Lorri Grainawi Steel Tank Institute. PA NISTM April 25, 2013 Harrisburg, PA
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1 Lorri Grainawi Steel Tank Institute PA NISTM April 25, 2013 Harrisburg, PA
2 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
3 1. INTRODUCTION Origin Produced as an industry service Prepared in response to requests from UST regulators, testers and operators Represents a single authoritative source of information
4 1. INTRODUCTION Origin Represents a synthesis of industry procedures and manufacturers recommendations and consensus of the PEI RP/1200 committee Information assembled from published and unpublished sources provided by equipment suppliers, UST owners, testing contractors, industry related associations and authorities having jurisdiction
5 1. INTRODUCTION Origin Committee is made up of representatives from: Equipment suppliers Tank owners Testing companies Industry associations Regulatory community
6 1. INTRODUCTION Origin In addition, the committee had the benefit of comments submitted by interested parties Public comment period January 24 March 26, comments received from various parties RP/1200 committee considered all comments
7 1. INTRODUCTION Public Comments Comments can be made by anyone at any time via the world wide web Publications & Resources Recommended Practices
8 1. INTRODUCTION Origin In instances where there were differences or omissions in material available from existing sources, the committee included its own consensus recommendations based on the practical experience of committee members
9 1. INTRODUCTION Background Spill, overfill, leak detection and secondary containment equipment required by regulations In order to operate effectively and safely, this equipment must be maintained, inspected and tested for proper operation on an ongoing basis
10 Purpose 1. INTRODUCTION Provide a concise summary of general guidelines for inspection and testing of at UST facilities: Spill prevention Overfill equipment Leak detection Secondary containment Shear valves Emergency stops
11 1. INTRODUCTION Purpose Intended to provide recommended practices that: Protect human health and the environment Promote safe and reliable operation of UST systems Prevent spills and overfills associated with deliveries Prevent damage to property and equipment
12 1. INTRODUCTION Purpose Not intended to: Endorse or recommend particular materials, equipment, suppliers or manufacturers Discourage the development or installation of new equipment Discourage the development of new or improved testing procedures and equipment
13 1. INTRODUCTION Scope RP/1200 applies to UST facilities that store Motor fuels Jet fuels Distillate fuel oils Residual fuel oils Lubricants Petroleum solvents Oils Other petroleum products
14 1. INTRODUCTION Scope Recommended Practices apply to: Underground storage tanks Connected underground piping Underground ancillary equipment Secondary containment systems
15 1. INTRODUCTION Scope Recommended Practices do not apply to: Aboveground storage tanks Mobile tanks (truck mounted refuelers) Dispensing equipment above grade level Tanks containing refrigerated liquids, liquefied petroleum gases, liquefied natural gases or compressed natural gases
16 1. INTRODUCTION Scope Test methods based on current industry practices Intended to demonstrate that a leak from the primary containment will be detected before it reaches the environment If AHJ requires testing to meet specific leak detection standards follow the regulatory requirements
17 1. INTRODUCTION Scope RP/1200 is not meant to provide interpretation of regulatory or legislative requirements related to UST systems
18 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
19 2. DEFINITIONS Tight Wrap Tank A type of tank construction that consists of a primary tank wrapped by a secondary containment that is structurally supported by the primary tank. Interstitial space is very small 110% Containment Tank A tank with secondary containment where the interstitial space volume is 10% of the total primary containment volume. Interstitial space is large
20 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
21 3. SAFETY Only properly trained individuals should inspect or test overfill, leak detection and release prevention equipment. These individuals are responsible for their own safety, and should take reasonable precautions to ensure the safety of facility employees, customers, and any other personnel in the work area. Refer to Appendix D for related safety publications.
22 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
23 4. TANK SECONDARY CONTAINMENT INTEGRITY TESTING 4.1 General - Interstice may be dry or liquid filled Dry = Vacuum Test Wet = Hydrostatic Test
24 4. TANK SECONDARY CONTAINMENT 4.2 Dry Test Method INTEGRITY TESTING Test procedure is general in nature Represents the consensus view of the committee Vacuum is pulled and monitored for a period of time Test duration depends on size of tank Amount of vacuum depends on type of tank
25 4. TANK SECONDARY CONTAINMENT INTEGRITY TESTING Dry Test Method Steel Tanks Must determine if tank is a tight wrap or 110% containment design If tank is tight wrap RP/1200 test procedure may be followed If tank is 110% - Follow Steel Tank Institute R012 Recommended Practice for Interstitial Tightness Testing of Existing Underground Double Wall Steel Tanks
26 4. TANK SECONDARY CONTAINMENT INTEGRITY TESTING Dry Test Method Fiberglass Tanks May use RP/1200 test procedure OR Fiberglass Tank & Pipe Institute Field Test Protocol for Testing the Annular Space of Installed Underground Fiberglass Double and Triple-wall Tanks with Dry Annular Space
27 4. TANK SECONDARY CONTAINMENT Dry Test Method INTEGRITY TESTING Table 4.1 Tank Type Vacuum, inches Hg Fiberglass 10 Steel 6 Test Parameters Capacity, gallons Duration, hours < , < ,000+ 2
28 4. TANK SECONDARY CONTAINMENT Dry Test Method INTEGRITY TESTING Pass = No loss of vacuum and no ingress of fluids Fail = Any loss of vacuum or any ingress of fluids
29 4. TANK SECONDARY CONTAINMENT 4.3 Hydrostatic testing INTEGRITY TESTING RP defers to the manufacturers test procedure Variables must be considered Too many differences between manufacturers procedures These tests, when conducted according to the manufacturers protocol, are precision tightness tests (0.1 gph) Manufacturers checklist/data log included as appendix
30 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
31 5. PIPING SECONDARY CONTAINMENT INTEGRITY TESTING Only tests the outer wall of double-walled pipe Containment sumps are tested separately RP/1200 test procedure is general in nature (no established leak rate)
32 5. PIPING SECONDARY CONTAINMENT INTEGRITY TESTING Piping interstice is pressurized with an inert gas to 5 psi and monitored for 1 hour Piping tested as one continuous system or in sections Sealing interstitial space of some piping systems (particularly older ones) can be problematic
33 5. PIPING SECONDARY CONTAINMENT INTEGRITY TESTING Pass = No pressure change Fail = Any pressure change If pressure increases repeat the test Note: Piping secondary containment testing is conducted only after the primary pipe has been precision tightness tested
34 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
35 6. SPILL BUCKET & CONTAINMENT 6.1 General SUMP TESTING Spill bucket and sump testing is grouped together since the test procedure is the same Spill buckets and containment sumps can be single-walled or double-walled
36 6. SPILL BUCKET & CONTAINMENT 6.1 General SUMP TESTING Spill Buckets - Test procedures for both single and double-walled spill buckets Single-walled = Hydrostatic OR Vacuum test Double-walled = Vacuum test of interstice Containment Sumps Test procedure for singlewalled containment sumps only Single-walled = Hydrostatic test
37 6. SPILL BUCKET & CONTAINMENT SUMP TESTING 6.2 Single-Walled Spill Bucket Hydrostatic Test Clean and examine the spill bucket Fill with water to within 1 ½ inches of top Measure water depth to nearest 1/16 inch Monitor for 1 hour Pass = Difference < 1/8 inch Fail = Difference 1/8 th inch
38 6. SPILL BUCKET & CONTAINMENT SUMP TESTING 6.2 Single-Walled Spill Bucket Hydrostatic Test Be sure tank fill cap seals properly Be sure drain valve seals properly If these components don t seal properly - water may enter tank Alternatively, you may temporarily install a plumber s plug in the fill riser and remove/plug the drain valve
39 6. SPILL BUCKET & CONTAINMENT SUMP TESTING 6.3 Single-Walled Spill Bucket Vacuum Test Clean and examine the spill bucket Install special test cover Pull a vacuum of 30 H 2 O column Monitor vacuum for 1 minute Pass = Ending vacuum level 26 H 2 O column Fail = Ending vacuum level < 26 H 2 O column
40 6. SPILL BUCKET & CONTAINMENT SUMP TESTING 6.4 Double-Walled Spill Bucket - Vacuum Test Clean and examine the spill bucket Pull a vacuum of 15 H 2 O column on interstice Monitor vacuum for 1 minute Pass = Ending vacuum 12 H 2 O column Fail = Ending vacuum < 12 H 2 O column
41 6. SPILL BUCKET & CONTAINMENT SUMP TESTING 6.4 Double-Walled Spill Bucket - Vacuum Test Testing the interstice of a double-walled spill bucket simultaneously tests both the primary and secondary
42 6. SPILL BUCKET & CONTAINMENT SUMP TESTING 6.5 Single-Walled Containment Sump Hydrostatic Test Clean, examine and prepare the containment sump Fill with water to 4 above the highest sump penetration or sidewall seam whichever is higher Measure water level to the nearest 1/16 inch Monitor water level for 1 hour Pass = Difference < 1/8 inch Fail = Difference 1/8 th inch
43 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
44 7. OVERFILL PREVENTION INSPECTION Federal Rule (40 CFR 280) Overfill Prevention Options: Shutoff flow at: a. 95% tank capacity OR b. before tank top fittings are wetted Restrict flow at: a. 90% tank capacity OR b. 30 minutes prior to overfilling Alert the operator at: a. 90% tank capacity OR b. 1 minute prior to overfilling
45 7. OVERFILL PREVENTION INSPECTION Shutoff Restrict Alarm
46 7. OVERFILL PREVENTION INSPECTION Committee decided to develop protocols reflective of the more conservative application of the rules Overfill prevention devices must be set to: Shutoff at 95% tank capacity Restrict flow at 90% tank capacity Alert the operator at 90% tank capacity
47 7. OVERFILL PREVENTION INSPECTION 7.1 Automatic Shutoff Devices (Flapper Valves) Remove from the tank Visually inspect Manually operate valve to ensure it is functional Measure length to ensure complete shutoff occurs when the tank is no more than 95% full Note: Ensure that complete shutoff point occurs at 95%
48 7. OVERFILL PREVENTION INSPECTION 7.2 Restriction Devices (Ball Float Valves) Remove from the tank Visually inspect Measure length to ensure flow restriction occurs when the tank is no more than 90% full Note: All tank top fittings must be tight in order for the ball float valve to effectively restrict the flow
49 7. OVERFILL PREVENTION INSPECTION 7.3 Alert Devices (Electronic Alarms) Electronic alarms typically part of ATG system Remove from the tank Visually inspect Measure length to ensure that alarm occurs when the tank is no more than 90% full Note: Overfill alarms must provide an audible and/or visible warning to the fuel delivery driver
50 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
51 8. ELECTRONIC MONITORING SYSTEM INSPECTION Test/Inspection of ATG system: Console In-tank probes Interstitial sensors (tanks & piping) Test is general in nature Not intended as calibration of ATG system
52 8. ELECTRONIC MONITORING SYSTEM INSPECTION 8.1 ATG Console Verify system is properly configured (setup) Verify all site specific parameters are correct Verify that indicator lamps function Verify that printer functions Verify that LCD display functions
53 Component Testing & Verification 8.2 ATG Probes Remove probe from tank Visually inspect probe tank cap assembly Visually inspect probe and floats Verify that floats move freely Verify all floats indicate the correct fluid levels and indicated fluid levels correspond with programming
54 8. ELECTRONIC MONITORING SYSTEM INSPECTION 8.3 Interstitial Sensors RP only considers sensors that function by detecting the presence of liquids (both discriminating and non-discriminating) RP only considers float switch type sensors as these are the most common For other types of sensors consult manufacturer
55 8. ELECTRONIC MONITORING SYSTEM INSPECTION 8.3 Interstitial Sensors Verify that sensor is properly installed Remove sensor from tank interstice or piping sump Visually inspect Submerge sensor in appropriate test fluid (water for non-discriminating type) Verify proper alarm condition and/or STP shutdown Verify sensor is properly labeled in ATG console setup
56 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
57 General 9. AUTOMATIC LINE LEAK DETECTORS Two types of automatic line leak detectors Mechanical Electronic
58 General 9. AUTOMATIC LINE LEAK DETECTORS Test procedures verify that the ALLD is capable of detecting a leak equivalent to 3 10 psi Test apparatus must have an adjustable orifice to properly simulate a leak equivalent to 3 10 psi Calibration of the adjustable orifice may be accomplished with or without the use of a pressure regulator Both procedures are described
59 General 9. AUTOMATIC LINE LEAK DETECTORS Test must confirm that the STP properly cycles on/off (verifies STP relays are functioning) Simulated leak must occur at the dispenser that is at the highest elevation above the STP If piping system has master/satellite configuration, simulated leak must occur at the farthest satellite dispenser
60 9. AUTOMATIC LINE LEAK DETECTORS 9.1 Mechanical Leak Detectors Visual inspection Verify leak detector trips when line pressure nears zero Verify leak detector sees a simulated leak equivalent to 3 10 psi Slow flow condition exists
61 9. AUTOMATIC LINE LEAK DETECTORS 9.2 Electronic Line Leak Detectors Visual inspection Verify system setup parameters are correct Verify leak detector searches for leak Verify leak detector sees simulated leak equivalent to 3 10 psi Causes alarm condition Causes STP shutdown if required by AHJ
62 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
63 10. SHEAR VALVE INSPECTION & TESTING Two types of shear valves Product Shear Valve Vapor Shear Valve
64 10. SHEAR VALVE INSPECTION & TESTING 10.2 Product Shear Valves Visual inspection Verify anchored securely and at correct height Confirm trip mechanism is functional Manually close the valve poppet Verify that no product flow occurs
65 10. SHEAR VALVE INSPECTION & TESTING 10.3 Vapor Shear Valves Visual inspection Verify anchored securely and at correct height
66 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop Switches 12. Documentation Appendices
67 11. EMERGENCY STOPS General May be more than one e-stop switch at the facility Must test every e-stop switch individually Verify e-stop is clearly labeled Verify easily accessible
68 11. EMERGENCY STOPS Manually activate switch to confirm power has been disconnected to: All dispensers All STPs All power, control and signal circuits associated with dispensers and STPs All other non-intrinsically safe electrical equipment in the classified areas of the UST system and dispensers
69 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
70 12. DOCUMENTATION Sample forms are provided for every test Proper documentation of testing is essential
71 PEI/RP Introduction 2. Definitions 3. Safety 4. Tank Secondary Containment Integrity Testing 5. Piping Secondary Containment Integrity Testing 6. Spill Bucket and Containment Sump Testing 7. UST Overfill Equipment Verification, Inspection and Testing 8. Electronic Monitoring System Inspection and Testing 9. Automatic Line Leak Detectors 10. Shear Valve Inspection and Testing 11. Emergency Stop 12. Documentation Appendices
72 APPENDIX A FRP Tank Manufacturer s Test Checklists/Data Logs Appendix A-1 & A-2 Fiberglass tank manufacturers precision tank tightness testing procedure for brine filled double-walled tanks
73 APPENDIX B Pressure & Vacuum Conversion Tables Convert Units for Measuring Pressure PSIG - Inches HG Mbar Bar Convert Units for Measuring Vacuum Inches H 2 O Inches HG PSIG Mbar - Bar
74 APPENDIX C SAMPLE TEST DATA SHEETS C-1 Tank Secondary Containment Integrity Testing Dry Test Method C-2 Piping Secondary Containment Integrity Testing C-3 Spill Bucket Integrity Testing Hydrostatic Test Method Single and Double-Walled Vacuum Method C-4 Containment Sump Integrity Testing Hydrostatic Testing Method C-5 UST Overfill Equipment Inspection Automatic Shutoff Device and Ball Float Valve C-6 Overfill Alarm Operation Inspection C-7 Automatic Tank Gauge Operation Inspection C-8 Liquid Sensor Functionality Testing C-9 Mechanical and Electronic Line Leak Detectors Performance Test C-10 Shear Valve Operation Inspection C-11 Emergency Stop Switch Operation Inspection
75 APPENDIX D PUBLICATION REFERENCE API FT&PI ICC NFPA PEI STI UL OSHA EPA
76 PEI RP/1200 Doing what we can to protect service stations
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