09_RFQ-24-702_Att9_DCBO_Best_Management_Guide_ada.pdf

California Energy Commission

DELEGATE CHIEF BUILDING

OFFICIAL (DCBO)

RFQ-24-702

BEST MANAGEMENT

PRACTICES GUIDE

Attachment 9

CALIFORNIA

ENERGY COMMISSION

Gavin Newsom., Governor

CALIFORNIA

ENERGY

COMMISSION

DISCLAIMER

Staff members of the California Energy Commission prepared this report.

As such, it does not necessarily represent the views of the Energy Commission, its employees, or the State of California. The Energy Commission, the State of California, its employees, contractors, and subcontractors make no warrant, express or implied, and assume no legal liability for the information in this report; nor does any party represent that the uses of this information will not infringe upon privately owned rights. This report has not been approved or disapproved by the Energy Commission nor has the Commission passed upon the accuracy or adequacy of the information in this report.

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TABLE OF CONTENTS

DCBO - BEST PRACTICES MANUAL

1.0 Introduction

1.1 Background

1.2 Intent

1.3 Energy Commission’s Third-Party Beneficiary Clause

2.0 Role of the DCBO

2.1 Conditions of Certification (COCs)

2.2 California Building Standards Code Compliance

2.3 Industrial Code Compliance

2.4 Document Control and Tracking

2.5 Limits of Engineering Document Review

3.0 Laws Ordinances Regulations and Standards

3.1 California Building Standards Code (CBSC)

3.2 Primary Industry Codes – Process Piping Systems

3.3 49 CFR Part 192 – Federal Natural Gas Pipeline Regulations 15

3.4 National Fire Protection Association (NFPA) Standards

3.5 Other Design-Related Conditions of Certification

4.0 Typical Project Responsibilities and Milestones

4.1 Contracting and the Energy Commission

4.2 Project Kickoff Meeting

4.3 Creation of DCBO Project Website

4.4 Initial Document Submittal Review – COC Compliance

Assistance

4.5 Document Submittal Reviews and Approvals

4.6 Construction Inspection and COC Compliance Oversight

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4.7 As-Constructed Document Package

5.0 Best Practices and Procedure Guidance

5.1 Document Submittal and Tracking System

5.2 Inspection Process

5.3 Site Presence

6.0 Specific Facility Guidance Issues

6.1 Common Issues Observed

6.2 Avoid Creating Issues

6.3 Excessive Design Reviews – Seek Energy Commission Input . 38

6.4 Specific Energy Commission Addressed Issues

Exhibit 1 – Abbreviations, Terms, and Definitions

Abbreviations and Terms

E2.1 Pre-Fabricated Assemblies (PFAs)

E2.2 Use of Industry Code Recommended Practices

E2.3 Ammonia Storage Tank Requirements – Anhydrous and Aqueous

E2.4 Labeling and Listing – Material Approvals vs. Inspection for Compliance

E2.5 Natural Gas Pipeline Regulations and Compressor Building Design

E2.6 Construction Oversight – Means and Methods vs. Code Compliance

E2.7 Professional Engineer (PE) Stamp Requirements for Out of State PFAs and Process Equipment

E2.8 G e n e r a t i n g Plant Start-Up Responsibilities of DCBO’s

E2.9 Pract ical vs. Hard-Line Approach to Code Interpretation

E2.10 Fire Suppression CFC Compliance – Special Equipment Protection iii

E2.11 PE Requirements for Plan Reviewers and DCBO

E2.12 Qualification of Steel Fabricators Prior to Start of Work

E2.13 Process Piping Hydrostatic Testing

E2.14 Chemical Spacing – Setbacks within Plant

E2.15 Process Piping Material QA/QC – ASME Code Requirements ... 55

E2.16 Turbines, Generators, etc. – Equipment Enclosures

E2.17 DCBO and Local Fire Authority Having Response Jurisdiction – Interaction

E2.18 ADA vs. CalOSHA/Federal OSHA Handrails and Platforms

E2.19 Liquid Storage

E2.20 Temporary Facilities

E2.21 Consistent Application of Importance Factors

E2.22 Seismic and Wind Loading of Wind Turbines

E2.23 Wind Loading of Solar Collecting Devices

E2.24 Solar Electric Generating Stations – Occupancy Category

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DCBO - BEST PRACTICES MANUAL

1.0 Introduction

1.1 Background

The Warren-Alquist Act (Public Resources Code sections 25000 et. seq.) grants the California Energy Commission (Energy Commission) exclusive jurisdiction to review and approve applications for certification (AFCs) and petitions to amend (PTAs) for the construction, operation, modification and eventual closure of:

1. Large thermal power plants (50 megawatts or greater).

The Energy Commission utilizes the California Building Standards Code (CBSC) as its model building code and is responsible for interpretation and enforcement of the CBSC.

Assembly Bill 205 establishes an Opt-in Certification program for eligible non-fossil-fueled power plants, energy storage, and manufacturing and assembly facilities to optionally seek certification (Energy Commission Public Resources Code, Division 15, Chapter 6.2, sections 25545-25545.13; California Code of Regulations, Title 20, Division 2, Chapter 5). The following types of facilities are eligible to apply for Opt-in Certification Program:

2. Solar photovoltaic or terrestrial wind electrical generating power plants (50 MW or greater).

3. Energy storage system (capable of storing 200 megawatt-hours (MWh) or more).

4. A stationary power plant using any source of thermal energy, excluding fossil or nuclear fuels (50 MW or greater).

5. Certain transmission lines associated with these generating and storage facilities.

6. Specified facilities that manufacture or assemble clean energy or storage technologies or related components.

Herein, throughout this document, all of these projects and facilities identified above in lines 1 through 6 will be referred to as “Project”. If Energy Commission approves a project, the certification would be in lieu of any permit, certificate, or similar document required by any state, local, or regional agency, or federal agency to the extent permitted by federal law, with some exceptions.

The Energy Commission utilizes the California Building Standards Code (CBSC) as its model building code and is responsible for interpretation and enforcement of the CBSC.

When the Energy Commission authorizes a Project owner to proceed with detailed design and construction, the Energy Commission must select a qualified third- party firm to act on behalf of the Energy Commission as their delegate chief building official

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(DCBO). In this capacity, the selected DCBO performs their plan review and construction inspection duties in accordance with the CBSC and the Commission Final Commission Decision for the facility. This document has been prepared to assist the DCBO in executing its duties for the Energy Commission.1

This guide provides additional Energy Commission expectations in the performance of the contract. The DCBO contractor is expected to follow the guide in performing the work, and failure to do so is considered a material breach of the contract that may result in termination of the contract by the Energy Commission without limiting the Energy Commission’s rights or remedies. The contractor may deviate from the guide upon prior written approval by the compliance project manager (CPM) responsible for the project for which the approval was requested or by the compliance office manager. In the event of any conflict or inconsistency between the guide and the scope of work, the scope of work shall control.

Within this document, the California Code of Regulations, Title 24, Parts 1 through 12 is referred herein as the CBSC. This may also include specific reference to the California Building Code (CBC), California Electric Code (CELC), California Plumbing Code (CPC), California Mechanical Code (CMC), and the California Fire Code (CFC) as needed for clarity. Other laws, ordinances, regulations, and standards (LORS) also apply to the design and construction of a typical Project.

Within this document, the term developer refers to the collection of entities and individuals working as a team for the owner of a Project, certified by the Energy Commission, to design and construct a Project and related facilities2 within California.

This includes the owner, owner’s engineer, and owner’s construction manager, the engineering firm of record, the construction contractor or contractors, and any other groups or individuals working as an agent of the owner.

1.2 Intent

The intent of these best practices is to promote consistency within the Energy Commission’s DCBO resource pool when performing construction document plan reviews and inspections pertaining to the construction of a Project. This document illustrates the best practices and methods expected of all Energy Commission DCBO’s.

1.3 Energy Commission’s Third-Party Beneficiary Clause

Once selected, the DCBO is required to execute an agreement with the project owner that includes a third-party beneficiary contractual clause, that establishes the requirements of service for the project specific DCBO. This language also defines the authority of the Energy Commission and the duties it delegates to the DCBO. The owner of a Project is required to compensate the DCBO for all work performed for the project

1 Subsequent sections of this document define the typical DCBO tasks and duties.

2 Cal. Code Regs. tit. 20, §1201(r)

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Energy Center on behalf of the Energy Commission as required by the conditions of certification (COCs) contained in the Final Commission Decision.

The DCBO is obligated to perform their duties as a delegate of the Energy Commission, and no contract signed, agreement made, or other negotiated term with the project owner relieves the DCBO from the requirements found in the guidance. The DCBO must present suggested changes/clarifications to the Energy Commission’s procedures outlined herein to the Energy Commission prior to implementation by the DCBO. Changes cannot be authorized by the project owner.

2.0 Role of the DCBO

The role of the DCBO extends beyond the responsibilities of a typical building department’s chief building official. It is important to remember that the authority given to the DCBO is a delegated authority of the Energy Commission. The Energy Commission does not relinquish that authority and has the final decision authority on all matters relating to the design, construction, and licensing of a jurisdictional Project in California and appurtenant facilities to the first point of interconnection. The Energy Commission has the authority to make final decisions relating to interpretations of the CBSC as may be necessary. As its delegate, the DCBO must abide by any interpretation of the CBSC made by the Energy Commission. In addition, all DCBO team members must be approved by Energy Commission staff including additions or replacement team members.

The following sections define the general roles and responsibilities of the DCBO in the performance of their duties delegated to them by the Energy Commission for a Project.

2.1 Conditions of Certification (COCs)

The COCs define the various design and construction compliance tasks imposed on a Project by the Energy Commission. These tasks may involve the performance of work not typically required by other jurisdictional agencies for other construction projects. The COCs are the compliance road map followed by a Project team; they define how a project is to proceed to completion and subsequently to begin operation. The DCBO will assist the Energy Commission with the compliance oversight of these COCs to ensure that they are completed and documented to the satisfaction of the Energy Commission. The DCBO works directly with an Energy Commission compliance project manager (CPM), an Energy Commission employee of the Siting, Transmission and Environmental Protection (STEP) Division, to ensure the Project complies with all of the COCs identified in the Final Commission Decision for the project. No DCBO has the authority to alter or substitute any COCs.

The DCBO shall provide for a professional safety monitor on site to track compliance with Cal/OSHA regulations and periodically audit safety compliance during both demolition and construction activities, commissioning, and for the hand-off to operational status. The safety monitor shall be selected by, and report directly to, the DCBO. The safety monitor will be responsible for verifying that the project owner’s construction safety supervisor implements all appropriate Cal/OSHA and Commission safety requirements. The safety

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Energy Center monitor shall conduct on-site safety inspections during demolition and construction at intervals necessary to fulfill those responsibilities. The safety monitor shall have the authority to issue a stop work order for unsafe conditions found on the work site. The stop work order shall be in writing and given to the construction safety supervisor with the corrective measures required to remedy the unsafe condition(s) before work can resume. The safety monitor will ensure that the corrective actions have been properly taken by the construction safety supervisor before work can resume.

2.2 California Building Standards Code Compliance

The primary role of the DCBO is the enforcement of the CBSC requirements. In this role, the DCBO performs two basic functions. The first function is the review and approval of the construction documents necessary for CBSC compliance. The second function is the observation and inspection of construction components to verify that the as-constructed facilities are consistent with the approved construction documents.

A. Design and Construction Document Review and Approval

A Project owner has the regulatory requirement to submit many documents during the course of the design and construction of a Project. The following list should not be considered all-inclusive but provides a guideline regarding the general nature of the required submittals. The COCs identify any special submittals required of the project owner for site, design, environmental, and other compliance aspects for the proposed Project.

■ Any documents defined by the COCs;

■ Master drawing list;

■ Master specification list;

■ Project schedule;

■ Monthly progress reports;

■ Personnel assignment approvals (engineering, inspection, etc.);

■ Storm water pollution prevention plans (SWPPP);

■ Oil Spill Prevention, Control, and Countermeasures plans (SPCC – submitted directly to Environmental Protection Agency (EPA) – confirmation of transmittal to DCBO only when thresholds for requirements of 40 CFR Part 112 are met);

■ Drawings and supporting calculations for temporary electrical, civil, mechanical, and structural facilities proposed during construction (temporary construction power, fire protection, tent warehouses, etc.);

■ Hazardous Materials Management Plan (HMMP) per CFC Chapter 50, Section 5001.5.1;

■ Civil drawings and supporting calculations (grading, paving, drainage plan and details, plot plans, etc.);

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■ Geotechnical investigations and reports;

■ Site rainfall/firewater runoff and drainage calculations;

■ Structural design (e.g. seismic and wind loading design methods to be employed, site class, importance category, occupancy category, design criteria, etc.) methodology;

■ Structural calculations (loading, load combinations, computer modeling input and output reports, etc.);

■ Structural drawings (reinforced concrete, rebar details, structural steel, connection details, pipe hangers, platforms, handrails and elevated walkways, stationary cranes, fire protection, component mounting and bracing, etc.);

■ Structural coatings specifications (insulation, fire protection, etc.);

■ Engineered shoring drawings where required;

■ Electrical drawings (one-line, conduit and wiring schedules, termination, duct bank, lighting plan and illumination intensity plans, and miscellaneous details);

■ Electrical area classification drawings;

■ Electrical calculation (voltage drop, conductor sizing, conduit fills, ground grid sizing, short circuit calculations, etc.);

■ Mechanical equipment plans and detail drawings (HVAC systems, fire water pumping/monitoring/sprinkling systems, etc.);

■ Fire water main, monitor, sprinkler hydraulic calculations;

■ Fire protection system alarm and control system design drawings and calculations;

■ Process piping system plan and detail drawings (all submitted to the

DCBO but only a sampling will be reviewed as outlined above for the process piping system design process verification – plan and details, piping and instrumentation diagrams, isometric details, etc.);

■ High energy process piping systems pipe stress and flexibility analysis (provide a sampling as outlined above for the process piping system design process verification);

■ Pressure vessel ASME code certification documentation;

■ As-built drawings;

■ Pipelines;

■ Transmission lines;

■ Non-compliance reports (NCR) and resolutions thereof; and

■ Monthly status of NCR’s will be included in the monthly report.

B. Inspection of Constructed Facilities

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The inspection of construction by the DCBO is the primary means of assurance to the Energy Commission that construction is proceeding consistent with approved construction documents. The inspection of construction activities will be performed directly by DCBO personnel or by individuals (special inspectors) contracted by the project owner with direct reporting responsibilities to the project owner and DCBO.

The project owner shall have personnel, or contract with firms and/or individuals that are qualified, and certified special inspectors (if not provided by the DCBO) who shall be responsible for the special inspections required by the CBC, Chapter 17, and Section 1704 Special Inspections. The qualification of an inspector shall be demonstrated by attaining certifications appropriate to his/her review and inspection duties as demonstrated by certification with the American Society of Mechanical Engineers (ASME), National Fire Protection Association (NFPA), American Welding Society (AWS), Institute of Electrical and Electronics Engineers (IEEE), and/or any other nationally-recognized testing and certifications appropriate to the scope of his/her duties. The project owner should create and submit a special inspection plan that identifies these special inspectors and their responsibilities. The DCBO shall review and approve the qualifications of the special inspectors. The project owner shall obtain the approvals of any special inspector prior to commencement of any construction activities where special inspection is required.

The special inspectors shall work under the direction of the project owner and DCBO and not the firm contracted to construct the Project or any portion thereof. Special inspections include, but are not limited to, the following types of construction and related quality control/quality assurance testing required by the building code:

■ Soil compaction;

■ Concrete placement and strength tests;

■ Bolts installed in concrete;

■ Special moment-resisting concrete frame construction;

■ Reinforcing steel and pre-stressing steel tendon installation;

■ Structural welding;

■ Welding of reinforcing steel in concrete;

■ High-strength bolting of structures;

■ Structural masonry reinforcement placement and unit placement;

■ Reinforced gypsum concrete construction;

■ Insulating concrete fill placement;

■ Spray-applied fire-resistive material placement;

■ Piling, drilled piers and caissons driving and testing;

■ Shotcrete placement and strength testing; and

■ Special grading, excavation, and filling.

In addition to the CBC required special inspections; the project owner shall perform and document the following additional designated special inspection tasks:

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■ Welding of ASME piping systems;

■ Hydrostatic testing of ASME piping systems;

■ Buried pipeline coating defect testing;

■ Electrical breaker trip testing;

■ Motor winding short circuit testing (high pot testing);

■ Conductor insulation resistance/short circuit testing; and

■ Fire protection system performance witness/performance testing.

Similar to CBC §1704.2.5.1, special inspections of the prefabricated elements within the above systems are not required where the work is done on the premises of a registered and approved fabricator. Such “approval” must be based upon review of the fabricator’s written procedural and quality control manuals and periodic auditing of fabrication practices by an approved special inspection agency. Upon fabrication completion, the approved fabricator must submit a certificate of compliance to the DCBO stating that the work was performed in accordance with the approved construction document.

The special inspectors shall:

■ Be a qualified person who shall demonstrate competence, to the satisfaction of the DCBO, if not directly employed by the DCBO, for inspection of the particular type of construction requiring special or continuous inspection;

■ Observe the work assigned for conformance with the DCBO-approved and stamped design drawings and specifications;

■ Furnish inspection reports to the DCBO and the engineer of record. All discrepancies shall be brought to the immediate attention of the contractor for correction, then, if uncorrected, to the DCBO and the engineer of record for corrective action [2022 CBC, Chapter 17, Section 1704.2.4, Report Requirements];

■ Submit a final signed report to the engineer of record and DCBO, stating whether the work requiring special inspection was, to the best of the inspector’s knowledge, in conformance with the approved plans and specifications and the applicable provisions of the CBSC; and

■ A certified welding inspector, certified by the American Welding Society (AWS), and/or American Society of Mechanical Engineers (ASME) as applicable, shall inspect welding performed on-site requiring special inspection (including structural, piping, tanks and pressure vessels).

2.3 Industrial Code Compliance

The design and construction of a typical Project includes many different types of piping systems. These include potable water, reclaimed water, sanitary sewers, storm water, steam, natural gas, ammonia, water, geothermal fluids, and other chemicals. It is important for the DCBO to understand and differentiate between process piping and

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Energy Center building/civil piping systems within the submitted plans and apply the appropriate codes to these systems. Generally, the California Building Codes (including the California Plumbing Code – CPC, and the California Mechanical Code – CMC) involve the DCBO more in the code compliance and quality assurance / quality control (QA/QC) process than the ASME Codes. The language of the ASME codes places no code compliance responsibility in the hands of the DCBO. These industry codes place the code compliance responsibility with the owner. However, the Energy Commission charges the DCBO with more involvement in the industry code plan review and inspection process than most process plant project owners typically encounter. The DCBO should establish a process that fulfills the Energy Commission’s COCs without adding excessively to the project’s mechanical design and inspection efforts. This process should be more of a design and construction QA/QC audit.

A DCBO shall communicate any concerns regarding a project owner’s design and QA/QC process and documentation to the CPM for issue resolution (see also Section 4.2 C).

2.4 Document Control and Tracking

The DCBO must develop an internet-based document submittal system that acts as a portal for the project owner to submit construction documents for DCBO review. All Project document submittals will utilize a system in which the DCBO assigns a unique tracking number to all submittals. This submittal system will be username and password protected to restrict access to the project web site where the document tracking system resides.

2.5 Limits of Engineering Document Review

The DCBO should be mindful that its job is to review plans for code compliance. The DCBO is responsible for making a diligent effort to ensure the project owner’s design is code compliant. As defined in CBC Section 202 – DEFINITIONS, enforcement is the “diligent effort to secure compliance (with the CBSC), including review of plans and permit applications….” Webster’s dictionary defines diligent as a constant careful effort. These definitions do not include these words: guarantee, warranty, error-free, over-zealous, or exhaustive. The DCBO must be mindful to be diligent, but not over-zealous in his or her efforts.

The DCBO’s job is not to engineer/design the Project; it is not the responsibility of the DCBO to offer opinions based on the economics of a design, or personal design preferences. It is not the responsibility of the DCBO to become a special design subject matter expert.

“The design of a Project often involves the incorporation of special machines and devices. It is not the Energy Commission’s intent for the DCBO to judge the performance standards of any machines. The DCBO’s focus is on the foundations and anchorages of these machines. It is not the responsibility of the DCBO to determine the loads the machines place on foundations and anchorages but rather to review the specifications used, and calculations performed, by the project owner’s engineer for load distribution on such foundations and anchorages”

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When code compliance issues arise, the DCBO may assist the project owner when asked by the project owner to do so. For example, the DCBO may suggest a method to solve a particular code-compliance issue that would comply with the applicable code. The project owner has the flexibility to find other solutions; beyond those suggested by the DCBO provided, if those solutions are code compliant.

3.0 Laws Ordinances Regulations and Standards

A Project, properly designed and constructed, will meet or exceed, the appropriate LORS. These include, but are not limited to, the following:

■ American National Standards Institute (ANSI);

■ American Petroleum Institute (API);

■ American Society for Testing and Materials (ASTM);

■ American Society of Civil Engineers (ASCE);

■ American Society of Mechanical Engineers (ASME);

■ California Building Standards Code (CBSC);

■ California Occupational Health, and Safety Administration (Cal/OSHA);

■ Environmental Protection Agency (EPA);

■ International Electrotechnical Commission (IEC);

■ Institute of Electrical and Electronics Engineers (IEEE);

■ National Fire Protection Association (NFPA);

■ Occupational Safety Health Administration (OSHA); and

■ Underwriters Laboratories (UL).

In many respects, a typical Project is more process plant than building structure. The DCBO needs to understand this balance and not overly rely simply on the CBSC as the single guidance document for all aspects of compliance.

3.1 California Building Standards Code (CBSC)

The design and construction of all civil, structural, mechanical (except process piping), electrical, and fire prevention facilities shall comply with the CBSC. The Energy Commission utilizes the 2022 California Code of Regulations, Title 24, Parts 1 through 12, (herein referred to as the CBSC), as their model building code. This Title includes the following code parts and their commonly referenced names:

■ Part 1 - California Administrative Code;

■ Part 2 - California Building Code (Volumes 1 and 2);

■ Part 2.5 - California Residential Code;

■ Part 3 - California Electrical Code;

■ Part 4 - California Mechanical Code;

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■ Part 5 - California Plumbing Code;

■ Part 6 - California Energy Code;

■ Part 7 - no longer in use;

■ Part 8 - California Historical Building Code;

■ Part 9 - California Fire Code;

■ Part 10 - California Existing Building Code (formally - California Code for

Building Conservation);

■ Part 11 - California Green Building Standards Code (CALGreen); and

■ Part 12 - California Reference Standards Code.

Included by reference in these CBSC parts are other applicable engineering LORS.

Project-specific LORS required for Energy Commission compliance will be defined within a project’s COCs.

3.2 Primary Industry Codes – Process Piping Systems

The design and construction of a typical Project includes many different types of piping systems. These include potable water, reclaimed water, natural gas, steam, hydrogen, sanitary sewers, storm water, etc. Figure 3.2.1 (see page 12) Piping Systems Code Boundaries illustrates the general jurisdictional limits of the various piping codes for typical Project. Exceptions should be handled individually. When a DCBO is unsure of how to classify a piping system, they should contact the Energy Commission’s assigned CPM for the project.

The appropriate industry codes utilized for piping systems within a Project design may include:

■ American Society of Mechanical Engineers (ASME) B31.1 – Power Piping,

■ ASME B31.3 – Process Piping, and/or

■ ASME B31.8 – Gas Transmission and Distribution Piping Systems.

■ ASME B31.12 – Hydrogen Piping and Pipelines.

Design, review, construction, and inspection of a particular piping system will conform to only one piping code. The potable water, sanitary sewers, storm drains, etc. are jurisdictional to the requirements of the California Plumbing Code (CPC) and California Mechanical Code (CMC). The modern Project includes many different types of process piping systems. These include steam, natural gas, ammonia, water, wastewater injection, hydrogen, and other chemicals, which are jurisdictional to the requirements of ASME B31.1 and B31.3 as, depicted on Figure 3.2.1 – Piping System Code Boundaries.

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A. ASME B 31.1 – Power Piping

ASME B31.1 Power Piping - This code prescribes minimum requirements for the design, materials, fabrication, erection, testing, and inspection of power and auxiliary service piping systems for electric generation stations, industrial institutional plants, and central and district heating plants. The code covers external piping for power boilers operated at high temperature and water boilers operated at high pressure. These vessels typically produce steam (or vapor) at a pressure of more than 15 pounds per square inch gauge (psig}. Operating conditions for the high temperature water piping are pressures exceeding 160 psig and/or temperatures exceeding 250 degrees F.

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This code addresses high-energy steam piping systems where steam alone is the primary energy source to drive rotating machines. These rotating machines are the drivers for electrical generators.

B. ASME B 31.3 – Process Piping

ASME B31.3 Process Piping - The Process Piping Code Section B31.3 has been developed considering piping typically found in petroleum refineries; chemical, pharmaceutical, textile, paper, semiconductor, and cryogenic plants; and related processing plants and terminals. This code prescribes the requirements for materials and components, design, fabrication, assembly, erection, examination, inspection, and testing of piping. This code applies to plant piping for all fluids (not covered by the CBSC or pipeline-related fluids), including: (1) raw, intermediate, and finished chemicals; (2) petroleum products; (3) gas, steam, air, and water; (4) fluidized solids; (5) refrigerants; (6) cryogenic fluids. Also included within the scope of this code is piping which interconnects pieces or stages within a packaged equipment assembly.

This code addresses the more complex plant environment where natural gas, steam, and chemical piping systems are present.

C. ASME B 31.8 – Gas Transmission and Distribution Piping Systems

ASME B31.8 Gas Transmission and Distribution Piping Systems - This code covers the design, fabrication, installation, inspection, and testing of pipeline facilities used for the transportation and distribution of gas, including natural gas. This code also covers safety aspects of the operation and maintenance of those facilities. Specifications for gas piping systems can vary depending on jurisdictional control. The DCBO should be aware of which specifications are applicable, as local, state (California Public Utilities Commission (CPUC)) and federal (Federal Energy Regulatory Commission (FERC)) specifications can differ.

D. ASME B 31.2 – Fuel Gas Piping

ASME B31.2 Fuel Gas Piping – This Code was withdrawn as an American National Standard on February 19, 1988; however it is still available from ASME as a historical document for reference. This obsolete code is not to be used for the design and construction of current or future Project fuel gas process piping.

E. ASME B31.12 – Hydrogen Piping and Pipelines

ASME B31.123 is applicable to piping and pipelines handling gaseous hydrogen and gaseous hydrogen mixtures and to piping in liquid hydrogen service. This Code is applicable up to and including the joint connecting the piping to associated pressure vessels and equipment but not to the vessels and equipment themselves. It is applicable to the location and type of support elements but not to the structure to which the support elements are attached. The design for pressure and temperature shall be in

3 https://www.asme.org/codes-standards/find-codes-standards/b31-12-hydrogen-piping-pipelines/2023/drm-enabled-pdf

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Energy Center accordance with the requirements of Part IP for industrial piping and Part PL for pipelines.

This Code is presented in the following parts and appendices:

(a) Part GR — General Requirements. Part GR contains requirements applicable to and referenced by other parts. It contains definitions and requirements for materials, welding, brazing, heat treating, forming, testing, inspection, examination, operation, and maintenance. It also contains quality system topics common to the other parts.

(b) Part IP — Industrial Piping. Part IP includes requirements for components, design, fabrication, assembly, erection, inspection, examination, and testing of piping.

(c) Part PL — Pipelines. Part PL sets forth requirements for components, design, installation, and testing of hydrogen pipelines.

(d) Mandatory Appendices I through IX

(e) Nonmandatory Appendices A through F

F. How DCBO Responsibilities Vary Between CBSC and Primary Industry Code Reviews

The Energy Commission charges the DCBO with the authority to ensure that the design and construction of ASME piping systems complies with the proper piping code (as required by the Final Commission Decision and COCs). However, the Energy Commission does not want to add DCBO exhaustive plan check and design review requirements to the existing ASME piping codes. This means that the DCBO should focus on the project owner’s overall design and quality assurance processes.

The DCBO design and quality assurance process should include reviews of the following items:

■ The DCBO shall review the methods employed by the project owner for high energy piping stress analysis. For ASME piping systems, samples of stress analyses should be reviewed to ensure that the proper methodology and that the stresses comply with codes allowable. This review should investigate the process to be used to evaluate field changes. This should include stress evaluation and documentation work processes.

■ The DCBO shall verify that piping design specifications adequately address the operating conditions and ranges of the anticipated process variables (e.g., pressure, temperature, pipe contents, vibration, coatings, material compatibility, etc.). This review should include checks to verify consistency between the specifications, the pipe models, and the design drawings (piping plan and details, isometrics, and piping and instrumentation diagrams).

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■ The DCBO shall review typical piping drawings (isometric and plan/elevation drawings), supports, etc.

■ The DCBO shall review welding procedures, welding procedure qualifications, and welder certifications.

■ The DCBO shall review the project owner’s process piping QA/QC process (e.g., material procurement, material certifications, material verification during fabrication, weld inspections, etc.) to ensure that the installed process piping systems comply with all design code requirements.

This review will inherently involve a demonstration of competence by the project owner.

With demonstrated competence, less frequent and extensive reviews may be required.

Identified problems may justify more frequent reviews and oversight.

The DCBO is to perform periodic material QA/QC process checks. No formal submission to the DCBO is required. Records (e.g. mill records and certificates) must be available for DCBO review to ensure that the QA/QC process is resulting in the desired result.

The construction QA/QC process should also be reviewed and periodically checked. Again, there are no formal submissions to the DCBO for welder certifications, welding procedures, and x-ray inspections. However, records must be available for the DCBO’s review to ensure code compliance.

The DCBO inspectors should periodically perform field observations of process piping construction to ensure a code compliant system is being constructed. This will provide the Energy Commission with a level of assurance that the systems are code compliant.

This by no means removes the involvement of the DCBO from the process piping design and construction process. It simply modifies the DCBO role for process piping systems to more of an oversight of the project owner’s design and construction process (assuming the project owner’s QA/QC systems are resulting in code-compliant construction). The DCBO should note and report any process breakdowns or shortcomings to the project owner and the CPM. The DCBO shall follow-up to review process corrections.

Generally, for process piping subject to the ASME codes, this design and construction process review will:

■ Eliminate the need for the DCBO to review and approve every process piping drawing and supporting calculations developed for the project,

■ Eliminate the need for the project owner to submit for approval copies of all process piping inspection documents (e.g., welding procedures, welding procedure qualification records, welder qualification records, etc.) to the DCBO, and

■ Eliminate the need for the project owner to submit for approval copies of all changes to the process piping system.

It is important for the project owner to note that this design process does not eliminate

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3.3 49 CFR Part 192 – Federal Natural Gas Pipeline Regulations Many power generation stations which are designed, constructed, and operated under the jurisdiction of the Energy Commission include natural gas pipelines and compressor station components. The design, construction, operation, inspection and maintenance of natural gas pipelines involves compliance with Federal Pipeline Safety Regulations 49 CFR Part 192 - Transportation of Natural and Other Gas by Pipeline: Minimum Federal Safety Standards. 49 CFR Part 192 incorporates by reference the design, construction, and testing standards of ASME B31.8 – Gas Transmission and Distribution Piping Systems, described above. These regulations and design standards have evolved over the years to improve public safety through improvements in design, integrity assessment, and integrity management. Operations and maintenance plans, and integrity management plans should be in place prior to the start of operations of any natural gas pipeline.

3.4 National Fire Protection Association (NFPA) Standards

The CBSC includes by reference a number of NFPA standards and recommended practices. These include a large number of specialized standards and practices, some of which have no bearing on the design and construction of a Project. Not referenced within the CBSC is the primary fire protection standard for a Project. This standard is NFPA 850 – Recommended Practice for Fire Protection for Electric Generating Plants and High Voltage Direct Current Converter Stations. Within this standard, many of the CBSC referenced NFPA standards are incorporated by reference. The appropriate application of those standards within the Project environment is presented. NFPA should be the primary fire protection standard used within the Project because of unique fire protection requirements of a Project as compared to a typical building structure.

3.5 Other Design-Related Conditions of Certification

COCs vary from project to project. The DCBO must understand this fact and become familiar with the applicable COCs for a particular project. Although not an inclusive list, these COCs typically involve:

■ Air Quality: stack height;

■ Biological Resources: avian protection measures;

■ Hazardous Materials: double-walled piping and tanks;

■ Land Use: setbacks, retaining walls, signage;

■ Noise: gas compressor enclosure, ACC/rooftop parapet, and other permanent sound walls/screens;

■ Soil and Water Resources: SWPPP, recycled water facilities;

■ Traffic and Transportation: route and specific design requirements;

■ Visual Resources: lighting requirements; and

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■ Worker Safety and Fire Protection: local fire codes.

The Energy Commission CPM will define the DCBO’s involvement, and their compliance oversight responsibilities for compliance with these COCs for each project. The CPM will coordinate with staff by providing staff with project construction information so that staff can make the necessary decision regarding DCBO’s involvement.

4.0 Typical Project Responsibilities and Milestones

The following sections describe the typical project milestones for a Project.

4.1 Contracting and the Energy Commission

The involvement of an Energy Commission DCBO begins with the STEP Division’s selection process and the subsequent third-party beneficiary clause included in the contracting documents drafted by the selected DCBO and the project owner.

The Energy Commission’s third-party beneficiary status does not burden the state with any financial responsibility to the DCBO. The project owner financially compensates a DCBO. The project owner and the DCBO enter into a contractual agreement that defines the scope and compensation of the DCBO. Work performed by the DCBO without a contract is at their risk. It is in the interest of the project owner to finalize a contract with the DCBO as expeditiously as possible to avoid delays.

4.2 Project Kickoff Meeting

All Project projects should include a project kickoff meeting conducted by the Energy Commission early in the project design process. The Energy Commission’s CPM schedules and conducts this meeting. The CPM is responsible for developing the agenda. Typically, this project kickoff meeting is held at the Energy Commission headquarters in Sacramento, California. Key members of the Energy Commission, the DCBO, the project owner, and other Federal / State agency stakeholders are invited and encouraged to attend. Key individuals are introduced to provide a face-to-face personal connection intended to foster communication and teamwork. Discussed at this kickoff meeting are high-level issues and the identification4 of plans forward. This kickoff meeting can be used to identify potential issue resolution teams.

A. Project Overview

An overview of the project is presented by the CPM and the project owner.

Communicated information includes the Project location, size, design basis, special technology, and other general project data. Presented during this discussion are project stakeholder expectations. All attendees have a chance to provide input from their project responsibility perspective. This interaction eliminates surprises during the project. Special

4 It is not the intent of the kickoff meeting to resolve all issues, but to identify those issues that require special attention and resolution.

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COC compliance issues and timeframes for completion are normally discussed.

B. Roles and Responsibilities

Attendees are briefed regarding the roles and responsibilities of the various groups anticipated to interact during the course of the development of the project. Where perceived overlaps exist, the kickoff meeting provides an opportunity to clarify the scope of responsibilities of each stakeholder. The intent is to clarify vague or undefined stakeholder involvement in an effort to develop a mutual understanding and increase project execution efficiency. It is an opportunity early in the project to communicate expectations and objectives and to resolve any misconceptions by the stakeholders regarding their roles and responsibilities.

C. Timing and Schedule / Critical Path and Conflict Resolution

During the kickoff meeting, both the Energy Commission and the project owner communicate their current work in progress and projected completion timelines.

Typically, the kickoff meeting precedes the Energy Commission’s notice-to-proceed with site construction efforts, and the COCs typically require a number of pre-construction site mobilization requirements. The pre-construction requirements are discussed at the kickoff meeting so that a critical path can be identified that enables the project owner to plan and schedule construction mobilization.

During this meeting, the project can discuss other critical path issues (once construction site work has commenced) and the impact they may have on the Energy Commission, the DCBO and other agencies. The Energy Commission, DCBO and other agencies can provide feedback to the project owner regarding anticipated timing and possible impediments to timely completion. In the case of the DCBO, any project desired compression of schedule might result in increased labor costs not included in their original contract documents with the project owner. The impact of planned construction schedule compression is best resolved before significant DCBO work begins. The emphasis of the kickoff meeting is information sharing to facilitate project implementation. While the parties are encouraged to resolve potential conflicts independently, if problems persist, or code interpretation is at issue, notify the CPM promptly. The CPM can provide guidance and facilitate the issues informally, or if resolution between the parties remains elusive, the CPM can convene a more formal meeting to seek resolution.

D. Document Submittal Process Review

The DCBO provides an overview of the document submittal process that includes a high-level demonstration of the web-based submittal process. This document submittal process shall be consistent with the Energy Commission’s expectation of such a system as defined herein. This review will provide an opportunity to resolve any issues regarding the submittal process before significant numbers of electronic submittals begin.

E. Inspection Performed and Inspection Request Process Review

Similar to the document submittal process review outlined above, the DCBO is

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4.3 Creation of DCBO Project Website

Upon execution of a contract with the project owner, the DCBO must create an Energy Commission project website. This website is where the Energy Commission accesses documents and reviews project progress. The DCBO selection letter will define the requirements for this password-protected internet website.

4.4 Initial Document Submittal Review – COC Compliance

Assistance

The DCBO should be mindful that the Energy Commission might request the DCBO to review some preliminary documents submitted to the Energy Commission as required by the COCs. The DCBO should communicate this to the project owner during their contract negotiations. The amount of time required for this type of work varies from project to project.

4.5 Document Submittal Reviews and Approvals

The bulk of the work performed by the DCBO involves the review of construction drawings, calculations, and other documents supporting the engineering. This work often begins after the execution of a contract. This document review and approval process requires the DCBO to develop an internet-based document management system. This document management system tracks the large number of documents from original submittal to the as-constructed stage of the project. A detailed description of the Energy Commission’s expectations for a document management system is included in this guidance document. The DCBO should anticipate concurrent document submittals with ongoing construction.

4.6 Construction Inspection and COC Compliance Oversight

The DCBO shall conduct field inspection and Energy Commission COC compliance oversight. In this role, the DCBO is responsible for the inspection of constructed facilities to ensure compliance with the approved construction drawings. The DCBO inspectors ensure that the DCBO plan review team approves all construction documents prior to use in the field. Construction should not proceed without stamped “approved for construction” drawings. The DCBO inspection team is responsible for the oversight of the special inspections performed by the project owner. This includes the oversight of the recordkeeping of the special inspectors.

There are tasks not typically performed by building departments inspectors that are a part of the Energy Commission DBCO responsibilities. These involve compliance items identified within the COCs, which are listed in this document.

4.7 As-Constructed Document Package

The final task performed by the DCBO is the oversight/development of the as-

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The as-constructed drawings originate from redlined construction drawings.