TRAINING GUIDE FOR OPERATORS OF

SMALL LP GAS SYSTEMS

Prepared for United States Department of Transportation, Pipeline and Hazardous Materials Safety Administration, Office of Pipeline Safety by the National Association of Regulatory Utility Commissioners Staff Subcommittee on Pipeline Safety

TO THE READER

The U.S. Office of Pipeline Safety promotes the safe transportation by pipeline of natural gas, LP gas, liquefied natural gas and hazardous liquids. This guidance manual for operators of small LP gas systems is part of our commitment to pipeline safety. This manual was developed to provide a broad overview of pipeline compliance responsibilities under federal pipeline safety regulations. It has been designed for the non-technically trained person who operates a master meter system, a small municipal system or a small independent system.

The federal government recognizes that most operators of small LP gas systems have not had extensive training in operation and maintenance of a gas system. In addition, many of the safety regulations are in technical language that addresses generic requirements for both large and small LP gas systems. Therefore, this manual attempts to simplify the technical language of the regulations.

For certain critical regulations, this manual provides specific details of methods of operation and selection of materials that will satisfy the pipeline safety regulations. However, this is often only one of several allowable options. To assure compliance in many areas of the pipeline safety regulations, this manual provides a set of examples that the operator of small systems can use to meet the minimum requirements of the pipeline safety regulations.

This training guide relies on sources representing the best opinion on the subject at the time of publication. However, it should not be assumed that all acceptable safety measures and procedures are mentioned in this manual. The LP operator is referred to 49 CFR Part 192 and NFPA 58 for additional details and other options for reaching and maintaining compliance.

Our aim is to provide basic information to LP operators of small gas distribution and master meter systems to ensure compliance with the Federal gas pipeline safety regulations.

It is hoped that this document will assist you in achieving and maintaining a safe and efficient LP system. The result will be to enhance public safety - the essential goal for the Office of Pipeline Safety.

Stacey Gerard Associate Administrator, Office of Pipeline Safety Pipeline and Hazardous Materials Safety Administration

ACKNOWLEDGEMENTS

The LP Gas Training Guide was initiated by the National Association of Regulatory Utility Commissioners Staff Subcommittee on Pipeline Safety.

The project was sponsored by the United States Department of Transportation, Pipeline and Hazardous Materials Safety Administration, Office of Pipeline Safety.

The following committee members are recognized as experts in their fields and have given generously of their unique knowledge. They were directly involved in the development of this training guide.

Richard G. Marini, P.E. (Committee Chair) New Hampshire Public Utilities Commission

Kenneth W. Wood Vermont Department of Public Service

Bill Lowry, P.E. USDOT/PHMSA/OPS Central Region

Vicki O’Neil Florida Department of Agriculture and Consumer Services

Jack Edwards USDOT/PHMSA/Transportation Safety Institute

Theodore C. Lemoff, P.E. National Fire Protection Association

Bennie Andrews USDOT/PHMSA/OPS Southern Region

This guidance manual was implemented under the sponsorship of the U.S. Department of Transportation. The manual relies on sources representing the best opinion on the subject at the time of publication. However, it should not be assumed that all acceptable safety measures and procedures are mentioned in this manual. The reader is referred to the Code of Federal Regulations (49 CFR Parts 190-199, Part 40 and also NFPA 58 and 59) for the complete pipeline safety requirements.

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TABLE OF CONTENTS INTRODUCTION

• Intro-1
• Definitions and Terms Intro-5
• Commonly Abbreviated Organizations Intro-7

CHAPTER I REPORTS REQUIRED BY THE FEDERAL GOVERNMENT I-1

• Incident Reports I-1
• Safety-Related Condition Reports I-2
• Annual Reports I-3

CHAPTER II

PLANS REQUIRED BY THE FEDERAL GOVERNMENT II-1

• Operations and Maintenance Plan II-1
• Operations Plans II-1
• Operating Pressure II-1
• Pressure Testing II-2
• Tapping and Purging II-3
• Odorization II-3
• Testing for Reinstating Service Lines II-4
• Abandonment or Deactivation of Facilities II-4
• Construction Records, Maps and Operating History II-5
• Unaccounted for Gas II-5
• Maintenance Plans II-6
• Pressure Limiting Devices II-7
• Patrolling II-8
• Key Valves II-8
• Accidental Ignition of Gas II-9
• Leak Survey II-9
• Corrosion Testing II-10
• Emergency Plans II-11
• Public Education Plan II-17
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CHAPTER III MATERIALS AND EQUIPMENT QUALIFIED III-1

FOR USE IN PROPANE GAS SYSTEMS

• Introduction III-1
• Tanks III-1
• Pipe III-2
• Tubing III-3
• Fittings III-3
• Valves III-7
• Overpressure Protection Equipment III-8

CHAPTER IV

CONSTRUCTION AND REPAIR IV-1

• Planning Ahead IV-1
• Pipe Installation, Repair and Replacement: General Comments IV-2
• Metallic Pipe Installation IV-2
• Plastic Pipe Installation IV-3
• Repair Methods - Plastic and Metal IV-15

CHAPTER V

PROPER LOCATION AND DESIGN OF TANKS REGULATORS AND METER SETS V-1

• Tanks, Regulators and Meters: Location V-1
• Tanks, Regulators and Meters: Protection from Damage V-2
• Customer Meter Installations: Operating Pressure V-3
• Service Lines: Location of Valves V-4
• Service Lines: Under a Building V-5
• Common Problems at Risers, Service Regulators and Customer Meters V-5

CHAPTER VI

ONE-CALL DAMAGE PREVENTION PROGRAM VI-1

• One-Call Systems VI-1 VI-1VI-2 VI-2 VI-2
• Excavation
• Emergency Excavation
• Precautions to Avoid Damage
• Repair of Excavation Damage

CHAPTER VII VII-1

OPERATOR QUALIFICATION

• General Requirements VII-1 VII-1 VII-1 VII-2
• Covered Task
• Operator Qualification Program
• Recordkeeping

CHAPTER VIII VIII-1

CORROSION CONTROL

• Federal Requirements VIII-1 VIII-1 VIII-1
• Procedures and Qualifications
• Techniques for Compliance
• Installed After July 31, 1971 VIII-1
• Corrosion Control Requirements for Pipelines Installed Before August 1, 1971 VIII-2VIII-3 VIII-3 VIII-3 VIII-3 VIII-4VIII-4 VIII-4 VIII-4 VIII-4 VIII-4
• Coating Requirements
• Examination of Exposed Pipe
• Criteria for Cathodic Protection
• Monitoring
• Electrical Isolation
• Test Points
• Internal Corrosion Inspection
• Atmospheric Corrosion
• Remedial Measures
• Records
• Some Principles and Practices of Cathodic Protection VIII-4
• Basic Terms VIII-5 VIII-14 VIII-16 VIII-16
• Fundamental Corrosion Theory
• Types of Cathodic Protection
• Galvanic Anode Systems
• Impressed Current Systems VIII-17
• Initial Steps in Determining the Need to Cathodically Protect a Small Gas Distribution System VIII-17
• Criteria for Cathodic Protection VIII-20
• Coatings VIII-21
• Mill Coated Pipe VIII-21
• Patching VIII-22
• Coating Application Procedures VIII-22
• Common Causes of Corrosion in Gas Piping Systems VIII-23

CHAPTER IX

LP GAS REGULATORS IX-1

• Basic Concepts for LP Gas Regulators IX-1
• Components of a Typical Regulator IX-2
• How a Regulator Works IX-3
• Typical positive back pressure regulator IX-3
• Relief operation IX-3
• Positive back pressure regulators IX-4
• Negative direct acting regulators IX-4
• Types of Regulator Systems IX-5
• Regulator Selection IX-9
• Installation IX-9

CHAPTER X

GAS LEAKAGE CONTROL GUIDELINES FOR PETROLEUM GAS SYSTEMS X-1

• Scope X-1
• General Discussion X-1
• Definitions X-1
• Leakage Detection X-3
• Qualification of Personnel X-3
• Reports from Outside Sources X-3
• Odors or Indications from Foreign Sources X-3
• Leakage Surveys and Test Methods X-4
• Subsurface gas detection survey X-4
• Bubble leakage test X-5
• Pressure drop test X-6
• Ultrasonic leakage test X-6
• Typically Available instruments for the Detection of Gas X-7
• Type and general usage X-7
• Maintenance of instruments X-7
• Calibration of instruments X-7
• Conversion curves X-8
• Leakage Classification and Action Criteria X-9
• General X-9
• Leak Grades X-9
• Leak Classification and Action Criteria X-9
• Follow-up Inspection X-9
• Reevaluation of a Leak X-10
• Table 3a-Leak Classification and Action Criteria-Grade 1 X-10
• Table 3b-Leak Classification and Action Criteria-Grade 2 X-11
• Table 3c-Leak Classification and Action Criteria-Grade 3 X-12
• Records and Self Audit Guidelines X-12 X-12 X-13 X-14X-14X-14 X-14 X-15
• Leak Records
• Leak Survey Records
• Self Audits
• Pinpointing
• Scope
• Procedure
• Precautions

Appendix A-Federal and State Listings A-1

Appendix B-Sample Forms B-1

• iv Corrosion Control Requirements for Pipelines
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