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. 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

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.