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(continued)
(d) Permits shall be issued only if tanks and systems comply in all respects with these orders and all inspection fees are paid.
(e) Qualified inspectors employed by insurance companies shall immediately notify the Division of the name of the owner or user, as shown on the permit to operate, the location and state serial number of every air tank on which insurance has been refused, canceled or discontinued, and shall give the reasons why.
(f) Qualified inspectors employed by other than insurance companies shall immediately notify the Division of the name of the owner or user and the location and state serial number of every tank inspected by them which is removed from active service or which is considered unsafe for further service as an air tank, and shall give the reasons why.
Note: Nothing in these order shall prevent a qualified safety engineer employed by the Division from inspecting any tank. However, no inspection fee shall be charged by the Division where the required inspection has been made and the provisions of subsection (c) above have been met.
(g) Qualified inspectors making the first field inspection of air tanks required by these Orders to have a permit to operate shall stamp on the tank a State serial number (unless a State serial number has previously been stamped thereon) which shall become a permanent means of identification. This assigned number shall be made either by steel die figures not less than 5/16 inch in height, or outlined by means of center punch dots with figures not less than 3/4 inch in height, and shall be stamped adjacent to the manufacturer's ASME Code stamping or above an inspection opening if the ASME Code stamping is not accessible.
(h) No state serial number or ASME Code stamping shall be permanently covered by insulating or other material unless such number and stamping is transferred to a fixed plate readily visible outside of all insulating material.
(i) Whenever the condition of an air tank is such as to make it unfit for air pressure service, a qualified safety engineer employed by the Division may affix a rejection mark (X) consisting of an "x" at least 1 inch in height with a circle at least 1/2 inch in diameter located between the upper arms of the "x." The rejection mark shall be outlined in center punch marks and located immediately above or adjacent to the state serial number.
(j) All air tanks shall have inspection openings in compliance with the ASME Code. When inspection openings are not provided, the owner or user shall provide such openings, one (1) in each head or in the shell near each head and approximately opposite the longitudinal seam, as follows:
(1) Tanks 12 inches or less in inside diameter shall have at least two threaded openings not less than 3/4 inch pipe size.
(2) Tanks less than 18 inches and more than 12 inches in inside diameter shall have at least two handholes or two plugged, threaded openings not less than 1 1/2 inch pipe size.
(3) Tanks 18 inches to and including 36 inches in inside diameter shall have a manhole or at least two handholes or two plugged, threaded inspection openings not less than 2-inch pipe size.
(4) Tanks exceeding 36 inches in inside diameter shall have a manhole, except those whose shape or use makes a manhole impractical; in which case two handholes 4 inches by 6 inches or two openings of equivalent area may be substituted for the manhole opening.
(5) (A) An elliptical manhole shall be not less than 11 inches by 15 inches or 10 inches by 16 inches in size. The inside diameter of a circular manhole shall be not less than 15 inches.
(B) A handhole shall be at least 2 inches by 3 inches in size. It may be larger, depending upon the size of the tank and the location of the opening.
(C) All access and inspection openings shall be designed in accordance with the rules of the ASME Code for openings.
(k) Air tanks used in systems which have had moisture removed to the degree that the air has an atmospheric dew point of -50 degrees F or less, shall not be required to have inspection openings.
(l) Air tanks shall meet and be installed in accordance with the following requirements:
(1) Air tank supports and appurtenances shall be in accordance with Paragraph UG-22 and recommended design practices of Appendix G of Section VIII, Division 1 of the ASME Code with sufficient clearance provided under the tank to allow for operation of the drain valve.
(2)(A) Air compressor units which have a reciprocating compressor and a driving unit over two horsepower mounted on the tank shall be in accordance with the requirements of paragraphs (B) and (C) as follows:
(B) The tank manufacturer's data report shall show the tank and machinery supports provided by the tank manufacturer. When reinforcing pads are used as a means of stress distribution at the legs and/or base plate attachment they shall be designed to minimize regions of high stress concentration and be sealed in such a manner as to inhibit corrosion.
(C) Based on written certification from the vessel manufacturer stating compatibility of the vessel and compressor-driving system, the assembler shall permanently affix a label or apply stamping with letters and figures not less than 5/32 inch in height to the side of the vessel machinery platform showing 462(l )(2) compliance. In those cases where the tank manufacturer is the assembler, this data shall be permitted to be stamped on the ASME Code nameplate, separated from the ASME Code stamping. Upon request of the Qualified Inspector or the Division, design calculations incorporating system dynamics or experimentally obtained test data shall be furnished by the tank manufacturer to verify compliance with this Order.
(D) New air tanks not complying with this subsection shall not have a reciprocating compressor and driving unit mounted on the tank unless the supports are modified to the satisfaction of the Qualified Inspector, and the Division.
(3) All visible undercuts at butt, groove, or fillet welds must be repaired prior to issuance of the permit to operate.
(4) The employer shall notify the Division and the inspection agency before further use in the event of cracking or leaking of the air tank.
(5) If an air tank has cracked because of the compressor mounting or supports, the compressor and driving unit shall be reinstalled separately from the air tank in accordance with the requirements of the applicable Safety Orders, unless the supports are modified to the satisfaction of the Qualified Inspector and the Division. Whenever possible, the reinstallation of the compressor and driving unit shall be in accordance with the recommendations of the original assembler. The reinstallation must be acceptable to the Qualified Inspector.
(m)(1) Air piping shall be in accordance with ANSI B31.1 or B31.3.
(2) All piping from the tank to the first shut-off valve shall be Schedule 80 metallic pipe.
(3) Plastic piping systems may be used for compressed air conveyance above and below ground, when meeting all of the following requirements:
(A) Only ductile plastic materials shall be used.
(B) Only plastic pipe, valves and fittings recommended for use by the manufacturer to convey compressed air shall be used.
(C) Plastic pipe, valves and fittings shall not be used for compressed air systems over 150 psi or temperatures over 140 degrees F.
(D) Plastic piping systems shall be designed, installed, maintained, and operated in full accordance with the manufacturer's specifications and instructions.
(E) All plastic pipe shall be permanently marked continuously, but not to exceed 5-foot intervals, with the following information:
1. Size;
2. Manufacturer's name;
3. Pressure rating at 73 degrees F and 140 degrees F;
4. Material name, specification, ASTM cell classification, batch number, and the date of manufacture;
5. The words "For Compressed Air"; and
6. Either Schedule, "Sch Number", or Standard Dimension Ratio, "SDR Number".
(F) All plastic valves and fittings shall be permanently marked with the following:
1. Size;
2. Manufacturer's name or logo;
3. Pressure rating at 73 degrees F; and
4. Material name.
(G) Plastic valves and fittings shall be of the same manufacturer and materials as the pipe.
(H) Only joining compounds meeting or exceeding manufacturer's specifications shall be used when assembling the plastic pipe.
(I) The employer shall use pipe that meets or exceeds the test requirements listed in Appendix C, and upon request, supply the Division written laboratory certification from the manufacturer that the pipe meets or exceeds all test requirements listed in Appendix C of these orders.
(J) The pipe system components, pipe, valves, fittings, and joining compounds shall be designed for the full working pressure of the system for its design life.
Exception: Pipe or tubing under 3/8-inch diameter need not meet these requirements.
(4) Plastic pipe and fittings that do not meet the requirements of subsection (m)(3) may be used in compressed air service, provided that all of the following conditions are satisfied:
(A) Pressure shall be limited to 150 psi, temperature to 120 degrees F, size up to 2-inch diameter pipe size, and wall thickness to Schedule 40 or heavier;
(B) The piping system shall be protected from mechanical damage along its entire length by either location or actual guarding. The guarding shall be of sufficient strength to withstand any anticipated impact. It shall also be capable of containing exploding fragments; and
(C) The piping system shall be supported and secured by U bolts, conduit supports, rigid hangers or similar methods at intervals not to exceed five (5) feet.
(n) Any air tank having dished heads or conical heads the skirt (flange) and/or the knuckle radius of which does not meet the minimum ASME Code requirements shall have such heads stayed as flat surfaces in accordance with the ASME Code rules for braced and stayed flat plates. Any head dished to a radius greater than the diameter of the tank to which it is attached shall be stayed as a flat surface in accordance with the ASME Code rules for braced and stayed flat plates. No allowance shall be taken in such calculations for the curved portion of the head.
(o) All air tanks, including existing installations, having unstayed dished heads without a transition knuckle for attachment to the shell shall be permanently removed from service with the rejection mark affixed by the qualified inspector, as required in Section 462 (i).
(p) The bottom dished head of an air tank operated in the vertical position shall not be dished inward but must be concave to pressure.
Note: Authority cited: Section 142.3, Labor Code. Reference: Sections 142.3, 7650 and 7681, Labor Code.
s 463. Certification of Inspectors.
Inspectors shall be certified in accordance with Section 779 of the Boiler and Fired Pressure Vessel Safety Orders.
s 464. Air Tank Inspection Fees.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 465. Safety Devices and Systems.
(a) Each air tank shall be protected by 1 or more safety valves and other indicating and controlling devices that will insure safe operation of the tank. If the tank has a volumetric capacity in excess of 2,000 gallons, it shall be fitted with at least 2 safety valves, the smallest of which shall have a relieving capacity of at least 50 percent of the relieving capacity of the largest valve.
(b) Safety relief valves shall:
(1) Be constructed and installed in accordance with ASME Boiler and Pressure Vessel Code, Section VIII.
(2) Be located and installed so that they cannot be readily rendered inoperative.
(A) No valve of any description shall be placed between the required safety valve or rupture disc and the air tank.
(B) The opening or connection between the tank and safety valve or valves shall have a cross-sectional area at least equal to the combined areas of all attached safety valve inlets.
(3) Be of the direct spring-loaded type. The springs shall not be adjusted to carry more than: 10 percent greater pressure than the set pressure stamped on the valve up to and including 250 psig; or 5 percent greater pressure than the set pressure stamped on the valve above 250 psig.
(A) For pressures of 2000 psig or less safety valves shall be equipped with a substantial lifting device so that the disc can be easily lifted from its seat not less than 1/8 the diameter of the seat when the pressure in the tank is 75 percent of that at which the safety valve is set to open.
(B) For pressures exceeding 2000 psig: the lifting device may be omitted providing the valve is removed for testing at least once each year and a record kept of this test and made available to the qualified inspector; acceptable rupture discs may be used in lieu of safety valves provided they are in compliance with Section 465 (b) (2), (4) and (5).
(4) Be set to open at not more than the allowable working pressure of the tank.
(5) Have a relieving capacity sufficient to prevent a rise of pressure in the tank of more than 10 percent above the allowable working pressure when all connected compressors are operating with all unloading devices rendered inoperative.
(6) When exposed to a temperature of 32 degrees Fahrenheit or less, have a suitable drain at the lowest point where water can collect.
(7) Not have seats or discs of cast iron.
(8) Be tested frequently and at regular intervals to determine whether they are in good operating condition.
(c) Discharge pipes from safety valves and rupture discs installed on air tanks shall:
(1) Have a cross-sectional area at least equal to the combined outlet areas of all valves discharging into them.
(2) Be designed and installed so that there will be no interference with the proper operation or discharge capacity of the safety valve or rupture disc.
(3) Have no valve of any description.
(4) Be fitted with open drains which will prevent the accumulation of liquid above the safety valve or rupture disc.
(5) Be installed and supported in a manner that will prevent undue stresses on the safety valve or rupture disc.
(6) Be led to a safe place of discharge.
(d) Each air tank shall be equipped with a suitable pressure-indicating gage with the dial graduated to approximately double the operating pressure, but in no case less than 1.2 times the pressure at which the safety-relieving device is set to function.
(e) Each air tank shall be equipped with a manually operated, valved drain located at the lowest point where water can collect. The valve for this drain shall be suitably located for convenient operation. Automatic drains shall not be considered as complying with this order unless also equipped with a manually operated by-pass.
Note: It is recommended that each air tank be completely drained of accumulated moisture at least once during each day of operation.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 466. Repairs and Alterations.
(a) No alteration or repair affecting the safety of any air tank covered by these Orders shall be made without the authorization of a qualified inspector.
(b) Any air tank which has suffered mechanical damage causing dents or other deformations exceeding a depth of 1 1/2 times the thickness of the deformed head or shell or two percent of the tank diameter, whichever is greater, shall be properly re-formed to its original shape or otherwise repaired as provided in these Orders. Deformations less than these amounts located in areas of high stress concentration and/or having abrupt changes in configuration may be required to be reformed to their original shape at the discretion of the qualified inspector.
(c) Any areas that are deteriorated by internal or external corrosion or by mechanical abrasion that affects the safety of the tank shall be properly repaired or the allowable working pressure shall be reduced proportionately. The building up by welding of such area is prohibited, except isolated pits shall be permitted to be properly prepared and welded at the discretion of the qualified inspector.
(d) No welded repair shall be permitted on a tank of brazed construction. If inspection openings are required in such tanks, they may be machine-cut and closed with handhole plates.
(e) Any welding necessary when making major repairs or alterations to tanks shall be done by a welder qualified in accordance with Section IX of the ASME Code in the position or positions used in making the repair or alteration.
(1) When minor welding repairs or alterations, such as closing openings not exceeding 2 inch pipe size, installing reinforcing rings around handhole openings, installing staybolts or through stays, etc., are made by a welder who is not ASME qualified, these repairs or alterations shall be authorized and approved by a qualified inspector.
(f) The qualified inspector who authorizes any welded repair or alteration shall report it to the Division within 21 days, giving full details, including the State serial number of the tank, the name and address of the owner or user, the location of the tank, and the name and address of the welder and the welder's employer.
(1) The qualified inspector shall stamp his/her certificate of competency number adjacent to all welded repairs authorized.
(g) If the longitudinal seam of any non-code air tank of welded construction is found to have incomplete penetration of the welded joint, the tank shall not be repaired. Such tanks shall be permanently removed from service, with the rejection mark affixed by the qualified inspector, as required in Section 462(i).
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 467. Controls.
(a) Any pressure vessel not specifically covered or exempted elsewhere in these Orders shall be protected by one or more safety valves or rupture discs set to open at not more than the allowable working pressure of the vessel and by such other controlling and indicating devices as are necessary to insure safe operation of the pressure vessel.
(b) The owner or user of any pressure vessel not specifically covered or exempted elsewhere in these Orders shall provide such inspection and maintenance as is necessary to insure safe operation of the pressure vessel.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
The provisions of Article 5 need not apply to liquefied petroleum gas
installations up to the point of delivery to a transportation tank in plants
manufacturing this product, nor beyond the storage tanks in plants using this
product for processing only and not for fuel; provided, however, that tanks
used in such plants shall be designed and constructed in accordance with
provisions of Article 2, and shall be maintained and operated in accordance
with the provisions of Article 4 of these Orders.
s 470. Permit to Operate.
(a) Except during the time a request for a permit remains unacted upon, no employer or employee shall use or cause to be used any pressure vessel for the storage or transportation of LP-Gas without first securing from the Division a permit to operate such container.
Exception: No permit to operate shall be required for pressure vessels of 125 gallons capacity or less or for cylinders used, inspected, and maintained in accordance with DOT regulations.
(b) Permits to operate dispensing units, trap tanks, and skid tanks shall expire in not more than 3 years while the permit to operate transportation tanks, mobile fuel tanks, and storage tanks shall expire in not more than 5 years.
It is intended that failure to maintain the installation in compliance with these Safety Orders will be justification to void the permit and require reinspection.
(c) The permit to operate any tank shall expire when any of the following occurs:
(1) The tank changes both ownership and location.
(2) Alterations are made which affect the safety of the installation.
(3) The tank has suffered mechanical or fire damage.
The permit to operate shall not expire due to the exchange or interchange of approved appurtenances intended for the same purposes.
(d) The permit to operate, or an acceptable copy, shall be kept readily available on the premises upon which the tank is located and shall be available at all times to any qualified inspector. In the case of a transportation or portable tank, the permit may be carried in the cab of the towing vehicle or in a suitable weatherproof container secured to the unit.
(e) No person shall charge LP-Gas into any tank requiring a permit to operate unless the permit to operate has been issued and posted, except where a request for a permit remains unacted upon. Containers shall be filled or used only upon authorization of the owner.
(f) No permit to operate shall be issued for any tank until all provisions of these Orders have been complied with and the required fee has been paid.
(g) Any tank that has been used for the storage or transportation of products other than LP-Gas shall be inspected internally by a qualified inspector at the time of the periodic inspection required by Section 470 (i).
(h) At the time of the first field inspection of each tank requiring a permit to operate, the qualified inspector shall stamp on the tank a state serial number in accordance with Section 462 (h).
(i) Except as permitted in Section 470 (a) each LP-Gas tank shall be inspected in accordance with the intervals shown in Section 470 (b).
(j) Inspectors shall be certified in accordance with Section 463.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 471. Control of Products in Tanks and Cylinders.
(a) No LP-Gas shall be transported or delivered into any vessel covered by these Orders until first odorized using a warning agent of such character that the gases are detectable, by a distinct odor, down to a concentration in air of not over one-fifth the lower limit of flammability.
Exception: When the LP-Gas is to be used exclusively in a process where the presence of an odorant would make the LP-Gas unfit for use in the process and for deliveries between refineries or between producing wells and refineries, a waiver may be obtained from the Division upon written request.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 472. Charging LP-Gas Containers.
(a) Air pressure shall not be used to displace LP-Gas during the transfer operation.
(b) All filling connections shall be kept effectively plugged or capped when not in use. These caps or plugs shall be so designed that they will vent to the atmosphere while at least 3 full threads are engaged.
(c) An accessible 24-hour communication service shall be required for self-service dispenser systems.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 473. Gauging Devices.
(a) A permanent dip pipe or a fixed level gauge shall be installed in all containers filled by volume and shall be of such length or position that it will indicate when the tank is 86 1/2 percent full.
(1) This fixed dip tube or fixed level gauge shall be permanently installed in the tank. Additional dip pipes or fixed level gauges may be used providing they are permanently marked to show the outage they indicate.
(b) Each tank 125-gallon capacity or more, filled by volume, shall be equipped with a liquid level gauging device, such as a rotary gauge, magnetic gage, or series of fixed pipes, in addition to the fixed dip pipe required in Section 473(a).
(c) Each tank having an allowable working pressure of less than 250 psi shall have a thermometer well. This Order does not apply to tanks built before January 1, 1946, or to code tanks constructed in accordance with Paragraphs U-68, U-69, and UW-52 (b) for a working pressure of 200 psi or more. The thermometer well shall be plugged or capped when not in use to prevent the entrance of moisture and the resulting hazard of corrosion.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 474. Approval of Devices.
(a) All devices which are used in LP-Gas installations shall be of an approved type and construction suitable for the use intended. See "Approved."
(b) LP-Gas shall not be used to operate any device or equipment designed to be operated with compressed air, nor shall LP-Gas vapor be released into the air, except as provided for by these Orders.
(c) Container valves, connectors, regulators, manifolds, piping, and tubing shall not be used as structural supports for heaters.
(d) All electrical wiring and electrical equipment shall be in accordance with the Electrical Safety Orders administered by the Division and NFPA 58 Section 3-7.2.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 475. Location of Storage Containers and Regulating Equipment.
(a) A single container of 575 gallons or less water capacity can be located 10 feet from an important building providing such container is at least 25 feet from any other container of more than 125 gallons water capacity. For important buildings constructed of concrete or masonry materials with no overhanging roof:
(1) A single container up to 500 gallons capacity may be located not less than 3 feet from an important building provided there is no opening in the building within 10 feet.
(2) A single container 501 to 1200 gallons capacity may be located not less than 3 feet from an important building provided there is no opening in the building within 25 feet.
(b) No stationary storage container shall be located less than 10 feet from the nearest street line or sidewalk, or less than 50 feet from the center line of any railroad main track.
(c) Installation of stationary LP-Gas containers on the rooftop shall be prohibited.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 476. Location and Installation of Underground Tanks.
s 477. Installation of Containers
(a) Aboveground Containers.
(1) Metallic structural supports, when used, shall be encased in concrete or other material having a fire-resistant rating of at least 2 hours when the distance between the lower surface of the tank and the top of the concrete or masonry foundation exceeds 18 inches.
(2) Aboveground storage containers shall be protected from impact from vehicles by means of crashposts, curbs, fences, railings or similar barriers. Where crashposts are used, they shall be no less than 5 feet long with 2 feet below ground and encased in concrete. Posts shall be no less than 4 inches in diameter and be filled with concrete if the wall thickness is less than that of standard pipe. Posts shall be 4 feet apart on centers (maximum) and at least 3 feet from the storage container. Other materials may be used and shall provide equivalent protection. Such curbs or fences shall be arranged so they will not hamper free ventilation around the containers.
(3) Containers installed in battery shall not be installed with liquid and vapor lines connecting into common headers unless either:
(A) the working pressure of all such containers is at least equal to the vapor pressure of the product stored in any such container; or,
(B) check valves or other devices are installed in the system to prohibit the introduction of the higher-pressure product into the lower-pressure container.
(b) Mounded Containers.
Containers shall not be mounded unless written permission to do so has been obtained from the Division.
In addition to the requirements of NFPA 58, Section 3-2.4.7, the following construction, maintenance, and documentation provisions shall apply:
(1) Construction.
(A) Where containers are to be installed closer than 30 inches above surrounding grade, a moisture barrier to prevent the upward migration of potentially corrosive salts or acids shall be installed.
(B) Drainage tile or pipe shall be installed to prevent the accumulation of moisture within the insulating medium. Where a moisture barrier is installed, the drainage material shall be placed above that barrier.
(C) Relief-valve capacity and installation shall be that which is required for aboveground containers and shall comply with NFPA 58, Section 3-2.6.3, as measured from the tank shell.
(D) All container-liquid and vapor-transfer openings shall be fitted with pneumatically-controlled internal-type valves incorporating excess-flow protection or spring-loaded backflow check valves. Remote emergency shutdown capability shall be provided.
(E) Container valves and appurtenances shall be accessible for operation, repair, or maintenance without disturbing mounding material.
Note: Access crawlways shall be evaluated for compliance with the Confined Space Safety Orders, General Industry Safety Order, Article 108.
(F) Prior to mounding, inaccessible plugged openings, joints, and other appurtenances shall be tested for leaks at operating pressure.
(G) Liquid level and pressure gauges shall be accessible visually and physically and shall be vented outside of the mounding.
(H) Mounded containers shall be protected against corrosion by coating the container with corrosion-resistant material approved for buried installations provided the material is applied in accordance with the manufacturer's recommendations. The employer/user shall submit to the Division a copy of the manufacturer's data for the coating material showing the method and procedures for coating prior to installation.
(I) All containers shall be cathodically protected and electrically isolated from connecting piping or electrically conducive structures in accordance with good engineering practice.
(J) Depth gauges shall be installed at intervals of not greater than 6 feet along the vertical center line of the container to visually indicate when insulating material becomes less than 1 foot in depth over the container.
(2) Maintenance Requirements.
(A) Filling densities shall be as required for aboveground containers.
(B) Voltage readings from the cathodic system shall be taken and recorded annually and shall produce a negative voltage of at least 0.85 volts with reference to a saturated copper-copper sulfide half cell.
(C) All mounded containers shall be completely uncovered for an inspection of all external surfaces at intervals of at least once every 5 years. The intervals shall be extended when no failure in the cathodic protection has been detected, provided that every container shall be uncovered at least once every 30 years. Alternate methods of inspection may be used, e.g., UT, internal inspection.
(D) Where passive cathodic protection is provided, amperage readings shall be taken annually from each sacrificial anode. Where impressed current is used, amperage and voltage readings shall be reported at 6-month intervals.
(E) The depth gauges across the top of the container shall be observed annually to determine that a minimum of one-foot coverage of insulating material exists over the top of the entire container.
(F) Leak surveys shall be conducted annually using a combustible-gas indicator or comparably effective instrument to sample the air from the drainage system beneath the container and from test holes surrounding the container at intervals not greater than 10 feet.
(3) Documentation.
(A) The following documentation shall be maintained for the life of the system:
1. The construction requirements of this Section and of NFPA 58, Section 3- 2.4.7 shall be documented through the use of photographs and other appropriate means.
2. All tests required in this Section shall be recorded in a system log showing the date the tests were taken, the related readings, and the name of the person making the tests. These tests shall be available to the Division at any time for the purpose of inspection and verification and shall be retained for the life of the installation.
3. The owner or operator of a mounded container shall send a copy of the system log for that container to the Division's principal safety engineer each year during the month of June.
(c) Underground Containers.
Containers shall not be installed underground unless written permission to do so has been obtained from the Division.
In addition to the requirements of NFPA 58, Section 3-2.4.8, the following construction, maintenance, and documentation provisions shall apply:
(1) Construction.
(A) Underground containers shall be protected against corrosion by coating the container with corrosion-resistant material approved for buried installations provided the material is applied in accordance with the manufacturer's recommendations. The employer/user shall submit to the Division a copy of the manufacturer's data for the coating material showing the method and procedures for coating prior to installation.
(B) All containers shall be cathodically protected and shall be electrically isolated from connecting piping or electrically conducive structures in accordance with good engineering practice.
(C) No tank used underground shall be installed aboveground until it has been inspected and found to be in compliance with requirements for an aboveground installation.
(2) Maintenance Requirements.
(A) Voltage readings from the cathodic system shall be taken and recorded annually and shall produce a negative voltage of at least 0.85 volts with reference to a saturated copper-copper sulfite half cell.
(B) All underground containers shall be completely uncovered for an inspection of all external surfaces at intervals of at least once every 5 years. The intervals shall be extended when no failure in the cathodic protection has been detected, provided that every container shall be uncovered at least once every 30 years.
Alternate methods of inspection such as internal inspection and ultrasonic testing may be used to check and verify the integrity of the container in lieu of it being uncovered.
(C) Where impressed current is used, amperage and voltage readings shall be recorded at 6-month intervals.
(D) Leak surveys shall be conducted annually using a combustible-gas indicator or comparably effective instrument to sample the air from the tests holes surrounding the container at intervals not greater than 10 feet.
(3) Documentation.
(A) The following documentation shall be maintained for the life of the system:
1. The construction requirements of this Section and NFPA 58, Section 3-2.4.8 shall be documented through the use of photographs and other appropriate means.
2. All tests required in this Section shall be recorded in a system log showing the date the tests were taken, the related readings, and the name of the person making the tests. These tests shall be available to the Division at any time for the purpose of inspection and verification and shall be retained for the life of the installation.
3. The owner or operator of a underground container shall send a copy of the system log for that container to the Division's principal safety engineer each year during the month of June.
(d) Partially Underground/Mounded Containers.
Partially underground or partially mounded containers shall be prohibited.
(e) Fusible plugs and/or rupture discs are prohibited for any container installed or reinstalled after the effective date of these orders.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 478. Skid and Trap Tanks, and Containers on Transportation and Bulk Delivery Vehicles.
(a) Unless installed in compliance with Section 477(a), skid and trap tanks shall not be used at any location for more than 180 days without written permission from the Division.
(b) Transportation tanks, or other tanks mounted on wheels, shall not be used in lieu of storage tanks or skid tanks without written permission from the Division. Such permission shall be granted for temporary use only and not to exceed 180 days.
Note: Authority cited: Section 142.3, Labor Code; and Section 13241, Health and Safety Code. Reference: Section 142.3, Labor Code.
s 479. Installation of Tanks on Transportation and Bulk Delivery Vehicles.
s 480. Pipes and Fittings for All Liquid Lines and for Vapor Lines Where the Pressure Exceeds 20 PSI.
(a) All pipe between the container and first shutoff valve shall be Schedule 80 (extra heavy). All fittings between the container and first shutoff valve shall be steel as required by Section 480(c).
Aboveground piping in excess of 1 1/2 inch pipe size may be Schedule 40 when used beyond the first shutoff valve, providing:
(1) Threaded connections are used and the piping is used for vapor service only at less than 125 psi.
(2) Welded connections are used and the piping is used for liquid or vapor service at less than 400 psi.
All other piping shall be Schedule 80.
Where used, flare nuts shall be of forged brass.
All welded piping shall be fabricated and tested in accordance with the ANSI Standard Code for Pressure Piping, Section 3, Petroleum Refinery Piping B-31.3, 1993 Edition or equivalent.
(b) Piping outside of buildings may be either buried or installed aboveground and shall be well-supported and protected against mechanical injury. All underground piping shall be Schedule 80 and shall be buried not less than 18 inches below the surface of the ground, unless otherwise protected, and shall be protected from corrosion by approved corrosion-resistant material and by cathodic protection.
Voltage readings from the cathodic system shall be taken and recorded annually and shall produce a negative voltage of at least 0.85 volts with reference to a saturated copper-copper sulfide half-cell. Where impressed current is used, amperage and voltage readings shall be recorded at 6-month intervals.
(c) All steel fittings used with Schedule 80 pipe shall be Schedule 80 if butt welded, 3,000 pounds WOG if socket welded, and 2,000 pounds WOG forged steel if threaded. All other steel fittings shall have a rating of at least Schedule 40 if butt welded, and 2,000 pounds WOG if socket welded or threaded.
All steel valves and fittings shall have a steam rating of at least one hundred fifty (150) psi, ANSI standard, with a minimum WOG rating of 250 psi. Valves of material other than steel shall have a pressure rating of at least two hundred (200) psi steam, or four hundred (400) psi WOG. The manufacturer of LP-Gas valves shall stamp or otherwise permanently mark the valve body to indicate the pressure rating. Steam valves when used for LP-Gas service shall be refitted for such service. Valve seat material, packing, gaskets, etc., shall be resistant to the action of LP-Gas.
(d) The use of the following is prohibited:
(1) Valves of a design that will allow the valve stem to be removed without removal of complete valve bonnet.
(2) Valves with valve stem packing glands which cannot be repacked under pressure, unless there is another valve of acceptable type between them and the tank.
(3) Aluminum tubing.
(4) Pipe nipples used in lieu of couplings or flanges on tanks.
(5) Multivalves without excess-flow valves and fixed dip tubes for use other than DOT cylinders.
(e) In addition to the valves required in NFPA 58, Section 2-3.3.2, all liquid and vapor connections shall be fitted with manually operated shutoff valves located as close to the container as practicable.
(f) Where containers are in liquid service or a combination of liquid and vapor service, all connections with manually operated shutoff valves shall be legibly labeled to indicate whether they communicate with the vapor or liquid space.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 481. Pipes and Fittings for Vapor Lines Where the Pressure Is 20 PSI or Less.
Note: Authority and reference cited: Section 142.3, Labor Code.
s 482. Hose Specifications.
s 483. Pressure Gages.
s 484. Vaporizer Installation.
(a) Surge tanks, gas-air mix tanks, etc., containing vapor only, shall be located at least 3 feet from important buildings and property lines. Such tanks operating at pressures exceeding 20 psi shall be located not less than 10 feet from any building opening, whereas such tanks exceeding 501 gallons shall be located not less than 25 feet from any building opening.
(b) The use of direct-fired container heaters is prohibited.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 485. Safety Valves.
s 486. Regulators.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 487. Regulator Installation.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 488. LP Gas Tank Inspection Fees.
See the Division of Occupational Safety and Health's regulations contained in Chapter 3.2, Group 2, Title 8, California Code of Regulations. The regulations for LP Gas tank inspection fees are reprinted in Appendix C of these orders.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 489. Warning Signs.
(a) All containers in excess of 125 gallons, except transportation containers and fuel containers on motor vehicles, shall have the word "FLAMMABLE" on each side that is readily visible. The letters of this sign shall be in standard-type letters and shall have a height of at least 1/12 of the diameter of the container, but need not be in excess of 1 1/2 inches for containers of 500 gallons capacity or less or 4 inches for containers exceeding 500 gallons capacity.
(b) Warning signs with the words "NO SMOKING, OPEN FLAMES OR OTHER SOURCE OF IGNITION PERMITTED WITHIN ______ FEET" shall be applied in letters at least 1 1/2 inches high, in sharply contrasting colors, on each stationary container or on a sign posted adjacent to the container. This sign shall also be posted adjacent to all loading and unloading terminals located more than 50 feet from the container.
(c) When 2 or more containers are installed in battery, the requirement of Sections 489 (a) and (b) will be considered as being complied with when the required warning signs are prominently displayed on all 4 sides of such battery of containers.
Note: The distance shall be that shown on the following table:
Volumetric capacity of .......... Minimum distance
Containers (in U.S. gallons) ... from source of ignition
125 to 500 inclusive............. 10 feet
501 to 2,000 inclusive........... 25 feet
Over 2,000....................... 50 feet
(d) The warning signs required in Section 489(b) shall be posted on each exterior wall of each room or building used for filling or storage of cylinders.
(e) When LP-Gas and one or more other gases are stored or used in the same area, the containers shall be marked to identify their content. Markings shall be in compliance with ANSI Z48.1-1992, "Method of Marking Portable Compressed Gas Containers To Identify the Material Contained."
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 490. Installation of Fuel Tanks for Motor Vehicles.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 491. Installation of Fuel Tanks and Cylinders Used on Tar Pots, Weed Burners, Etc.
s 492. Use of Tanks and Cylinders of Less than 60 U.S. Gallons.
s 493. Storage or Utilization of LP-Gas Within Buildings.
s 494. Repairs and Alterations.
(a) No repairs or alterations involving flame, arc, or other method of welding shall be made on any container cylinder, or system unless such container, cylinder, or system shall first have been certified as gas free or oxygen free by a qualified person.
(b) No repair or alteration affecting the safety of any container or cylinder shall be made until the contemplated repair or alteration has been authorized by a qualified inspector. The owner or user of the LP-Gas container shall ensure that the repair or alteration is performed by a company with a valid ASME "U" or a National Board "R" Certificate of Authorization. The exchange or interchange of valves, fittings, and accessories intended for the same purpose shall not be considered a repair or alteration.
(c) No container or cylinder that has been subjected to a fire shall be returned to service until it has been inspected by a qualified inspector and found to be safe.
Any container or cylinder which has suffered mechanical damage causing dents or other deformation exceeding a depth of 1 1/2 times the thickness of the deformed head or shell or two percent of the container diameter, whichever is greater, shall be re-formed to its original shape or otherwise repaired as provided in these Orders.
(d) Any vessel requiring repair or alteration or that has been subjected to a fire shall not be recharged until it has been retested in accordance with the requirements for its original hydrostatic test and found to be suitable for continued service, when such test is deemed necessary by the qualified inspector.
(e) The owner or user of the LP-Gas container shall ensure that all repairs or alterations affecting the safety of LP-Gas tanks are reported to the Division within 21 days by the ASME "U" or National Board "R" certificate holder making such repairs or alterations using the appropriate National Board Form, "R-1", Report of Welded Repair, or "R-2", Report of Alteration, or equivalent (See Appendix D). The owner or user shall ensure that the qualified inspector stamps his/her certificate of competency number adjacent to all welded repairs authorized by him/her, except that in the case of repairs to quenched and tempered steels, this number need not be stamped. This exception shall be noted in the inspector's report.
(f) Any welding necessary when making repairs or alterations to containers shall be done by a welder qualified in accordance with Section IX of the ASME Code in the position or positions used in making the repair.
(g) Repairs to DOT cylinders shall be made under DOT regulations and control in accordance with the requirements of 49 CFR Section 173.34.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code; and Section 13241, Health and Safety Code.
s 500. Approval of Devices.
(a) All devices which are used in anhydrous ammonia service shall be of a type and construction suitable for the use to which they are put. They shall preferably be listed by at least one nationally recognized testing laboratory such as, but not limited to, Underwriters Laboratories, Inc. and Factory Mutual Engineering Corp. (For the purposes of this paragraph, the word "listed" means that equipment is of a kind mentioned in a list which is published by a nationally recognized laboratory which makes periodic inspection of the production of such equipment, and states such equipment meets nationally recognized standards or has been tested and found safe for use in a specified manner.)
The Division may approve or accept devices upon satisfactory evidence that they are designed and constructed for safe operation in anhydrous ammonia service.
Drawings and calculations for custom-built devices must be submitted to the Division for acceptance. Both the drawings and calculations must be signed by a registered professional engineer.
s 501. Installation of Aboveground Storage Tanks for Other Than Refrigeration Service.
(a) Stationary tanks shall be installed aboveground on firm masonry or concrete foundations, or on full length skids providing a bearing area limiting foundation loadings to not more than 2,000 pounds per square foot. Unless supported by continuous skids welded to pads on the tank shell, aboveground horizontal storage tanks shall have no more than 2 points of support longitudinally. Where necessary, tanks shall be securely anchored or weighted to prevent floating.
A tank may be installed on saddles, directly on concrete foundations, or it may be supported by properly designed metallic structural supports. When the tank is installed directly on concrete foundations, a corrosion pad shall be provided at the points of contact with the foundation. These corrosion pads shall be at least 3/16 inch thick, and shall have a width at least equal to the width of the foundation at the point of contact with the tank, but in no case shall they be less than 8 times the shell thickness in width.
When corrosion pads or pad-type steel supports are used, the pad shall have rounded or semielliptically shaped ends, and shall be attached to the shell with a continuous seal weld. Corrosion pads shall be not less than 1/4 the circumference of the shell in length.
Unless installed on concrete pads, skid tanks shall be placed on engineered soil or road base topped with well-drained gravel or oiled sand, capable of supporting 2,000 pounds per square foot.
Sufficient space shall be provided between stationary storage tanks to permit access for fire fighting. This space shall not be less than 5 feet for tanks over 1,200-gallon capacity. Tanks exceeding 1,200-gallon capacity shall be so installed that the bottom outside surface of the tank is at least 12 inches above ground level. (continued)