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RULE 4455 COMPONENTS AT PETROLEUM REFINERIES, GAS LIQUIDS 

PROCESSING FACILITIES, AND CHEMICAL PLANTS (Adopted April 20, 

2005) 

1.0 Purpose 

 The purpose of this rule is to limit VOC emissions from leaking components at 

petroleum refineries, gas liquids processing facilities, and chemical plants. 

2.0 Applicability 

This rule shall apply to components containing or contacting VOC at petroleum 

refineries, gas liquids processing facilities, and chemical plants. 

3.0. Definitions 

3.1 APCO: The Air Pollution Control Officer of the San Joaquin Valley Unified Air 

Pollution Control District, or any person authorized to act on behalf of the APCO. 

3.2 ARB: California Air Resources Board as established by the California Health and 

Safety Code Section 39510, or any person authorized to act on its behalf 

3.3 Background: a reading on a portable hydrocarbon detection instrument which is 

determined at a distance no greater than two (2) meter upwind from any 

component to be inspected and which is uninfluenced by any specific emission 

point.

3.4 Chemical Plant: an establishment that produces organic chemicals and/or 

manufactures products by organic chemical processes. 

3.5 Closed-vent System: an APCO-approved system that is not open to the 

atmosphere and that is composed of hard-piping, ductwork connections and, if 

necessary, flow inducing devices that transport gas or vapor from a piece or 

pieces of equipment to an APCO-approved control device that has a overall 

VOC collection and destruction or removal efficiency of at least 95%, or that 

transports gases or vapors back to a process system. 

3.6 Commercial Quality Natural Gas: a mixture of gaseous hydrocarbons with at 

least 80 percent methane by volume (≥ 80 vol%) and less than ten percent by 

weight (<10 wt%) VOC as determined by the test method specified in Section 

6.4.2, and meets the criteria specified in Public Utilities Commission (PUC) 

General Order 58-A. 
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3.7 Component: includes, but is not limited to, any valve, fitting, threaded 

connection, pump, compressor, pressure relief device, pipe, flange, process 

drain, sealing mechanism, hatch, sight-glass, meter or seal fluid system in VOC 

service. 

3.7.1 Major Component: any pump 5 brake horsepower or larger, any 

compressor, and any pressure relief valve 4 inches in diameter or larger. 

3.7.2 Minor Component: any component that is not a major component. 

3.8 Component Type: includes, but is not limited to, any one (1) of the following 

groups: valves, fittings, threaded connections, pumps, compressors, pressure 

relief devices, pipes, flanges, process drains, sealing mechanisms, hatches, 

sight-glasses, and meters in VOC service. 

3.9 Compressor: a device used to compress gases or vapors or a combination of 

gases and vapors by the addition of energy, and includes all associated 

components used for connecting and sealing purposes. The phrase "all 

associated components used for connecting and sealing purposes" means the first 

VOC leak points (first components) on the body of the compressor. For 

example, a valve that is connected to a threaded hole on body of the 

compressor, the first VOC leak point is the threaded connection on the body of 

the compressor, but the valve itself is not a "first VOC leak point". Similarly, a 

compressor shaft seal is considered as a first “VOC leak point”. 

3.10 Compressor Part: for the purpose of Section 5.3.7, a compressor part refers to 

the “first VOC leak point” as explained in Section 3.9. 

3.11 Critical Component: any component that would require the shutdown of a critical 

process unit if that component was shut down or disabled. 

3.12 Critical Process Unit: a process unit that must remain in service because of its 

importance to the overall process that requires it to continue to operate, and has no 

equivalent equipment to replace it or cannot be bypassed, and it is technically 

infeasible to repair leaks from that process unit without shutting it down and 

opening the process unit to the atmosphere. 

3.13 Critical Process Unit Shutdown: the shutdown of a critical process unit or part of 

the critical process unit that causes the entire unit to cease operating. 

3.14 District: San Joaquin Valley Unified Air Pollution Control District. 

3.15 Essential Component: a component that cannot be taken out of service without 

reducing, by more than 33 percent, the throughput of the process unit that it 

serves. 
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3.16 Flange: a projecting rim on a pipe used to attach it to another pipe or any other 

component in a piping system. 

3.17 Fitting: a component, excluding flanges and threaded connectors, used to attach 

or connect pipes or piping system. Examples of a “fitting” include, but are not 

limited to quick-disconnect fitting, push-in-fittings, and cam-locks. 

3.18 Gas Liquids Processing Facility: a facility that is engaged in the catalytic 

processing of gas liquids to produce finished products. 

3.19 Gas/Vapor Service: a component is considered to be in gas/vapor service when 

the fluid in contact with the component contains VOCs and the fluid is primarily 

in gaseous state at operating conditions. 

3.20 Inaccessible Component: a component located over 15 feet above ground when 

access is required from the ground; or a component located over six (6) feet 

away from a platform when access is required from the platform; or a 

component that would require the elevation of monitoring personnel higher than 

six (6) feet above permanent support surfaces. 

3.21 Inspection: means checking and/or testing of components in order to detect leaks. 

3.21.1 Operator Inspection: inspection of components conducted by the operator 

pursuant to the inspection and re-inspection schedules specified in this rule 

for the purpose of demonstrating compliance with this rule. 

3.21.2 District Inspection: inspection of components by District personnel or 

their representative to insure facilities and/or operators are in compliance 

with District requirements. 

3.22 Leak: the dripping of VOC-containing liquid or the detection of a concentration 

of total organic compound, above background, determined according to the test 

method specified in Section 6.4.1 that exceeds the limits in Table 1, Sections

3.22.1 and Section 3.22.2 of this rule. Any liquid or gas coming from a 

component undergoing repair or replacement, or during sampling of process 

fluid from a component into a container is not considered a leak provided such 

activities are done as expeditiously as possible and with minimal spillage of 

material and VOC emissions to the atmosphere. 
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Table 1 – Gas Leak Standard in ppmv as Methane 

Type of Component Major Gas Leak Minor Gas Leak 

Components in 

Liquid Service 

Components in 

Gas/Vapor Service 

1. Valves Greater than 10,000 200 to 10,000 400 to 10,000 

2. Threaded connections Greater than 10,000 200 to 10,000 400 to 10,000 

3. Flanges Greater than 10,000 200 to 10,000 400 to 10,000 

3. Pumps Greater than 10,000 500 to 10,000 1,000 to 10,000 

4. Compressors Greater than 10,000 500 to 10,000 1,000 to 10,000 

5. PRD Greater than 10,000 100 to 10,000 200 to 10,000 

6. Other component types not 

listed in 1 through 6 above 

Greater than 10,000 500 to 10,000 1,000 to 10,000 

3.22.1 Major Liquid Leak: a visible mist or a continuous flow of liquid that is 

not seal lubricant. 

3.22.2 Minor Liquid Leak: a liquid leak, except seal lubricant, that is not a 

major liquid leak and drips liquid at a rate of more than three drops per 

minute. 

3.23 Leak Minimization: reducing a leak to the lowest achievable level without 

damaging the component using best modern practices which include, but are not 

limited to, adding sealing material to the component, tightening the component, 

or adjusting the component without shutdown of the process that the component 

serves and that can be safely accommodated. 

3.24 Liquid Service: a component is considered to be in liquid service when the fluid 

in contact with the component contains VOCs and the fluid is primarily liquid at 

operating conditions. 

3.25 Open-ended Line or Valve: any line or valve, except PRV, having one side of the 

line or valve seat in contact with the process fluid and one side open to the 

atmosphere, either directly or through an open piping. 

3.26 Portable Hydrocarbon Detection Instrument: a hand-held hydrocarbon analyzer 

that meets the criteria specified in US EPA Method 21, 40 CFR Part 60. The 

instrument shall be calibrated with methane.

3.27 Pressure Relief Device (PRD): a pressure relief valve or a rupture disc. 

3.28 Pressure Relief Valve (PRV): an automatic pressure-relieving device associated 

with a process vessel or piping system that is activated by pressure upstream of 

the device and relieves to the atmosphere (atmospheric PRV).
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3.29 Process Drain: any open portion of a non-continuous piping system, including 

open origination portion(s) of such a system used for collection and transport of 

liquids discharged from process vessels, spills, or other sources. Drain 

origination points and drain termination points are not open-ended lines. 

Process drains are not open-ended lines. 

3.30 Process Equipment: equipment that is used to produce intermediate or final 

products from petroleum, unfinished petroleum derivatives, or other 

intermediates. 

3.31 Process PRD: a PRD that is vented to the atmosphere and is located on a process 

equipment other than storage tanks, liquefied petroleum gas storage vessels, or 

pipelines used to transport materials. 

3.32 Process System: an APCO-approved system that is not open to the atmosphere 

and is composed of hard-piping, ductwork connections and, if necessary, flow 

inducing devices that transport gases or vapors from a piece of equipment to a 

process stream, fuel gas system, or sales gas system. 

3.33 Pump: a device used to transport fluids by the addition of energy, and includes 

all associated components used for connecting or sealing purposes. The phrase 

"all associated components used for connecting and sealing purposes" means the 

first VOC leak points (first components) on the body of the pump. For 

example, a valve that is connected to a threaded hole on body of the pump, the 

first VOC leak point is the threaded connection on the body of the pump, but the 

valve itself is not a "first VOC leak point". Similarly, a pump shaft seal is 

considered as a first “VOC leak point”. 

3.34 Pump Part: for the purpose of Section 5.3.7, a pump part refers to the “first VOC 

leak point” as explained in Section 3.33. 

3.35 Refinery: an establishment that processes petroleum as defined in the Standard 

Industrial Classification Code under 2911 (Petroleum Refining). 

3.36 Release: a VOC emission to the atmosphere from process PRD caused by an 

increase in upstream pressure. A leak caused by improper reseating of the PRD 

is not a release. 

3.37 Rupture Disk: a rigid diaphragm held between flanges for the purpose of 

isolating organic compounds from the atmosphere or from a downstream pressure 

relief valve. Most rupture disks are designed to fail at a certain pressure point. 

3.38 Tag: a piece of paper, metal, plastic or other suitable material that is attached to a 

component for the purpose identification or other information. 
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3.39 Turnaround: scheduled shutdown of a process unit for maintenance and repair 

work. 

3.40 Sight glass: a device located on a fluid line or a process vessel that allows an 

operator to view the product or material inside a fluid line or a process vessel. 

3.41 Unsafe-to-Monitor Component: a component that is installed at a location that 

would prevent the safe inspection or repair of a component as defined by OSHA 

standards or in provisions for worker safety stated in 29 CFR 1910. 

3.42 US EPA: United States Environmental Protection Agency 

3.43 Vacuum Service: operating under a negative gauge pressure or below 

atmospheric pressure. 

3.44 Valve: a device that regulates the flow of fluid in a piping system by means of 

an external actuator acting to permit or block passage of fluid. 

3.45 Volatile Organic Compound (VOC): as defined in Rule 1020 (Definitions). 

4.0 Exemptions 

4.1 The requirements of this rule shall not apply to components subject to Rule 4623 

(Storage of Organic Liquids); or to components included in the inspection and 

maintenance (I&M) program implemented pursuant to Section 5.7 of Rule 4623. 

4.2 Except for complying with the applicable requirements of Sections 6.1 and 7.3, 

the requirements of this rule shall not apply to components described in Sections 

4.2.1 through 4.2.8. An operator claiming an exemption pursuant to Section 

4.2 shall provide proof of the applicable criteria to the satisfaction of the APCO. 

4.2.1 Pressure relief devices, pumps, and compressors equipped with a closedvent system as defined in Section 3.0. 

4.2.2 Components buried below ground. 

4.2.3 Components exclusively handling liquid streams which have less than 10 

percent by weight (<10 wt%) evaporation at 1500 C as determined by the 

test method specified in Section 6.4.3. 

4.2.4 Components exclusively handling liquid streams with a VOC content less 

than ten percent by weight (<10 wt%), as determined by the test 

methods in Section 6.4.2. 
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4.2.5 Components exclusively handling gas/vapor streams with a VOC content 

of less than one percent by weight (<1wt%), as determined by the test 

method specified in Section 6.4.2. 

4.2.6 Components incorporated in lines exclusively in vacuum service. 

4.2.7 Components exclusively handling commercial natural gas. 

4.2.8 One-half inch nominal or less stainless steel tube fittings which have been 

demonstrated to the APCO to be leak-free based on initial inspection using 

the test method specified in Section 6.4.1. 

5.0 Requirements 

5.1 Operating Requirements 

5.1.1 The operator shall not use any component that leaks in excess of the 

applicable leak standards of this rule, or that is found to be in violation 

of the provisions specified in Section 5.1.3. Components that have been 

found leaking in excess of the applicable leak standards of this rule may 

be used provided such leaking components have been identified with a 

tag for repair, are repaired, or are awaiting re-inspection after being 

repaired, within the applicable time period specified in this rule. 

 

5.1.2 Each hatch shall be closed at all times except during sampling or adding 

of process material through the hatch, or during attended repair, 

replacement, or maintenance operations, provided such activities are 

done as expeditiously as possible and with minimal spillage of material 

and VOC emissions to the atmosphere. 

5.1.3 Determination of Compliance with the Leak Standards 

 5.1.3.1 District Inspection 

The operator shall be in violation of this rule if any District 

inspection demonstrates that one or more of the conditions in 

Sections 5.1.4 exist at the facility. 
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5.1.3.2 Operator Inspection 

5.1.3.2.1 Except for annual operator inspection described in 

Section 5.1.3.2.3, any operator inspection that 

demonstrates one or more of the conditions in 

Section 5.1.4 exist at the facility shall not constitute 

a violation of this rule if the leaking components are 

repaired as soon as practicable but not later than the 

time frame specified in this rule. Such components 

shall not be counted towards determination of 

compliance with the provisions of Section 5.1.4. 

5.1.3.2.2 Leaking components detected during operator 

inspection pursuant Section 5.1.3.2.1 that are not 

repaired, replaced, or removed from operation as 

soon as practicable but not later than the time frame 

specified in this rule shall be counted toward 

determination of compliance with the provisions of 

Section 5.1.4. 

5.1.3.2.3 Any operator inspection conducted annually for a 

component type (including operator annual 

inspections pursuant to Section 5.2.5, 5.2.6, 5.2.7, 

or 5.2.8) that demonstrates one or more of the 

conditions in Section 5.1.4 exist at the facility shall 

constitute a violation of this rule regardless of 

whether or not the leaking components are repaired, 

replaced, or removed from operation within the 

allowable repair time frame specified in this rule. 

 5.1.4 Leak Standards 

For the purpose of this rule, a component shall be considered leaking if 

one or more of the conditions specified in Sections 5.1.4.1 through 

5.1.4.4 exist at the facility. 

 

5.1.4.1 An open-ended line or a valve located at the end of the line that 

is not sealed with a blind flange, plug, cap, or a second closed 

valve that is not closed at all times, except during attended 

operations requiring process fluid flow through the open-ended 

lines. Attended operations include draining or degassing 

operations, connection of temporary process equipment, 

sampling of process streams, emergency venting, and other 

normal operational needs, provided such operations are done as 
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expeditiously as possible and with minimal spillage of material 

and VOC emissions to the atmosphere. 

5.1.4.2 A component with a major liquid leak. 

5.1.4.3 A component with a gas leak greater than 50,000 ppmv. 

5.1.4.4 A component leak described in Sections 5.1.4.4.1 through 

5.1.4.4.3 and numbering in excess of the maximum allowable 

number or percent specified in Table 2. 

 5.1.4.4.1 A minor liquid leak; or 

5.1.4.4.2 A minor gas leak; or 

5.1.4.4.3 A gas leak greater than 10,000 ppmv up to 50,000 

ppmv. 

Table 2 – Maximum Allowable Number or Percent of Leaking Components 

Per Inspection Period 

Component Type Maximum Number 

of Leaks for 200 or 

less Components 

Inspected 

Maximum Percent or 

Number of Leaks for more 

than 200 Components 

Inspected* 

1. Valves 1 0.5% of number inspected 

2. Threaded Connections 1 0.5% of number inspected 

3. Flanges 1 0.5% of number inspected 

4. Pumps 2 1.0% of number inspected 

5. Compressors 1 1 leak 

6. PRD 1 1 leak 

7. Other component types not listed in 

items 1 through 6 above 

1 1 leak 

8 Pipes Maximum Number of Leaks 

2 

*The maximum number of leaks in Table 2 shall be rounded upwards to the nearest integer, 

where required. The maximum allowable percent of leaks is calculated from the total 

number of components of a given type inspected during the specified inspection period. 

5.2 Inspection and Re-Inspection Requirements 

5.2.1 The operator shall audio-visually (by hearing and sight) inspect for leaks 

all accessible operating pumps, compressors, and PRDs in service at 

least once every 24 hours, except when operators do not report to the 

facility for that given 24 hours. 
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5.2.2 Any audio-visual inspection of all accessible operating pumps, 

compressors, and PRDs in service performed by an operator that 

indicates a leak that cannot be immediately repaired to meet the leak 

standards of this rule shall be inspected using the test method specified in 

Section 6.4.1 not later than 24 hours after conducting the audio-visual 

inspection. If a leak is found, the leak shall be repaired as soon as 

practicable but not later than the time frame specified in Table 3 of this 

rule. 

5.2.3 Notwithstanding the requirement of Sections 5.2.1 and 5.2.2, the operator 

shall inspect all components at least once every calendar quarter using the 

test method specified in Section 6.4.1, except for inaccessible components, 

unsafe-to-monitor components, or pipes. Inaccessible components and 

unsafe-to-monitor components shall be inspected in accordance with the 

provisions of Sections 5.2.5 and 5.2.6, respectively. Pipes shall be 

inspected in accordance with the provisions of Section 5.2.7. 

5.2.4 The operator shall inspect, immediately after placing into service, all 

new, replaced, or repaired fittings, flanges, and threaded connections 

using the test method specified in Section 6.4.1. 

5.2.5 The operator shall inspect all inaccessible components at least once every 

12 months using the test method specified in Section 6.4.1. 

5.2.6 The operator shall inspect all unsafe-to-monitor components during each 

turnaround using the test method specified in Section 6.4.1. 

5.2.7 The operator shall visually inspect all pipes for leaks at least once every 12 

months. 

 

 5.2.7.1 Any visual inspection of pipes that indicates a leak that cannot 

be immediately repaired to meet the leak standards of this rule 

shall be inspected using the test method specified in Section 

6.4.1 not later than 24 hours after conducting the audio-visual 

inspection. If a leak is found, the leak shall be repaired as soon 

as practicable but not later than the timeframe specified in Table 

3 of this rule. 

 5.2.7.2 The operator may conduct the annual pipe inspection required 

by Section 5.2.7 in conjunction with the annual pipe inspection 

required by the Spill Prevention Control and Countermeasure 

Plan pursuant to 40 Code of Federal Regulation Part 112 (Oil 

Prevention and Response: Non-Transportation-Related Onshore 

and Offshore Facilities). Records of annual pipe inspection
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Administrative Change 12/5/05 

4455 - 11

required by SPCC may be used to document the inspection 

required by Section 5.2.7. The operator shall maintain the 

records of such inspections at the facilities. The records shall 

be made available to the APCO, ARB, and US EPA upon 

request. 

5.2.8 Notwithstanding the requirement of Section 5.2.3, the operator may 

apply for a written approval from the APCO to change the inspection 

frequency from quarterly to annually for a component type, or an 

operator who is already on an annual inspection frequency on or before 

April 20, 2005 may apply for a written approval from the APCO to 

continue conducting annual inspections for a component type, provided 

the operator meets all the criteria specified in Sections 5.2.8.1 through 

5.2.8.3. This approval shall apply to accessible component types, 

specifically designated by the APCO, except pumps, compressors, and 

PRDs which shall continue to be inspected on a quarterly basis. 

5.2.8.1 The operator was not in violation of any provision of Sections 

5.1 during five consecutive quarterly inspections for that 

component type. 

5.2.8.2 The operator did not receive a Notice of Violation from the 

APCO during the previous 12 months for violating any 

provisions of this rule for that component type. 

5.2.8.3 The written request shall include pertinent documentation to 

demonstrate that the operator has successfully met the 

requirements of Sections 5.2.8.1 and 5.2.8.2. 

5.2.9 The annual inspection frequency approved by the APCO pursuant to 

Section 5.2.8 shall revert to quarterly inspection frequency for a 

component type if either one of the following occurs: 

5.2.9.1 Operator inspection or District inspection demonstrates that a 

violation of the provisions of Sections 5.1, 5.2, and 5.3 exists for 

that component type, or 

5.2.9.2 The APCO issued a Notice of Violation for violating any of the 

provisions of this rule during the annual inspection period for that 

component type. 

5.2.10 When the inspection frequency changes from annual to quarterly 

inspections pursuant to Section 5.2.9 above, the operator shall notify the 

APCO in writing within five (5) calendar days after changing the 
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inspection frequency. The written notification shall include the reason(s) 

and date of change to quarterly inspection frequency. 

5.2.11 The operator shall initially inspect a process PRD that releases to the 

atmosphere as soon as practicable but not later than 24 hours after the time 

of the release. The operator shall re-inspect the process PRD using the 

test method specified in Section 6.4.1 not earlier than 24 hours after the 

initial inspection but not later than 15 calendar days after the date of the 

release to insure that the process PRD is operating properly, and is leakfree. If the process PRD is found to be leaking at either inspection, the 

PRD leak shall be treated as if the leak was found during quarterly 

operator inspections. 

5.2.12 Except for process PRD subject to the requirements of Section 5.2.11, a 

component shall be inspected within 15 calendar days after repairing the 

leak or replacing the component using the test method specified in Section 

6.4.1. 

 5.2.13 A District inspection in no way fulfills any of the mandatory inspection 

requirements that are placed upon operators and cannot be used or counted 

as an inspection required of an operator. Any attempt by an operator to 

count such District inspections as part of the mandatory operator’s 

inspections is considered a willful circumvention of the rule and is a 

violation of this rule. 

5.3 Maintenance Requirements 

5.3.1 Upon detection of a leaking component, the operator shall affix to that 

component a weatherproof readily visible tag. 

5.3.2 The tag shall remain affixed to the component until all the conditions 

specified in Sections 5.3.2.1 through 5.3.2.3 have been met. 

5.3.2.1 The leaking component has been repaired or replaced; and 

5.3.2.2 The component has been re-inspected using the test method in 

Section 6.4.1; and 

5.3.2.3 The component is found to be in compliance with the 

requirements of this rule. 

5.3.3 The tag shall include the following information: 

5.3.3.1 Date and time of leak detection. 
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5.3.3.2 Date and time of leak measurement. 

5.3.3.3 For gas leaks, indicate the leak concentration in ppmv. 

5.3.3.4 For liquid leaks, indicate whether it is a major liquid leak or a 

minor liquid leak. 

5.3.3.5 For essential components, unsafe–to-monitor components, or 

critical components, so indicate on the tag. 

5.3.4 An operator shall minimize all component leaks immediately to the 

extent possible, but not later than one (1) hour after detection of leaks in 

order to stop or reduce leakage to the atmosphere. 

5.3.5 If the leak has been minimized but the leak still exceeds the applicable 

leak standards of this rule, an operator shall comply with at least one of 

the requirement of Sections 5.3.5.3, 5.3.5.4, or 5.3.5.5 as soon as 

practicable but not later than the time period specified in Table 3. For 

each calendar quarter, the operator may be allowed to extend the repair 

period as specified in Table 3, for a total number of leaking components, 

not to exceed 0.05 percent of the number of components inspected, by 

type, rounded upward to the nearest integer where required. 

5.3.5.1 The leak rate measured after leak minimization has been 

performed shall be the leak rate used to determine the repair 

period specified in Table 3. 

5.3.5.2 The start of the repair period shall be the time of the initial leak 

detection. 

5.3.5.3 Repair or replace the leaking component; or 

5.3.5.4 Vent the leaking component to a closed vent system as defined 

in Section 3.0. 

5.3.5.5 Remove the leaking component from operation. 
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Table 3. Repair Period 

Type of Leak Repair Period 

in Calendar 

Days 

Extended 

Repair Period 

in Calendar 

Days 

Gas Leaks 

 Minor Gas Leak (See Table 1) 7 7 

Major Gas Leak greater than 10,000 ppmv but equal to 

or less than 50,000 ppmv 

3 2 

Major Gas Leak greater than 50,000 ppmv 2 0 

Liquid Leaks 

Minor Liquid Leak (See Section 3.22.2) 3 0 

Major Liquid Leak (See Section 3.22.1) 2 0 

5.3.6 If the leaking component is an essential component or a critical component 

and which cannot be immediately shut down for repairs, the operator shall: 

5.3.6.1 Minimize the leak within one hour after detection of leaks; and 

5.3.6.2 If the leak has been minimized, but the leak still exceeds any of 

the applicable leak standards of this rule, the essential component 

or critical component shall be repaired or replaced to eliminate 

the leak during the next process unit turnaround, but in no case 

later than one year from the date of the original leak detection, 

whichever comes earlier. 

 

 5.3.7 For any component that has incurred five repair actions for major gas 

leaks or major liquid leaks, or any combination of major gas leaks and 

major liquid leaks within a continuous 12-month period, the operator 

shall comply with at least one of the requirements specified in Sections 

5.3.7.1, 5.3.7.2, 5.3.7.3, or 5.3.7.4 by the applicable deadlines 

specified in Sections 5.3.7.5 and 5.3.7.6. If the original leaking 

component is replaced with a new like-in-kind component before 

incurring five repair actions for major leaks within 12-consecutive 

months, the repair count shall start over for the new component. An 

entire compressor or pump need not be replaced provided the 

compressor part(s) or pump part(s) that have incurred five repair actions 

as described in Section 5.3.7 are brought into compliance with at least 

one of the requirements of Sections 5.3.7.1 through 5.3.7.6. 

 

 5.3.7.1 Replace or retrofit the component with the control technology 

specified in Table 4. Notify the APCO in writing prior to 

replacing or retrofitting the component; or
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Administrative Change 12/5/05 

4455 - 15

Table 4 - Component Control Technology Replacement/Retrofit 

Component Type Control Technology 

Compressors Replace existing seal with dual mechanical seal, oil-film seal, gas seal, or 

face-type seal. 

Pumps Replace with seal-less pump or replace with dual mechanical seal. 

PRD Replace PRD and install a rupture disc in the line which precedes the PRD 

such that the PRD is in series with and follow the rupture disc. 

Valves Replace with sealed bellows valve, or graphite or teflon chevron seal rings 

in a live-loaded packing gland. 

Threaded 

Connections 

Weld connections or replace threaded connections with flanges. 

Sampling 

Connections 

Replace with closed-loop sampling system 

5.3.7.2 Replace the component with Achieved-in-Practice Best 

Available Control Technology (BACT) equipment, as 

determined in accordance with Rule 2201 (New and Modified 

Stationary Source Review Rule), and as approved by the APCO 

in writing; or 

5.3.7.3 Vent the component to an APCO approved closed vent system 

as defined in Section 3.0; or 

 5.3.7.4 Remove the component from operation. 

5.3.7.5 For any component that is accessible, is not unsafe-to-monitor, 

is not an essential component, is not a critical component, the 

operator shall comply with the requirement of Section 5.3.7.1, 

Section 5.3.7.2, Section 5.3.7.3, or Section 5.3.7.4 as soon as 

practicable but not later than twelve (12) months after the date 

of detection of the fifth major leak within a continuous 12-

month period as indicated in Section 5.3.7. 

5.3.7.6 For any inaccessible component, unsafe-to-monitor component, 

essential component, or critical component, the operator shall 

comply with the requirement of Section 5.3.7.1, Section 

5.3.7.2, Section 5.3.7.3, or Section 5.3.7.4 as soon as 

practicable but not later than the next turnaround or not later 

than two (2) years after the date of detection of the fifth major 

leak within a continuous 12-month period as indicated in 

Section 5.3.7, whichever comes earlier. 
SJVUAPCD 4/20/05 

Administrative Change 12/5/05 

4455 - 16

5.4 Process PRD Requirements 

5.4.1 The operator shall monitor process PRD by using electronic process 

control instrumentation that allows for real time continuous parameter 

monitoring or by using telltale indicators for the process PRD where 

parameter monitoring is not feasible. 

5.4.2 By October 20, 2005, the operator shall submit to the APCO a 

compliance plan, as part of the Operator Management Plan required by 

Section 6.1, containing the inventory of process PRD by size, set 

pressure and location, and the type of monitoring system to be used in 

order to comply with the requirement of Section 5.4.1. If applicable, the 

operator shall indicate the process parameter selected for continuous 

monitoring and the justification for such selection. 

5.4.3 The operator shall comply with the process PRD release notification and 

recordkeeping requirements specified in Section 6.3. 

5.4.4 After a release from process PRD in excess of 500 pounds of VOC in a 

continuous 24-hour period, the operator shall immediately conduct a 

failure analysis and implement corrective actions as soon as practicable 

but not later than 30 days to prevent the reoccurrence of similar release. 

 For refineries processing greater than 20,000 barrels of crude oil per 

day, any subsequent release in excess of 500 pounds of VOC within a 

continuous 24-hour period shall be subject to the requirements of Section 

5.4.5. 

5.4.5 The operator of a refinery processing greater than 20,000 barrels of 

crude oil per day shall connect all process PRD serving that process 

equipment to an APCO-approved closed vent system as defined in 

Section 3.0 if any of the conditions specified in Sections 5.4.5.1 and 

5.4.5.2 occurs. Process PRD subject to the provisions of Section 5.4.5 

shall be connected to an APCO-approved closed vent system as soon as 

practicable, but no later than the first turnaround after the requirement to 

connect becomes effective. 

5.4.5.1 A second release from any process PRD serving the same piece 

or pieces of equipment and each release is in excess of 500 

pounds of VOC in a continuous 24-hour period and provided 

the second release occurs within any five year period of the first 

release. 

5.4.5.2 Any release in excess of 2,000 pounds of VOC in a continuous 

24-hour period, from any process PRD serving the same piece 

or pieces of process equipment.
SJVUAPCD 4455 - 17 4/20/05 

5.5 Component Identification Requirements 

 5.5.1 All major components and critical components shall be physically 

identified clearly and visibly for inspection, repair, and recordkeeping 

purposes. The physical identification shall consist of labels, tags, 

manufacturer’s nameplate identifier, serial number, or model number, or 

other system approved by the APCO that enables an operator or District 

personnel to locate each individual component. The operator shall 

replace tags or labels that become missing or unreadable as soon as 

practicable but not later than 24 hours after discovery. 

5.5.2 The operator shall comply with the requirements of Sections 6.1.4 if 

there is any change in the description of major components or critical 

components. 

6.0 Administrative and Recordkeeping Requirements 

6.1 Operator Management Plan 

6.1.1 By October 20, 2005, an operator whose existing components are either 

subject to the rule or whose existing components are exempt pursuant to 

Section 4.2 on or before April 20, 2005 shall submit an Operator 

Management Plan for approval by the APCO. 

6.1.2 The operator shall keep a copy of the APCO-approved Operator 

Management Plan at the facility and make it available to the APCO, ARB 

and US EPA upon request. 

6.1.3 The operator shall describe in the Operator Management Plan all 

components subject to this rule and all components that are exempt 

pursuant to Section 4.0 of this rule or part of this rule. The Plan shall 

contain a description of the procedures that the operator will use to comply 

with the requirements of this rule. The Plan shall include, at a minimum 

all of the following information: 

6.1.3.1 Identification and description of any known hazard that might 

affect the safety of an inspector. 

6.1.3.2 Diagrams, charts, spreadsheets, or other methods approved by 

the APCO which describe the following information: 
SJVUAPCD 4455 - 18 4/20/05 

6.1.3.2.1 Except for pipes, the number of components that are 

subject to this rule by component type and type of 

service (i.e., liquid service or gas/vapor service). 

 6.1.3.2.2 Except for pipes, the number and types of major 

components, inaccessible components, unsafe-tomonitor components, critical components, and 

essential components, that are subject to this rule, 

including the reason(s) for such designation. 

 

 6.1.3.2.3 Except for pipes, the location of components that are 

subject to this rule (components may be grouped 

together functionally by process unit or facility 

description). 

 6.1.3.2.4 Except for pipes components exempt pursuant to 

Section 4.2 (except for components buried below 

ground) may be described in the Operator 

Management Plan by grouping them functionally by 

process unit or facility description. The results of any 

laboratory testing or other pertinent information to 

demonstrate compliance with the exemption criteria 

for components for which an exemption is being 

claimed pursuant to Sections 4.2 shall be submitted 

with the Operator Management Plan. 

6.1.3.4 Detailed schedule of inspection to be conducted as required by 

this rule. 

 6.1.3.5 Include the compliance plan for process PRD as required by 

Section 5.4.2 of this rule. 

6.1.3.6 Specify whether a qualified contractor or in-house team will 

perform the inspections. 

6.1.3.7 Establish an employee training program for inspecting, repairing, 

and recordkeeping procedures, as necessary. 

6.1.3.7.1 Specify the training standards for personnel 

performing inspections and repairs. 

6.1.3.7.2 Document the leak detection training using the test 

method in Section 6.4.1 for new operators, and for 

experienced operators, as necessary. 
SJVUAPCD 4455 - 19 4/20/05 

6.1.3.7.3 The operator shall maintain copies of the training 

records at the facility. Copies of the training records 

shall be made available to the APCO, ARB, and US 

EPA upon request. 

6.1.4 By January 30 of each year, the operator shall submit to the APCO for 

approval, in writing, an annual report indicating any changes to an existing 

Operator Management Plan. 

 

6.1.5 The APCO shall provide written notice to the operator of the approval or 

incompleteness of a new or revised Operator Management Plan within 60 

days of receiving such Plan. If the APCO fails to respond in writing 

within 60 days after the date of receiving the Plan, it shall be deemed 

approved. No provision of the Plan, approved or not, shall conflict with or 

take precedence over any provision of this rule. 

6.2 Inspection Log 

6.2.1 An operator at each facility shall maintain an inspection log containing, 

at a minimum, the following information: 

6.2.1.1 Total number of components inspected, and total number and 

percentage of leaking components found by component types. 

6.2.1.2 Location, type, name or description of each leaking component, 

and description of any unit where the leaking component is 

found. 

6.2.1.3 Date of leak detection and method of leak detection. 

6.2.1.4 For gaseous leaks, record the leak concentration in ppmv, and for 

liquid leaks record whether the leak is a major liquid leak or a 

minor liquid leak. 

6.2.1.5 Date of repair, replacement, or removal from operation of 

leaking components. 

6.2.1.6 Identification and location of essential component and critical 

components found leaking that cannot be repaired until the next 

process unit turnaround or not later one year after leak detection, 

whichever comes earlier. 

6.2.1.7 Methods used to minimize the leak from essential components 

and critical components that cannot be repaired until the next 
SJVUAPCD 4455 - 20 4/20/05 

process unit turnaround or not later one year after leak detection, 

whichever comes earlier. 

6.2.1.8 After the component is repaired or is replaced, the date of reinspection and the leak concentration in ppmv. 

6.2.1.9 Inspector’s name, business mailing address, and business 

telephone number. 

6.2.1.10 The facility operator responsible for the inspection and repair 

program shall sign and date the inspection log certifying the 

accuracy of the information recorded in the log. 

6.2.2 Records of leaks detected by quarterly or annual operator inspection, and 

each subsequent repair and re-inspection, shall be submitted to the 

APCO, ARB, or US EPA upon request. 

 6.2.3 Records of each calibration of the portable hydrocarbon detection 

instrument utilized for inspecting components, including a copy of 

current calibration gas certification from the vendor of said calibration 

gas cylinder, the date of calibration, concentration of calibration gas, 

analyzer reading of calibration gas before adjustment, instrument reading 

of calibration gas after adjustment, calibration gas expiration date, and 

calibration gas cylinder pressure at the time of calibration. 

 

6.2.4 Copies of all records required by Section 6.2 of this rule shall be retained 

for a minimum of five (5) years after the date of an entry. Such records 

shall be made available to the APCO, ARB, or US EPA upon request. 

6.3 Process PRD Release Notification 

6.3.1 The operator shall notify the APCO, by telephone or other methods 

approved by the APCO, of any process PRD release described in 

Sections 5.4.4 and 5.4.5, and any release in excess of the reportable 

quantity limits as stipulated in 40 CFR, Part 117, Part 302 and Part 355, 

including any release in excess of 100 pounds of VOC, within one hour 

of such occurrence or within one hour of the time said person knew or 

reasonably should have known of its occurrence. 

6.3.2 The operator shall submit a written report to the APCO within thirty (30) 

calendar days of following notification of process PRD release subject to 

6.3.1. The written report shall include all of the following information: 

6.3.2.1 Process PRD type, size, and location. 
SJVUAPCD 4/20/05 

Administrative Change 12/5/05 

4455 - 21

6.3.2.2 Date, time and duration of the process PRD release. 

6.3.2.3 Types of VOC released and individual amounts, in pounds, 

including supporting calculations. 

6.3.2.4 Cause of the process PRD release. 

6.3.2.5 Corrective actions taken to prevent a subsequent process PRD 

release. 

6.3.3 The operator shall keep records of the process (s) parameters monitored 

pursuant to Section 5.4.1 for a period of five (5) years, and make the 

records available to the APCO, ARB, and US EPA upon request. 

6.4 Test Methods 

Equivalent test methods other than specified in Sections 6.4.1 through 6.4.5 may 

be used provided such test methods have received prior approval from the US 

EPA, ARB, and APCO. 

6.4.1 Measurements of gaseous leak concentrations shall be conducted according 

to US EPA Method 21 using an appropriate portable hydrocarbon 

detection instrument calibrated with methane. The instrument shall be 

calibrated in accordance with the procedures specified in US EPA 

Method 21 or the manufacturer’s instruction, as appropriate, not more 

than 30 days prior to its use. The operator shall record the calibration 

date of the instrument. 

6.4.2 The VOC content shall be determined using American Society of Testing 

and Materials (ASTM) D 1945 for gases and South Coast Air Quality 

Management District (SCAQMD) Method 304-91 for liquids. 

6.4.3 The percent by volume liquid evaporated at 1500

C shall be determined 

using ASTM D 86-82. 

6.4.4 The control efficiency of any VOC control device, measured and 

calculated as carbon, shall be determined by US EPA Method 25, except 

when the outlet concentration must be below 50 ppm in order to meet the 

standard, in which case Method 25a may be used. US EPA Method 18 

may be used in lieu of US EPA Method 25 or US EPA Method 25a 

provided the identity and approximate concentrations of the 

analytes/compounds in the sample gas stream are known before analysis 

with the gas chromatograph and the gas chromatograph is calibrated for 

each of those known analyte/compound to ensure that the VOC 

concentrations are neither under- or over-reported. 
SJVUAPCD 4455 - 22 4/20/05 

6.4.5 Halogenated exempt compounds shall be analyzed by US EPA Method 

18 or ARB Method 422 “Determination of Volatile Organic Compounds 

in Emission from Stationary Sources”. 

7.0 Compliance Schedule 

7.1 On and after April 20, 2006, the operator shall be in full compliance with the 

requirements of this rule, unless otherwise specified in certain provisions of this 

rule. 

7.2 Operators may continue performing their quarterly inspection schedules that 

exist on or before April 20, 2005. Operators who are already on an annual 

inspection frequency on or before April 20, 2005 may apply for a written 

approval from the APCO to continue conducting annual inspections provided the 

operators meet all the criteria specified in Sections 5.2.8. 

7.3 Any component that is exempt pursuant to Section 4.2 that becomes subject to all 

the requirements of this rule through the loss of exemption status shall be in 

compliance with this rule on and after the date the exemption status is lost.