RELIABILITY PROGRAM

Owner: Inspection Department

Responsibility: Terminal Area Inspector / Terminal Operations / Maintenance

Code of Federal Regulations:

33 CFR 156.170

33 CFR 154.500 & 510

Purpose: To assure the system is leak-free and able to withstand maximum applied pressure. Also, to meet Coast Guard requirements for annual testing and labeling of hoses and loading arms.

Work Process:

A.  Planning (Terminal Planner / Scheduler)

• Terminal Planning creates a standing work order at the beginning of each year to perform annual testing of hoses, loading arms, and dock lines.

B.  Function Test

• Maintenance and Operations supervise contract company testing crews and ensure all systems are tested.
• Equipment is isolated, filled, and pressurized with water (or sometimes product on dock lines only) by Terminal Operations and Maintenance. The Inspection Department is notified once the system is ready.
• Test is held at 1.5 times the Maximum Allowable Working Pressure (MAWP), not to exceed 10% overpressure, while being checked for leaks and witnessed by the Area Inspector.
• System is then de-pressured upon completion.
• Test dates are stenciled on hoses and loading arms; dock lines are not stenciled.

C.  Dock Crane / Load Arm Hydraulic Tubing Inspection

• Visual inspection is performed on hydraulic tubing and fittings by the Area Inspector.

D.  Repairs

• Minor items such as gasket or valve packing leaks are repaired and the system is re-tested.
• If piping or tubing replacement is required, the Terminal Area Inspector issues a recommendation and creates an Notification. Once the repair is complete, the system is re-tested and inspected.
• Repairs are tracked.
• If hose repairs are required, Terminal Operations ships the hose off-site to a repair facility; the hose is re-tested upon return.

Records:

• A form titled "ANNUAL HYDROTEST OF DOCK PIPING, DOCK HOSES AND LOADING ARMS" is completed for each test. This form contains all information relevant to each test.
• When the test is accepted, these forms are signed off by Operations, Maintenance, and Inspection.
• The Inspector witnessing the testing maintains a running list of Dock Hoses showing dates tested, pressures, sizes, and service.
• All dock piping, hose, and loading arm test results are stored in a binder for review during the annual audit by the Coast Guard. These binders are maintained in the Terminal Inspection Office.