • Check the open-close indicators for integrity. • Touch up paint as required.

  12. Maintenance of DOT Regulated Valves • PROCEDURE (Continued) • Function Test • Operate the valve, fully or partially, to insure functionality. • Determine reason(s) for any malfunction and repair if possible. • Schedule additional maintenance or repair as required. • Return the valve to its original position. • Return valve wheels, handles and/or wrenches to secured position to prevent unauthorized operation.

  13. Maintenance of DOT Regulated Valves • PROCEDURE (Continued) • Fugitive Emissions Test • Use a CGI or soap bubble test to check for fugitive emissions on all fittings and connections. • Tighten leaking fittings, flanges, or valve packing, if necessary and possible. • Reschedule maintenance and indicate the special requirements for correcting the defect if immediate repair is not possible.

  14. Maintenance of DOT Regulated Valves • PROCEDURES (Continued) • Documentation • Maintenance report shall be placed in the equipment file. • Send a copy of the report to DOT coordinator. • Send a copy of the report to the Senior Inspector.

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