SAN JOAQUIN VALLEY UNIFIED AIR POLLUTION CONTROL DISTRICT

RULE 4451 VALVES, PRESSURE RELIEF VALVES, FLANGES, THREADED

CONNECTIONS AND PROCESS DRAINS AT PETROLEUM

REFINERIES AND CHEMICAL PLANTS

(Adopted April 11, 1991); (Amended December 17, 1992; April 20, 2005)

1.0 Purpose

The purpose of this rule is to limit leaks from valves, flanges, threaded connections and

process drains that may result in fugitive emissions of VOC at petroleum refineries and

chemical plants. Inspection, repair and maintenance schedules, recordkeeping and

administrative requirements, and test methods are specified.

2.0 Applicability

This rule applies to all valves, pressure relief valves, flanges, threaded connections and

process drains at petroleum refineries and chemical plants that may be the source of

fugitive VOC emissions. The provisions of this rule shall expire on April 19, 2006.

3.0. Definitions

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

taken at least three (3) meters upwind from any valve, pressure relief valve (PRV),

flange, threaded connections, or process drain to be inspected and which is

uninfluenced by any specific emission point.

3.2 Chemical plant: an establishment that produces organic chemicals and/or

manufactures products by organic chemical processes.

3.3 Commercial natural gas: a mixture of gaseous hydrocarbons, chiefly methane and

less than ten (10) percent VOCs excluding ethane as determined in accordance

with ASTM Methods E168-67, E169-63, or E260-73, used as a fuel and obtained

from a company licensed to dispense such gases.

3.4 Component Type: any one (1) of the following groups: valves, pressure relief

valves, flanges, threaded connections, and process drains.

3.5 Essential Device: any device which cannot be taken out of service without

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

serves.

3.6 Essential Refinery Operation: any operation which cannot be taken out of service

without reducing by more than 33 percent the throughput of the process unit

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

component in a piping system.

3.8 Inaccessible: a location that is over 15 feet above ground when access is required

from the ground; or a location that is over six (6) feet away from a platform when

access is required from the platform.

3.9 Leak:

3.9.1 for valves, flanges and threaded connections:

3.9.1.1 the dripping of liquid organic compounds at a rate of more than

three (3) drops per minute;

3.9.1.2 a reading of methane on a portable hydrocarbon detection

instrument in excess of 10,000 ppm above background

when measured at a distance of one (1) centimeter of the

potential source with an instrument calibrated with

methane.

3.9.2 for pressure relief valves (PRVs) a reading of methane on a portable

hydrocarbon detective instrument in excess of 10,000 ppm above

background when measured in the plane at the centroid of any atmospheric

vent with an instrument calibrated with methane.

3.9.3 for process drains a reading of methane on a portable hydrocarbon

detection instrument in excess of 10,000 ppm above background when

measured at a distance of one (1) centimeter of the potential source with

an instrument calibrated with methane.

3.10 Maintenance Operation: a routine program of inspection and repair of equipment

designed to detect and eliminate conditions which may result in a breakdown.

3.11 Portable Hydrocarbon Detection Instrument: a hydrocarbon analyzer which uses

the flame ionization detection or thermal conductivity methods and satisfies

Method 21, 40 CFR Part 60. The instrument shall be equated to calibrating on

methane and sampling at one (1) liter per minute.

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

with a process vessel or piping system which is activated by static pressure

upstream of the device and relieves to the atmosphere.

3.13 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. Drains used exclusively during

breakdown conditions pursuant to Rule 1100 (Equipment Breakdown) or

exclusively for maintenance operations are not process drains for the purposes of

this rule.

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

Industrial Classification Code under 2911 (Petroleum Refining).

3.15 Unsafe: those components which are operating at temperatures or pressures

which make inspection of these components hazardous to inspection personnel.

3.16 Valve: any 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.

4.0 Exemptions

4.1 Valves, PRVs, flanges, and threaded connections handling only commercial

natural gas are exempt from the provisions of this rule.

4.2 Valves, PRVs, flanges, threaded connections, and process drains handling

material which has less than ten (10) percent by weight VOCs (as determined in

accordance with ASTM Methods E-168-67, E-169-63, E-260-73), are exempt

from the provisions of this rule.

4.3 The requirements of Section 5.2.1 and 5.2.2 shall not apply to valves, flanges,

threaded connections and PRVs that are unsafe to inspect due to conditions of

operation (e.g. high temperature). Prior written concurrence of the APCO shall be

obtained and such valves, threaded connections and PRVs shall be inspected for

signs of leakage during turnaround.

4.4 The requirements of Section 5.2.1 and 5.2.2 shall not apply to valves, flanges,

threaded connections and PRVs which are in inaccessible locations provided the

prior written concurrence of the APCO has been obtained and such valves,

threaded connections and PRVs are inspected for leakage during each process unit

shutdown or annually, whichever is more frequent.

4.5 The requirements of this rule shall not apply to components handling exclusively

heavy liquid streams which have less than ten (10) percent evaporation at 150o

 C

as determined by ASTM Method D-86-78 and provided the operator so identifies

such components as outlined in Section 6.1 or prior to changing service of

existing components.

4.6 Except in Kern County, the requirements of Section 5.1.1 shall not apply to

components handling VOCs with a TVP less than or equal to 1.55 pounds,
process drains and threaded connections, until November 1, 1991. In Kern

County, the requirements of Section 5.1.1 shall be effective upon date of adoption.

4.7 The requirements of Sections 5.1.4 and 5.2.1 shall not apply to threaded

connections provided that the operator inspects each threaded connection after

assembly with a portable hydrocarbon detection instrument to establish such

connections do not have VOC emissions under operating conditions, and provided

such connections are visually inspected at least quarterly and no leakage is

detected. This section shall also apply to threaded connections in service prior to

the adoption of this rule.

4.8 Ethane shall be excluded from the requirements of this rule if the ethane content

of the stream being handled is less than 20 percent by volume. A facility operator

requesting exemption of ethane shall demonstrate for each leak detected, that such

stream has an ethane content less than 20 percent. Analysis of ethane content

shall be by gas chromatographic (qualitative and quantitative determination in

accordance with ASTM Method E-260-73) analysis.

5.0 Requirements

5.1 General

5.1.1 A facility operator shall not use any valve, PRV, flange, threaded

connections, or process drain at a petroleum refinery or chemical plant for

handling VOCs unless such valve, PRV, flange, threaded connection, or

process drain does not allow the material being handled to leak into the

atmosphere.

5.1.2 Emissions from components which have been tagged by the facility

operator for repair within fifteen calendar days or which have been

repaired and are awaiting re-inspection pursuant to Section 5.2 shall not be

in violation of the prohibition in Section 5.1.1 providing the total number

of leaking components of any component type does not exceed two (2)

percent of the total number of components of that type that were inspected

and that are subject to the prohibitions of this rule.

5.1.3 In a petroleum refinery or chemical plant a facility operator shall inspect

every valve, PRV, flange, threaded connection, and process drain handling

VOCs in accordance with Section 5.2. Any such device that leaks shall be

repaired in accordance with Section 5.3, such that each device shall not

leak.

5.1.4 A facility operator shall not use any valve, other than a valve on a product

sampling line, a safety pressure relief valve, or a double block and bleeder

valve, which is located at the end of a pipe or line containing VOCs unless
such valve is sealed with a blind flange, plug or cap. This shall not

include loading spouts and water drain valves.

5.1.5 Every leaking valve, PRV, flange, threaded connection, and process drain

shall be affixed with a record of inspection which shall bear a legible

record of all inspections for at least a fifteen month period or coded with

the records kept in a centralized location.

5.2 Inspection

5.2.1 All valves, threaded connections and PRVs handling VOCs shall be

inspected for leakage at least once every three (3) months. If less than two

(2) percent of the components of any component type subject to the

prohibitions of this rule, except PRVs, are found to leak during each of

five (5) consecutive quarterly inspections, the inspection frequency for that

component type may be changed from quarterly to annual. If any annual

inspection shows that two (2) percent or more of all of a specific

component type subject to the prohibitions of this rule are leaking, then

quarterly inspections of that component type shall be resumed.

5.2.2 All flanges and process drains handling VOCs shall be inspected at least

once every 12 months.

5.2.3 Within three (3) days after any PRV vents to atmosphere the operator shall

inspect with a portable hydrocarbon detection instrument any such PRV

and shall repair any leak in accordance with Section 5.3.1.

5.2.4 Inspection shall be accomplished by sampling for vapors with a portable

hydrocarbon detection instrument and by visual examination for indication

of liquid leakage.

5.2.5 Any leaking component shall be identified by affixing a weatherproof,

readily visible tag bearing the date on which the leak is detected. The tag

shall remain in place until repair and reinspection documents compliance

with the requirements of this rule.

5.2.6 Each leak detected shall be recorded on the inspection record along with

the date of inspection, component identification number, actual instrument

reading, and the inspector's initials.
5.3 Repair

5.3.1 Within 15 days after detection any valve, PRV, flange, threaded

connection, or process drain found to leak shall be repaired or vented to a

flare satisfying the requirements of 40 CFR 60.18 or to a vapor control

device that is at least 95 percent efficient as measured by EPA Method 25.

5.3.2 The following repair schedule shall apply to any valve, PRV, flange,

threaded connection, or process drain that is found to leak and that cannot

be repaired to a no-leak condition without requiring the shutdown of

essential refinery operations:

5.3.2.1 If the leak rate is less than ten (10) drops per minute the following

shall be required and the APCO shall be notified of:

5.3.2.1.1 the expected date of repair, not to exceed

one (1) year or the date of the next process

unit turnaround whichever is less, for each

valve, PRV, flange, threaded connection,

and process drain, and

5.3.2.1.2 the actual date of repair for each valve, PRV,

flange, threaded connection, and process

drain.

5.3.2.2 If the leak rate is greater than nine (9) drops per minute or 10,000

ppm measured one (1) centimeter from the source, the

following shall be required and the APCO shall be notified

of:

5.3.2.2.1 an emergency repair, within 15 days after

detection, to reduce the leak to less than ten

(10) drops per minute or 10,000 ppm as

methane measured one (1) centimeter from

the source, or

5.3.2.2.2 the venting, within 30 days after detection,

of the emission to a flare or vapor control

system that satisfies the requirements of

Section 5.3.1, or

5.3.2.2.3 a demonstration, within 30 days after

detection, that measures in Sections 5.3.2.1

and 5.3.2.2 are infeasible. The

demonstration shall include documentation
that the component is an essential device and

that no vapor control device that satisfies the

requirements of Section 5.3.1 exists.

5.3.2.3 Repair an essential device to eliminate the leak during the next

process unit shutdown, but in no case later than one (1) year

from the date of the original leak detection.

6.0 Administrative Requirements

6.1 Operator Management Plans

6.1.1 Each operator shall, not later than November 1, 1991, submit a

management plan to the APCO. The management plan shall describe how

the operator will comply with the requirements of this rule.

The management plan must include:

6.1.1.1 description of any hazard which might affect the safety of an

inspector;

6.1.1.2 identification of process units which cannot be immediately

shutdown for repair of leaks;

6.1.1.3 identification of components for which an exemption in

accordance with Sections 4.1 through 4.6 of this rule is

requested;

6.1.1.4 specific identification of the resource commitment to a program to

implement, inspect, and repair components;

6.1.1.5 schedule of quarterly inspections to be conducted in accordance

with EPA Method 21.; and

6.1.1.6 repair procedures to be used within 15 calendar days following

leak detection which results in compliance with the

requirements of this rule.

6.1.2 The operator of a new facility or a facility to be modified shall submit a

new or modified operator management plan to the APCO prior to

implementation of an Authority to Construct.

6.1.3 Each management plan shall:

6.1.3.1 specify whether contractor or employee inspection will be used;
6.1.3.2 specify training standards for personnel performing inspections,

and

6.1.3.3 provide leak detection training (using a portable hydrocarbon

detection instrument) for new operators, and for

experienced operators as necessary.

6.1.4 Changes to the management plan must be submitted to the APCO before

implementation. If the APCO fails to respond to the plan in writing within

30 days, it shall be deemed approved.

6.2 Recordkeeping

6.2.1 Each facility operator shall maintain an inspection log containing, at a

minimum, the following:

6.2.1.1 name, location, type of components, and description of any unit

where leaking components are found.

6.2.1.2 date of leak detection, emission level (ppm) of leak, and method of

detection.

6.2.1.3 date and emission level of recheck after leak is repaired.

6.2.1.4 identification of leaks that cannot be repaired until next process

unit turnaround.

6.2.1.5 total number of components inspected, and total number and

percentage of leaking components found.

6.2.2 Copies of the inspection log shall be retained by the operator for a

minimum of two (2) years after the date of an entry.

6.2.3 Copies of the inspection log shall be made available upon request to

District personnel.

6.3 Test Methods:

6.3.1 Analysis of halogenated exempt compounds shall be by ARB Method 432.

6.3.2 Efficiency of VOC destruction device shall be measured by EPA Method

25, 25a, or 25b, as applicable, and analysis of halogenated exempt

compounds shall be analyzed by ARB Method 422.
6.3.3 The TVP of organic liquids, including light crude and petroleum

distillates, shall be measured using Reid vapor pressure ASTM Method

No. D-323-82 modified by maintaining the hot water bath at storage

temperature. Where storage temperature is above 1000F, TVP may be

determined by Reid Vapor pressure at 1000F and ARB approved

calculations. Organic liquids listed in Table 1 shall be deemed to be in

compliance with the appropriate vapor pressure limits for the material,

provided actual operating temperature does not exceed the corresponding

maximum temperature listed.

6.3.4 Leak detection shall be performed with a portable hydrocarbon detection

instrument in accordance with EPA Method 21.
Table 1

TEMPERATURE VERSUS VAPOR PRESSURE

ORGANIC LIQUID Reference Properties Maximum Temp °F

Not to Exceed

Gravity

°API

IBP

°F

0.5 (psia) 1.5 (psia)

Middle Distillates

Kerosene 42.5 350 195 250

Diesel 36.4 372 230 290

Gas Oil 26.2 390 249 310

Stove Oil 23 421 275 340

Jet Fuels

JP-1 43.1 330 165 230

JP-3 54.7 110 --- 25

JP-4 51.5 150 20 68

JP-5 39.6 355 205 260

JP-7 44-50 360 205 260

Fuel Oil

No. 1 42.5 350 195 250

No. 2 36.4 372 230 290

No. 3 26.2 390 249 310

No. 4 23 421 275 340

No. 5 19.9 560 380 465

Residual 19.27 --- 405 ---

No. 6 16.2 625 450 ---

Asphalts

60-100 pen. --- --- 490 550

120-150 pen. --- --- 450 500

200-300 pen. --- --- 360 420

IBP = Initial Boiling Point