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(continued)
(A) Any signs of leakage or deterioration detected in the interval between inspections shall require inspection of that piping and re-evaluation by the piping inspector, the piping engineer, or a corrosion specialist of the inspection interval for that piping class. This re-evaluation may necessitate a decrease in the inspection interval or an increase in the number of inspection locations. If service conditions change the risk classification, the interval between inspections shall be re-evaluated.
(B) The piping inspection interval for each risk classification shall be established by individuals experienced in piping corrosion and inspection, and shall be set as follows:
1. Class 1 piping systems shall be inspected on a representative sample of piping, as corrosion damage may cause generalized wall thickness loss. The inspection interval shall not exceed 5 years or half the remaining life as determined from the corrosion rate calculation, whichever is less. In cases where the remaining life is estimated to be less than 4 years, the inspection interval may be the full remaining life up to 2 years maximum and the number of piping systems inspected shall be increased within that class to detect worst case deterioration rates.
2. Class 2 piping systems shall be inspected on a representative sample of piping. The inspection interval shall not exceed 10 years or half the remaining life as determined from the corrosion rate calculation, whichever is less.
3. Class 3 piping systems shall be inspected on a representative sample of piping. The inspection interval shall not exceed 15 years or 3/4 of the remaining life as determined from the corrosion rate calculation, whichever is less.
4. Class 4 piping systems shall be inspected and tested in accordance with good engineering practices.
(5) When the inspection of a piping system shows measured losses, the inspector or the piping engineer shall evaluate those losses. This evaluation shall include: establishing maximum allowable working pressure, performing remaining life calculations, retirement thickness determination and assessment of wall losses from general, local and pitting corrosion.
(6) The inspector or the piping engineer shall review all repairs to Class 1 piping systems. Repairs to other piping classes shall be reviewed by the inspector or piping engineer, or the inspector may give prior authorization for specific repair procedures, provided the inspector has reviewed and approved the competency of the repair organization.
(7) Each owner or user shall maintain records of piping inspections. Records shall include classification, inspection type, inspection interval, inspector, inspection results, and corrective actions taken for all piping systems covered.
(c) Pressure relief devices and valves.
(1) Low pressure piping systems connected to a high pressure piping system shall be protected with pressure relief devices that are set to open at a pressure not to exceed the lowest rated working pressure of any component they protect.
(2) Open-ended pipe lines, bleeder lines and flow lines which can be subjected to pressure shall be securely anchored to prevent swinging, revolving, or whipping.
(3) Safe access shall be provided to all valves, or their remote controls, whenever it is necessary to operate them.
(4) Valves or their remote controls shall be provided with a means of ready and safe access when required by the frequency of operation or the necessity of emergency operation. Included in this classification are:
(A) Valves manually operated as often as once a shift.
(B) Valves on fuel lines to a plant, unit, or internal combustion engine.
(C) Line valves.
(5) Manually operated valves required for the emergency shutdown of units shall be maintained in operating condition and provided with ready and safe access. Such valves shall plainly indicate whether they are opened or closed.
(6) Quarter turn valves shall be provided with a means to indicate whether the valve is in the open or closed position.
(7) If a permanently attached handle is used on a quarter turn valve, it shall be installed or placed on the valve in such a position that the handle is at right angles to the line when in the closed position, and parallel with the line when in the open position. If compliance with the provisions of the subsection obstructs a passageway or walkway, the handle may be bent so as to provide clearance.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6535. Opening Pipe Lines and Equipment.
(a) Before opening lines or other equipment, the pressure shall be reduced to atmospheric or as near atmospheric as is practicable. Employees shall be informed of the hazards from the contents of lines or equipment, and shall be instructed on precautions necessary.
(b) When practicable flammable gas or vapor lines and equipment shall be emptied of their contents. When necessary to protect employees, such lines or equipment shall be washed or steamed before being opened.
(c) All sources of ignition shall be eliminated or controlled and be sufficiently remote so as to present no hazard before bleeding or opening lines containing flammable liquids, gases or vapors.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6536. Blinding or Isolating Pipe Lines and Equipment.
(a) Employees whose duties require them to perform work within a tank, vessel or still/heater shall be protected from the hazards of liquid, vapor or gas that may be discharged through connected pipe lines. Isolation of equipment shall be accomplished by blinding or disconnecting and disaligning.
(1) Where blinding or disconnecting and disaligning is not possible, a double block and bleeder system (DBBS) shall be utilized to isolate pipe lines or equipment. When th DBBS will be used, written operating procedures containing at least the following, must be approved by the Location Management and available:
(A) Block valves used in DBBS shall be monitored for leakage while in use.
(B) Double block valves shall be tagged and locked in the closed position. The bleeder shall be tagged and locked in the open position.
(C) The bleeder valve shall be checked to ensure that it is not plugged and is functioning properly.
(D) The bleeder valve shall be sized to handle the flow and pressure if the block valve fails.
(E) Discharge of leakage through the bleeder valve shall be directed so as not to create a hazard if the block valve fails.
(F) Block valve bonnets must be vented to ensure that no gases or liquids are trapped in the valve.
(G) Before the double block valve(s) is opened, a qualified person shall determine that it is safe.
(b) Blinds shall be designed and installed to preclude failure when subjected to the conditions of service.
(c) When isolated as a unit, vessels, tanks or stills/heaters with compartments or trays shall have the top and bottom manhole covers removed and it shall be determined that ventilation is established through these manholes.
(d) When welding or flame cutting on oil or gas pipe lines, the lines shall be isolated and gas free unless hot-work method in accordance with American National Standards Institute/American Welding Society F4. 1-1988-Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, pages 1-4, which is hereby incorporated by reference, recommendations or equivalent are used.
(e) Blinds installed in a line shall clearly indicate whether the line is open or closed.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6538. Drainage.
(a) Drainage sumps, pits or ponds for collecting oil or oil and water mixtures, or hazardous liquids shall be in a safe location away from probable sources of ignition.
(b) Adequate drainage shall be provided to prevent a hazardous accumulation of oils around pump bases.
(c) Drainage pits or ponds shall be located, or other means of protection shall be provided, to ensure employees are not exposed to the vapors of hazardous liquids.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6539. Housekeeping.
(a) Oil storage facilities shall be maintained reasonably free from oil, grease, and other combustible waste material.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6540. Leakage and Spill Control.
Sources of leaks and spills which occur shall be repaired immediately or as the operation permits. Where a hazard to employees exists, and repairs can not be immediately made, the hazard shall be isolated and/or guarded and only those employees necessary to mitigate the hazard shall be permitted in the area.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6542. Hazardous Substances.
Hazardous substances requirements shall be in accordance with the provisions of the General Industry Safety Orders, Section 5194.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6544. Agitation and Heating of Liquids in Tanks.
Tanks in which liquids at temperatures above one hundred and forty degrees Fahrenheit (140 degrees F.), corrosive liquids, or flammable liquids are agitated or heated by steam (applied directly or indirectly), or agitated by means of air or gas pressure, shall have their control equipment located where employees operating it will not be exposed to the hazards of splashes or froth overs. If this is not possible, equivalent protection shall be provided by means of shelter which shall include safe access and exit.
Note: (See General Industry Safety Orders under "Static Electricity.")
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6546. Reservoirs and Stationary Tanks.
(a) Design and construction of stationary tanks shall be in accordance with the provisions of the General Industry Safety Orders, Article 145.
(b) Tank roofs shall be capable of supporting anticipated live loading.
(c) Where it is necessary for employees to gage, sample, or perform other operating duties at a tank roof level or from or on tank roofs, safe access to the roof shall be provided.
(1) Locations on tank roofs where operating duties are performed shall be provided with safe platforms and safe means of access. A walkway will be accepted as a safe platform if the operating duties are performed entirely from the walkway.
(2) If such duties are performed from a ladder providing access to the tank top, the ladder shall be equipped with a cage, ring, or equivalent protection to support the employee while performing such duties.
(d) Where the means of access, the walkways, or the platforms of a group of two or more tanks are connected, there shall be a safe alternate means to permit an employee to escape from the roof, walkway or platform of any tank in the group in the event the walkway or platform of any other tank in the group becomes impassable due to fire or other emergency. This subsection shall not apply to tanks containing non-combustible liquids.
(e) Within this subsection tanks shall be classified as follows:
Class A -Tanks with fixed steel roofs, except steel waterseal roofs.
Class B -Tanks with nonmetal roofs.
Class C -Tanks with steel waterseal roofs.
Walkways and platforms on tank roofs required by subsections (c) and (d) of this section, and the railings and toeboards, shall be provided as follows:
(1) The roofs of Class A tanks shall have walkways as follows:
(A) Tank roofs having a thickness less than one-eighth inch (1/8 ") shall not be used as a walkway regardless of the slope of the roof. In measuring the thickness of metal roofs, allowance shall be made for manufacturer's tolerances.
(B) Tank roofs having a slope of two inches (2 ") or less per foot may be used as a walkway. Such walkways shall be clearly defined by color contrast, and if the slope of the tank roof is one inch (1 ") or more per foot the walkway shall have a nonskid surface.
(C) Tank roofs having a slope greater than two inches (2 ") per foot shall be provided with independent walkways of steel or wood.
(2) Class B and C tank roofs shall have independent walkways of metal or wood.
(3) No independent walkways on Class A or B tank roofs shall have a slope greater than three inches (3 ") per foot.
(4) No walkway on Class A or B tank roofs shall have a transverse slope greater than two inches (2 ") per foot.
(5) Walkways on tank roofs shall have a minimum clear width of 20 inches (20 "). Walkways shall be designed to carry the load to the supporting structure of the tank roof and shall be securely attached to the tank.
(6) Platforms on Class A, B and C tanks shall be at least equivalent in safety to the type of walkway required for the tank class.
(7) Class A, B and C tanks more than 30 inches (30 ") above ground or floor level below shall either:
(A) Have railings and toeboards at those portions of their walkway and platform edges that are within six feet (6 ') of the roof edge; or
(B) Have railings and toeboards on tank edges that are within six feet (6') of the walkways or platforms.
Toeboards are not required on the side of a platform that faces the peak of the roof, unless their absence would create a hazard to employees.
(f) Where a roof is found to be unsafe, barriers shall be erected to block off the entire roof or that portion which is unsafe. Legible signs shall be posted at all approaches to the tank or reservoir if the entire roof is blocked off, or on the barrier facing all approaches to the defective area if only the unsafe portion is barricaded. These signs shall read: "Danger -Unsafe Roof - Keep Off," or equivalent wording, in letters at least two inch (2 ") high.
(g) Tank roofs, platforms, walkways and stairways shall be kept clear of loose material or equipment except for sampling and gaging equipment kept on tank roofs in special racks or containers. Oil spills shall be cleaned up to prevent fire and slipping hazards.
(h) When in the open position, the covers of gage, sampling and manhole openings in tank roofs shall be securely attached to the roof or roof opening fixture.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6547. Reservoir and Stationary Tank Maintenance.
(a) Maintenance work shall not be performed on the roof of a tank or reservoir or shell of a tank at any location where the employee is exposed to a hazardous concentration of flammable or toxic gases or vapors.
(b) If such work is contemplated and there is reason to suspect the existence of any of the hazards mentioned in subsection (a), tests shall be made of the atmosphere at the location of the proposed work to determine the presence or absence of these hazards. Additional tests shall be made during the progress of the work to determine whether a safe atmospheric condition still exists.
This order does not prohibit an employee protected by approved respiratory equipment from entering such a hazardous atmosphere.
(c) If tank or reservoir roof plates or sheathing are known to be weak or defective, and it is necessary for employees to go on a roof to determine the extent of the weak and defective parts or to remove them, the following precautions, or substantially equally safe procedure, shall be used:
(1) Employees shall work at least two rafters apart, be provided with and use an approved safety harness with an independent safety line securely attached to safe supports.
(2) If rafters, girders or posts are known to be weak or defective in an area which cannot be spanned by thrustout planking and thus support employees, temporary shoring shall be installed inside the tank or reservoir before employees are permitted to work on the weak or defective roof area. If this is impracticable, an overhead life line shall be installed and employees shall attach their safety belts to this life line.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6548. Drainage, Dikes and Walls for Aboveground Tanks.
(a) Drainage, diking and retaining walls for aboveground tanks shall be provided for employee protection as required by the provisions in the General Industry Safety Orders, Section 5595.
(b) (1) At least one means of safe access shall be provided over retaining walls to the ground level within the walled area.
(2) Where walls exceed three feet (3 ') in height, there shall be provided at least one emergency exit located as nearly opposite the means of access as practicable. The emergency exit shall be a stairway, walkway, fixed ladder or ramp.
(3) Walkways and ramps may be structures of metal or wood. For earthen retaining walls with sloping embankments, they may be suitably surfaced natural walkways or ramps on the embankment, in which case the slope of the walkway or ramp shall be no more than twenty degrees (20 degrees) from the horizontal.
(4) If the slope is greater than two inches (2 ") per foot, structural walkways or ramps shall have securely attached and uniformly spaced cleats not over sixteen inches (16 ") apart, or other protection against slipping.
(c) Stairways, walkways, and ramps over retaining or diversion walls more than thirty inches (30 ") high shall be provided with a stair railing or railings on the exposed sides, unless the stairways or ramps are laid upon sloping earth embankments. In that case, a railing or stair railing may be installed on one side only, if the vertical distance from the nose of the stairway tread or from the surface of the ramp to the earth below is no more than two feet (2 ').
(d) Roadway or walkway openings in diversion and retaining walls are prohibited, except temporarily during repairs.
(e) There shall be no openings or holes in diversion or retaining walls.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6549. Pits and Sumps.
Open pits or sumps which constitute a hazard to employees, shall be guarded by readily visible barricades, rails or other equally effective means.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6551. Pressure Vessels and Boilers.
(a) All unfired pressure vessels, boilers, and fired pressure vessels shall meet all applicable requirements of the Unfired Pressure Vessel Safety Orders and the Boiler and Fired Pressure Vessel Safety Orders unless the design, material and construction of the pressure vessel or boiler is accepted by the Division as equivalent to the ASME Code.
(b) Maximum allowable working pressure.
(1) The employer shall establish, or cause to be established, the maximum allowable working pressure of each boiler or pressure vessel in accordance with the rules of recognized pressure vessel codes applicable to the pressure vessel service involved.
(2) No pressure vessel shall be operated above its maximum allowable working pressure at coincident design temperature(s).
(3) The maximum allowable working pressure for each vessel shall be evaluated at intervals sufficiently frequent to give due consideration to corrosion and other factors causing deterioration. The original code of construction shall be used to establish the allowable stresses and joint efficiencies when re-rating, de-rating or calculating the pressure boundary minimum thickness of a vessel.
(c) Maintenance, inspection, and repair procedures of unfired pressure vessels shall comply with API 510, Pressure Vessel Inspection Code, Eighth Edition, June 1997, Addendum 4, August 2003; or the ANSI/NB-23, American National Standard/National Board Inspection Code, 2004 Edition; which are hereby incorporated by reference.
(1) A written risk-based inspection program, as described in API 510-2003 and API 580, Risk-based Inspection, Recommended Practice, First Edition, May 2002, which is hereby incorporated by reference, may be used to increase the internal or on-stream inspection limits required by API 510-2003 Section 6.4 to a maximum of 15 years, or the external inspection interval described by API 510- 2003, Section 6.3 to a maximum of 10 years, provided it is reviewed and accepted by the Division before the program is implemented, and every three years thereafter. Any revisions made to the accepted risk-based inspection program must also be submitted, reviewed, and accepted by the Division prior to implementation of these revisions.
(A) The risk-based inspection program shall be submitted to the Division in writing, and shall be reviewed and accepted by the Division before the program is implemented, and every three years thereafter. Any revisions made to the accepted risk-based inspection program must also be submitted, reviewed and accepted by the Division prior to implementation of these revisions.
(B) The risk-based inspection program shall not be used for pressure vessels and boilers that require "Permits to Operate" issued by the Division.
(C) The plan shall not be used for safety relief devices.
(D) The program shall indicate:
1. Acceptance by signature of plant management.
2. Involvement of plant operating, engineering, inspection, and maintenance personnel by signature.
3. The type of vessels covered.
4. The methodology used to create the program.
5. A listing of the vessels covered by the program, with a clear indication of those vessels that have an inspection interval beyond the 10-year or half remaining life as required by API 510-2003, Section 6.4.
(2) If a written fitness-for-service program, as described in Section 5.8 of API 510-2003, is used to evaluate pressure vessels for continued service when found to have degradation that could affect their load carrying capability, it shall comply with API 579, Fitness-for-Service, Recommended Practice, First Edition, January 2000, which is hereby incorporated by reference.
(A) The fitness-for-service program shall be submitted to the Division in writing, and shall be reviewed and accepted by the Division before the program is implemented, and every three years thereafter. Any revisions made to the accepted fitness-for-service program must also be submitted, reviewed and accepted by the Division prior to implementation of these revisions.
(B) The program shall indicate:
1. Acceptance by signature of plant management.
2. The type of vessels covered.
3. How fitness-for-service results are documented. As a minimum, this documentation shall include acceptance of the fitness-for-service evaluation by signature of a technically competent company employee that is designated to review and accept the evaluation.
4. Involvement of plant operating, engineering, inspection, and maintenance personnel by signature.
5. The procedures in place for notifying the Division no later than the next business day of initiating a level 2 or 3 fitness-for-service evaluation as described in API 579-2000. Level 2 and 3 evaluations are subject to the acceptance by the Division. If the review is subsequent to returning the vessel to service, the Division may, in its reasonable discretion, require the unit be removed from service.
(d) Repair and alterations.
(1) Repair and alteration of boilers and pressure vessels shall meet all applicable requirements of the Unfired Pressure Vessel Safety Orders and the Boiler and Fired Pressure Vessel Safety Orders, and shall comply with API 510, Pressure Vessel Inspection Code, Eighth Edition, June 1997, Addendum 4, August 2003; or the ANSI/NB-23, American National Standard/National Board Inspection Code, 2004 Edition; which are hereby incorporated by reference.
(2) Repairs and alterations of pressure vessels performed in a state other than California shall be done by a company with a valid National Board 'R' stamp and inspected by an inspector holding a valid National Board Commission and Certificate of Competency (or equivalent) for the state in which the work is being performed. The repair or alteration shall conform to all the requirements of this section and be stamped in accordance with ANSI/NB-23-2004.
(3) Repairs.
(A) Repairs shall be performed by one of the following:
1. An organization in possession of a valid ASME Certificate of Authorization; or
2. An organization in possession of a valid National Board Certificate of Authorization.
(B) The API 510-2003 Code shall not be used for the repair of boilers and pressure vessels as follows:
1. Boilers and fired pressure vessels as defined in the Boiler and Fired Pressure Vessel Safety Orders.
2. Vessels as defined in the Unfired Pressure Vessel Safety Orders, Section 460.
3. Vessels used in compressed air, LPG, CNG, LNG and NH3 services as defined in the Unfired Pressure Vessel Safety Orders.
(C) The employer making the repair in accordance with API 510-2003 or ANSI/NB-23-2004, shall provide for inspection, documentation and certification of the work and shall ensure prior authorization for the repair by a Qualified Inspector as defined in the Unfired Pressure Vessel Safety Orders.
1. Inspection and certification of repairs shall be made by an inspector regularly employed by one of the following:
a. The Division;
b. A City or County;
c. The Authorized Inspection Agency of the organization making the repair;
d. The Authorized Inspection Agency which insures the boiler or pressure vessel; or,
e. The owner/user inspection agency.
(D) Fillet weld patches shall not be permitted unless acceptable to the Division. Acceptance by the Division will be based on the materials, design and construction providing safety equivalent to the original code of construction.
(4) Alterations.
(A) Alterations to pressure vessels shall be performed in compliance with ANSI/NB-23, 2004, unless the material design and construction are accepted by the Division as equivalent to the ASME Code.
1. No alteration to a pressure vessel shall be made until authorized by a Qualified Inspector as defined in the Unfired Pressure Vessel Safety Orders.
2. Alterations shall be performed by one of the following:
a. An organization in possession of a valid ASME Certificate of Authorization, provided that the alteration is within the scope of such authorization, and provided that the organization's alteration program has been reviewed and accepted by the Division.
b. An organization in possession of a valid Certificate of Authorization issued by the National Board of Boiler and Pressure Vessel Inspectors to use the National Board "R" symbol stamp provided that the alteration is within the scope of such authorization, and provided that the organization's alteration program has been reviewed and accepted by the Division.
3. For alterations performed at a field site, the scope of such authorization shall include field fabrication.
4. The employer making the alteration shall provide for inspection, documentation and certification of the work and shall ensure prior authorization of the alteration by a Qualified Inspector holding a valid Certificate of Competency issued by the Division.
5. Inspection and certification of alterations shall be made by a Qualified Inspector, employed by one of the following:
a. The Division;
b. A City or County;
c. The Authorized Inspection Agency of the organization making the alteration;
d. The Authorized Inspection Agency which insures the boiler or pressure vessel; or,
e. The owner/user inspection agency, provided the work was not performed by the Qualified Inspector's employer.
6. A pressure test shall be applied after an alteration as required by the applicable ASME Code section. An alternate test or examination may be used subject to prior acceptance by the Division.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6552. Pressure-Relieving Devices.
(a) All pressure vessels shall be protected by a pressure relief device. Such relief devices shall be set to prevent the pressure in the vessel from exceeding limits established by the ASME Code or, where permitted, the Unfired Pressure Vessel Safety Orders. Pressure vessels that are connected together in a system with piping not containing valves that can isolate any pressure vessel while connected to its source or pressure may be considered as one unit.
(b) A vessel having a stop valve that can isolate the vessel from its pressure-relieving device, as permitted in subsection (c), shall be protected by an additional safety device, if the vessel may become entirely filled with liquid, and if it is possible that pressure may be generated by continued input of heat through exchanger tubes or similar devices or by exposure to sun or adjacent hot equipment. This additional safety device shall be connected to the vessel at all times except as permitted in subsection (c)(3). The additional safety device may be set at a pressure not greater than one and one-quarter times the maximum allowable working pressure.
(c) Stop Valves Between Pressure-Relieving Device and Vessel.
(1) A vessel in which pressure can be generated because of service conditions shall have no stop valve between the vessel and its pressure-relieving device except for inspection or repair purposes, as permitted in subsection (c)(3), or except in cases where multiple pressure-relieving devices are provided and the stop valves are so constructed that they can not be operated so as to reduce the pressure-relieving capacity below that required.
(2) A vessel in which the pressure originates from an outside source exclusively may have its pressure-relieving device on the vessel or at any point on the system between the vessel and its source of pressure, provided that the pressure-relieving device is set to function at not over the maximum allowable working pressure of the vessel. Under these conditions there may be a stop valve between the vessel and the pressure-relieving device which need not be locked open if the stop valve also closes the vessel from its source of pressure. Any stop valve between the pressure-relieving device and the vessel which does not close the vessel from its source of pressure shall meet the requirements given in subsection (c)(1) above.
(3) Stop valves may be installed between a pressure relief device and the operating vessel for the purposes of inspection, repair and/or replacement of the pressure relief device. Where stop valves are installed, the employer shall develop, implement, and maintain a written plan containing all of the following:
(A) Procedures to ensure that stop valves are open and locked or sealed during normal operations and are not to be closed except by a qualified person(s).
NOTE: In the case of multiple relief device installations having spare capacity or spare relief valves, the stop valve can be closed on the inactive relief valves providing sufficient system relief capacity is maintained.
(B) Procedures to minimize the frequency of closing stop valves while the vessel is in service. Stop valves shall remain open and locked or sealed until a replacement pressure relief device is available for installation.
Exception: Stop valves may be closed for emergencies such as pressure relief device failure.
(C) Procedures to ensure that a replacement pressure relieving device or needed replacement parts are readily available prior to closing the stop valve and removing the pressure relief device. An index for the location of all stop valves subject to this section shall be maintained.
(D) Before the removal of a pressure relief device from operating equipment, facility management shall review and approve a written operations plan for closing the stop valves. The plan shall incorporate, at a minimum, the following elements:
1. An engineering review to ensure that no increase in the capacity, pressure, severity, and/or operating condition of the unit or vessel will affect the safety of employees or equipment while the pressure relief device is out of service.
2. Provisions for written notification and operational procedures to unit controllers, operators and other affected personnel, including the safeguards and estimated time the valve will be out of service.
3. Identification of the functional position(s) or employees having knowledge of the operating equipment and pressure relieving device(s) authorized to approve closing a stop valve; and,
4. Identification of the qualified person(s) or functional position(s) authorized to actually close and then reopen a stop valve.
(E) A written overpressure relief plan for each safety relief device shall be developed prior to closing the stop valve. The plan shall include:
1. The means by which overpressure-relief protection will be provided during the time that the pressure relief device is out of service;
2. The procedures to be followed to minimize the time that the stop valve will be closed;
3. The operating conditions, limitations, and other safety measures which are required to be observed to protect employees and equipment; and,
4. In the event that the plan requires a standby person to manually operate a vent to the atmosphere, a replacement safety relief valve shall be available for installation prior to closing the valve. Employees shall be protected from hazards as identified by Article 10 of the General Industry Safety Orders.
(F) The written overpressure-relief plan shall be made available to the Division upon request during the course of the work operation to which it applies.
(4) Valves as permitted above shall not be gate valves installed with the stems pointing above the horizontal plane of the valve body or globe valves installed so that the disk will open against pressure. This limitation need not apply to stop valves closing the vessel from its source of pressure. Other provisions acceptable to the Division may be used to assure that the valve is in the open position.
(d) Capacity of Pressure-Relieving Devices.
(1) The aggregate capacity of the pressure relief devices applied to any pressure vessel or system shall be sufficient to carry off the maximum quantity of material that can be generated in, or supplied to, the attached equipment without permitting a rise in pressure within the vessel above the limits permitted by the ASME Code.
(2) Pressure relief devices designed to relieve hydrostatic pressure caused by heat as outlined under subsection (b) shall have sufficient relieving capacity to prevent a hydrostatic pressure within the vessel in excess of 1.33 times the maximum allowable working pressure.
(e) Discharge lines from pressure relief devices shall be secured against movement. The lines shall be designed to facilitate drainage or shall be fitted with drains to prevent liquid entrapment in the discharge side of the relief device. The lines shall discharge at a location or in a manner to prevent injury to employees. The size of the discharge lines shall be such that any pressure that may exist or develop will not reduce the relieving capacity of the relief device below that required to properly protect the vessel. No valve shall be placed in a discharge line from a pressure relief device except when such discharge line discharges to a common header, in which case such valve shall be installed in compliance with subsection (c)(4) and locked or sealed open. Such valves may be closed only as allowed by subsection (c)(3).
(f) The employer shall maintain each pressure relief device installed on operating equipment so as to ensure the proper functioning of the device at the intended pressure. Such maintenance shall include inspection, testing, and the repair of the pressure relief device at frequencies as required by the service conditions.
(g) Pressure relief valve settings shall be changed only by authorized employees assigned such duties.
(h) A permanent and progressive record for each pressure vessel shall be maintained at the plant or the field office where the vessel is located. The record shall be available for inspection by the Division and shall include the following:
(1) The serial or identification number of the vessel.
(2) The established maximum allowable working pressure of the vessel.
(3) The coincident design temperature(s),
(4) Manufacturer's data reports, when obtainable, and any calculations used in establishing the maximum allowable working pressure.
(5) Such documents as necessary to record the results of tests, inspections, repairs, or alterations. Information on maintenance activities and events affecting the pressure vessel's integrity shall be included.
(i) Each pressure relief device in service shall have a serial or identification number stamped upon it and, in addition, a metal plate or tag shall be attached showing the pressure setting and the date the device was installed in service. A permanent and progressive record showing the serial or identification number, the location, the pressure setting, the date of installation in service, and the date of testing shall be maintained at the plant or field office where the pressure relieving device is located or at the supervising office.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6553. Gas Compressors and Gas Plant Protection.
(a) When a gas compressor plant discharges gas into a line to which other sources of gas supply are connected, except when discharging into a public utility distributing system, there shall be a valve installed in the plant's discharge line, or lines, for the purpose of preventing the return flow of gas.
(b) Gas compressor discharge lines shall have a pressure relief device. There shall be no intervening valves or fittings between the compressor and its pressure relief device nor between the pressure relief device and its point of discharge, which would render the pressure relief device ineffective.
The pressure relief safety device shall be set to open at a pressure not to exceed one hundred and ten percent (110%) of the maximum allowable working pressure of the cylinder. The relieving capacity of the pressure relief device shall be such as to prevent a rise of pressure in the cylinders of more than ten percent (10%) above their maximum allowable working pressure as established by the manufacturer.
Note: A valve locked in the open position does not render the pressure relief device ineffective.
(c) Where a gas compressor pressure relief device discharges into the atmosphere, the discharge outlet shall be located outside of the compressor building; and if it discharges adjacent to the building, the discharge outlet shall be located above the compressor building eaves.
(d) Where hazardous quantities of liquid may be present in the incoming gas to compressors, an inlet scrubber shall be provided and a device installed on it that will either give an audible warning or shut down the compressors if the liquid in the scrubber exceeds a predetermined level.
(e) Gas lines connected to compressor intakes shall be provided with shut-off valves in a safe location outside the compressor building, if there is one, but in no case within a reasonable distance of the compressor.
(f) Before maintenance work requiring the opening of lines or equipment containing gas is performed on a compressor or its suction or discharge piping, the valves in the intake and discharge lines shall be closed and locked to protect employees from the danger of escaping gas. If this is inadequate, the lines shall be blinded, or other equally effective means taken, to prevent the escape of gas.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6554. Stationary Internal Combustion Engine Driving Air or Gas Compressors.
(a) Air and gas compressor engines of over thirty (30) horsepower shall be provided with means other than manual for starting. Manual starting is permitted in emergencies only.
(b) In a gas compressor building or in buildings where there may be an accumulation of flammable gases, internal-combustion engine ignition systems or wires shall not be manipulated in a manner that may produce an open spark, unless tests indicate that the flammable gas or vapor content of the atmosphere is less than twenty percent (20%) of the lower explosive limit.
(c) Cylinder cocks of internal-combustion engines shall not be opened at any time when a flame or spark may be discharged from the cylinder cock into a gas compressor room or in buildings where there may be an accumulation of flammable gases, unless tests indicate that the flammable gas or vapor content of the atmosphere is less than twenty percent (20%) of the lower explosive limit.
(d) In addition to the throttle valve, other means shall be provided by the use of one or more valves, blinding, or other provisions giving equivalent safety, to prevent fuel gas entering cylinders and actuating moving parts while maintenance work is being performed upon an internal combustion engine, or upon the equipment connected to and driven by the engine, when such maintenance work would otherwise expose the employee to possible injury.
(e) The main fuel gas line to gas compressor engines and other internal combustion engines located in gas compressor buildings shall be equipped with a suitable master shut-off valve located outside the building but in any case within a reasonable distance of the engine.
(f) A check valve shall be provided in the engine or in the starting air line adjacent to each internal combustion engine cylinder using compressed air as the means of starting.
(g) The compressed air supply for starting an engine shall be prevented from so functioning while maintenance work is being performed on an idle internal combustion engine, or on the equipment connected to and driven by the engine, when such maintenance work is of a nature that employees may be endangered should the starting air cause the engine to move or turn over. This shall be accomplished by one of the following means:
(1) Disconnecting the starting air line union and disaligning the pipe.
(2) Having two closed valves in the starting air line with an open tee between them having a discharge capacity equal to the capacity of the starting air line.
(3) Other means giving equally effective positive protection as (1) or (2) above.
(h)(1) In addition to the governor controlling the fuel supply, an overspeed trip or overspeed regulator operating to cut off the engine ignition shall be installed on stationary internal combustion engines which are equipped with external flywheels and which drive gas compressors.
(2) On turbo-charged compressor drive engines, the overspeed control shall also shut off the fuel supply. Internal combustion engines which have the flywheel installed within the engine body as an integral part of the engine are not included in this order.
(3) The overspeed trip or overspeed regulator shall be so installed and adjusted as to prevent the engine from overspeeding, and shall be maintained in an operative condition.
(i) Provisions shall be made to prevent the contact of flammable liquids with exhaust pipes of internal combustion engines.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6556. Identification of Wells and Equipment.
(a) Every producing or injection well shall have placed in a conspicuous place, the name or number of the well. The operator and the name or number of the lease on which the well is located shall be clearly identified at the entrance(s) to the property or at the well site.
(b) Each stationary tank or vessel containing flammable, corrosive, or hazardous liquids or gases shall be identified by a letter, number, name or combination of these. Such identification should include information which either conveys the health and/or physical hazards of the substance in the tank or vessel or may be used to identify the hazards from readily available literature such as material safety data sheets. The identifications shall, when practical, be located so as to be legible from the location at which the tank or vessel is operated or controlled.
Note: National Fire Protection Association (NFPA) 704 may be used as a hazard identification method on stationary tanks or vessels.
(c) Pipe lines containing flammable, corrosive, or hazardous liquids or gases shall be identified to indicate their contents or purpose when such identification is practical and the correct operation of the valves of the line is essential to the safety of employees. The identification of the lines shall be by name or color placed on the lines or on the valves in the lines and shall be legible from the place at which the valves are operated. This shall not prohibit identification by the use of both a name and a color. Identifications shall be maintained so as to be legible.
Exception: Drilling and well servicing equipment.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6558. New and Old Installations.
(a) Derricks to which the orders in this article apply are classified into three groups, as follows:
Group 1 consists of derricks constructed before March 1, 1924.
Group 2 consists of derricks constructed after March 1, 1924, and before June 13, 1952.
Group 3 consists of derricks constructed after June 13, 1952.
Note: A dismantled derrick re-erected after June 13, 1952, shall be considered a new installation and governed by the orders designated as Group 3.
(b) The abbreviations G-1, G-2, and G-3 indicate Group 1, Group 2, and Group 3, respectively. Where one or more of these abbreviations precedes a specific order it means that the order applies to the group or groups of derricks indicated by the abbreviation.
(c) Where none of these abbreviations precedes an order, it means that the order applies to all three groups of derricks.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6559. Derrick Floors.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6560. Inside Derrick Platforms.
(a) An inside derrick platform shall be provided in the derrick tower at each elevation where an employee is normally required to handle pipe, sucker rods or other equipment racked in the derrick tower.
(b) The working edge of inside derrick platforms shall be placed with sufficient clearance for safe passage of the traveling block and to permit the employee, if working from the platform, to reach the elevator.
(c) Every inside derrick platform, monkey board type excepted, shall completely cover the space from the working edge back to the derrick girts.
(d) Every monkey board type platform shall be secured to the derrick with bolts or equivalent fastenings to resist being shifted or dislodged under normal operating conditions.
(e) Except for the monkey board type, every inside derrick platform of metal construction shall have the decking at each end and near the working side secured to the derrick girts or other platform supports with machine bolts, "U" bolts, or "J" bolts.
(f) The space between the derrick girt and the monkey board shall be completely covered at the normal point of access to the monkey board. Monkey board type platforms shall be at least twenty-four inches (24 ") across their least horizontal dimension.
(g) Except for the monkey board type, every inside derrick platform of wood construction shall have each end of the decking plank or planks on the working side secured to the derrick girts or other platform supports with machine bolts, "U" bolts, or "J" bolts.
(h) A vertical clearance of at least six and one-half feet (6 1/2 ') shall be maintained above the decking of each inside derrick platform.
(i) No inside derrick platform shall be in such a position that the hoisting line, running to the hoist drum, will run through or in contact with the platform unless provisions are made to prevent the platform from being abraded by the line and the line guarded to prevent employees working on the platform contacting it.
(j) Inside derrick platform shall not be installed in a derrick in such a position that it would obstruct the driller's or hoist operator's view, when at their operating stations, of either the crown block or the traveling block at any point of its travel.
(k) An inside derrick platform which is more than three and one-half feet (3 1/2 ') above the outside derrick platform which serves it and to which the main derrick ladder does not provide direct access shall have access provided thereto by means of an auxiliary derrick ladder from the outside derrick platform below to a point not less than three and one-half feet (3 1/2 ') above the inside platform.
(l) A finger or finger brace shall not be used as a principal inside derrick platform. A finger board may be used as an inside derrick platform when it meets the requirements for an inside derrick platform and provides safe working space between the traveling block or hoisting lines and the pipe racked in the derrick tower.
Exception: This subsection does not apply to (G-1) derricks unless the monkey board type platform is installed after the effective date of these orders.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 6561. Outside Derrick Platforms.
(a) Every derrick used for drilling or redrilling shall have a continuous outside derrick platform at least two feet (2 ') wide completely around the derrick at an elevation not more than two feet (2 ') above and not more than one (1) girt [not to exceed eight feet (8 ')] below the principal inside derrick platform.
(b) Every derrick used for drilling or redrilling shall have an outsidederrick platform at least two feet (2 ') wide across the side of the derrick in which each auxiliary inside derrick platform is located. This outside derrick platform shall be parallel to the longest side of the inside platform and shall be two feet (2 ') or less from adjacent derrick legs and at an elevation not more than two feet (2 ') above and not more than one (1) girt [not to exceed eight feet (8 ')] below the inside platform. A minimum vertical clearance of at least six and one-half feet (6 1/2 ') shall be maintained between outside derrick platforms. (continued)