(a) Except for branch connections and assemblies of standard pipe and fittings joined by circumferential welds, the design pressure of each component fabricated by welding, whose strength cannot be determined, must be established in accordance with paragraph UG-101 of the ASME Boiler and Pressure Vessel Code (BPVC) (Section VIII, Division 1) (as described in section 10.3 of this Title).
(b) Each prefabricated unit that uses plate and longitudinal seams must be designed, constructed, and tested in accordance with the ASME BPVC (rules for Construction of Pressure Vessels as defined in either Section VIII, Division 1 or Section VIII, Division 2) (as described in section 10.3 of this Title), except for:
(1) manufactured butt-welded fittings;
(2) pipe that has been produced and tested under a specification listed in Appendix 14-B of this Title;
(3) partial assemblies such as split rings or collars; or
(4) prefabricated units that the manufacturer certifies have been tested to at least twice the maximum pressure to which they will be subjected under the anticipated operating conditions.
(c) Orange-peel bull plugs and orange-peel swages may not be used on pipelines that are to operate at a pressure of 125 psig (862 kPa) or more.
(d) Except for flat closures designed in accordance with the ASME BPVC (Section VIII, Division 1 or 2) (as described in section 10.3 of this Title), flat closures and fish tails may not be used on pipe that either operates at 100 psig (689 kPa) or more, or is more than 3 inches (76 millimeters) nominal diameter.
(e) The test requirements for a prefabricated unit or pressure vessel, defined for this subdivision as components with a design pressure established in accordance with subdivision (a) or (b) of this section are as follows.
(1) A prefabricated unit or pressure vessel installed after July 14, 2004, is not subject to the strength testing requirements at subdivision 255.505(b) of this Part provided the component has been tested in accordance with subdivision (a) or subdivision (b) of this section and with a test factor of at least 1.5 times maximum allowable operating pressure (MAOP).
(2) A prefabricated unit or pressure vessel must be tested for a duration specified as follows:
(i) A prefabricated unit or pressure vessel installed after July 14, 2004, but before October 1, 2021, is exempt from subdivisions 255.505(c) and (d) and 255.507(c) of this Part provided it has been tested for a duration consistent with the ASME BPVC requirements referenced in subdivision (a) or (b) of this section.
(ii) A prefabricated unit or pressure vessel installed on or after October 1, 2021, must be tested for the duration specified in either subdivisions 255.505(c) or (d), 255.507(c), or 255.509(a) of this Part, whichever is applicable for the pipeline in which the component is being installed.
(3) For any prefabricated unit or pressure vessel permanently or temporarily installed on a pipeline facility, an operator must either:
(i) Test the prefabricated unit or pressure vessel in accordance with this section and sections 255.501 through 255.517 of this Part after it has been placed on its support structure at its final installation location. The test may be performed before or after it has been tied-in to the pipeline. Test records that meet subdivision 255.517(a) of this Part must be kept for the operational life of the prefabricated unit or pressure vessel; or
(ii) For a prefabricated unit or pressure vessel that is pressure tested prior to installation or where a manufacturer's pressure test is used in accordance with subdivision (e) of this section, inspect the prefabricated unit or pressure vessel after it has been placed on its support structure at its final installation location and confirm that the prefabricated unit or pressure vessel was not damaged during any prior operation, transportation, or installation into the pipeline. The inspection procedure and documented inspection must include visual inspection for vessel damage, including, at a minimum, inlets, outlets, and lifting locations. Injurious defects that are an integrity threat may include dents, gouges, bending, corrosion, and cracking. This inspection must be performed prior to operation but may be performed either before or after it has been tied-in to the pipeline. If injurious defects that are an integrity threat are found, the prefabricated unit or pressure vessel must be either non-destructively tested, repressure tested, or remediated in accordance with applicable Part 255 requirements for a fabricated unit or with the applicable ASME BPVC requirements referenced in subdivisions (a) or (b) of this section. Test, inspection, and repair records for the fabricated unit or pressure vessel must be kept for the operational life of the component. Test records must meet the requirements in subdivision 255.517(a) of this Part.
(4) An initial pressure test from the prefabricated unit or pressure vessel manufacturer may be used to meet the requirements of this section with the following conditions:
(i) The prefabricated unit or pressure vessel is newly-manufactured and installed on or after October 1, 2021, except as provided in subparagraph (e)(4)(ii) of this section.
(ii) An initial pressure test from the fabricated unit or pressure vessel manufacturer or other prior test of a new or existing prefabricated unit or pressure vessel may be used for a component that is temporarily installed in a pipeline facility in order to complete a testing, integrity assessment, repair, odorization, or emergency response-related task, including noise or pollution abatement. The temporary component must be promptly removed after that task is completed. If operational and environmental constraints require leaving a temporary prefabricated unit or pressure vessel under this paragraph in place for longer than 30 days, the operator must notify PHMSA and State or local pipeline safety authorities, as applicable, in accordance with section 255.18 of this Part.
(iii) The manufacturer's pressure test must meet the minimum requirements of this part; and
(iv) The operator inspects and remediates the prefabricated unit or pressure vessel after installation in accordance with subparagraph (e)(3)(ii) of this section.
(5) An existing prefabricated unit or pressure vessel that is temporarily removed from a pipeline facility to complete a testing, integrity assessment, repair, odorization, or emergency response-related task, including noise or pollution abatement, and then reinstalled at the same location must be inspected in accordance with subparagraph (e)(3)(ii) of this section; however, a new pressure test is not required provided no damage or threats to the operational integrity of the prefabricated unit or pressure vessel were identified during the inspection and the MAOP of the pipeline is not increased.
(6) Except as provided in subparagraph (e)(4)(ii) and paragraph (e)(5) of this section, on or after October 1, 2021, an existing prefabricated unit or pressure vessel relocated and operated at a different location must meet the requirements of this part and the following:
(i) The prefabricated unit or pressure vessel must be designed and constructed in accordance with the requirements of this part at the time the vessel is returned to operational service at the new location; and
(ii) The prefabricated unit or pressure vessel must be pressure tested by the operator in accordance with the testing and inspection requirements of this part applicable to newly installed prefabricated units and pressure vessels.