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

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.

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.

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

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

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

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.

Maintenance for DOT Regulated Valves 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 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

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.

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.

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.

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.

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.