Operator_Qualification_Program_Plan.pdf

DDEESSCC OOQQ PPRROOGGRRAAMM PPLLAANN

August 2009

DDEEFFEENNSSEE EENNEERRSSUUPPPPOORRTT CCEENNTTEERR

OOPPEERRAATTOORR QQUUAALLIIFFIICCAATTIIOONN PPRROOGGRRAAMM

PPLLAANN

Prepared For:

U.S. Army Corps of Engineers Huntsville Engineering & Support Center

Post Office Box 1600 Huntsville, Alabama 35807-4301 and

Defense Energy Support Center

8725 John J. Kingman Road Suite 2833

Fort Belvoir, Virginia 22060-6222

Contract No. W912DY-08-D-0001 Delivery Order 0005

NationView Project No. 8080020

Prepared By:

1608 13TH AVENUE SOUTH, SUITE 160

BIRMINGHAM, ALABAMA 35205

205.930.9494 ~205.930.9485 Fax

OOQQ PPRROOGGRRAAMM PPLLAANN DDEESSCC

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September 2008 i

DDEEFFEENNSSEE EENNEERRGGYY SSUUPPPPOORRTT CCEENNTTEERR

OOPPEERRAATTOORR QQUUAALLIIFFIICCAATTIIOONN PPRROOGGRRAAMM PPLLAANN

TABLE OF CONTENTS

1 Introduction ..................................................................................... 1-1

2 Premises and Definitions ................................................................ 2-1

2.1 Premises ...........................................................................................................2-1

2.2 Definitions .........................................................................................................2-1

2.2.1 Regulatory Definitions ...........................................................................2-1

2.2.2 API Definitions .......................................................................................2-3

3 Task Identification and Analysis ...................................................... 3-1

4 Evaluation Methods and On-Going Evaluation................................ 4-1

4.1 Evaluation Methods ..........................................................................................4-1

4.1.1 Knowledge Test .....................................................................................4-1

4.1.2 Oral Exam .............................................................................................4-1

4.1.3 Work Performance History Review ........................................................4-2

4.1.4 Observation During Performance on the Job .........................................4-2

4.1.5 Observation During OJT ........................................................................4-2

4.1.6 Simulations ............................................................................................4-2

4.1.7 Certification by Vendors or Industry Organizations ................................4-2

4.2 Types of Qualifications ......................................................................................4-3

4.2.1 Transitional Qualification .......................................................................4-3

4.2.2 Initial Qualification .................................................................................4-3

4.2.3 Subsequent Qualification .......................................................................4-3

4.2.4 Re-Evaluation ........................................................................................4-3

4.3 DESC Employee Qualification...........................................................................4-5

4.3.1 Transitional Qualification .......................................................................4-5

4.3.2 Initial Qualification .................................................................................4-5

4.3.3 Subsequent Evaluation ..........................................................................4-6

4.3.4 Re-Evaluation ........................................................................................4-6

4.4 Operating Contractor Qualifications ..................................................................4-7

4.4.1 Transitional Qualification .......................................................................4-7

4.4.2 Initial Qualification .................................................................................4-7

4.4.3 Subsequent Qualification .......................................................................4-8

4.4.4 Re-Evaluation ........................................................................................4-8

4.5 Other Contractors .............................................................................................4-9

4.5.1 Transitional Qualification .......................................................................4-9

4.5.2 Initial Qualification .................................................................................4-9

4.5.3 Subsequent Qualification ..................................................................... 4-10

4.5.4 Re-Evaluation ...................................................................................... 4-10

4.6 Management of Changes ................................................................................ 4-11

5 Non-Qualified Individuals ................................................................ 5-1 ii August 2009

6 Contractor Personnel ...................................................................... 6-1

7 Record Keeping .............................................................................. 7-1

7.1 Records for Retention .......................................................................................7-2

7.2 Retention Period ...............................................................................................7-3

8 References ..................................................................................... 8-1

Tables Table 3-1. Covered Task List ................................................................................................. 3-2 Table 7-1. Record Retention Requirements ........................................................................... 7-1

Appendices A 49 CFR Part 195 Subpart G B List of DESC Operated Pipelines List of DESC and DFSP Pipelines regulated Under 49

CFR Part 195 C Expanded Covered Task List D Checklists and Forms

August 2009 1-1

1 INTRODUCTION

1.1 Background

The Defense Energy Support Center (DESC) Operator Qualification (OQ) Program has been established to ensure the DESC has a qualified workforce and to reduce the probability and consequence of accidents or incidents caused by human error. This OQ Program has been developed in accordance with 49 Code of Regulations (CFR) 195, Subpart G, Sections 195.501 through 195.509 (included as Appendix A).

The OQ Program addresses the following seven elements required by 49 CFR §195.505:

1. Identification of covered tasks that personnel perform on the DESC-operated pipelines.

2. Ensuring, through evaluation, that individuals are qualified to perform covered tasks.

3. Allowing non-qualified individuals to perform covered tasks under the direct observation of a qualified person.

4. Evaluation of individuals if there is a reason to believe that the individual’s performance of a covered task contributed to an accident or incident as defined by 49 CFR Part 195.

5. Evaluation of individuals if there is a reason to believe that the individual is no longer qualified to perform the covered task.

6. Ensuring that changes affecting covered tasks are appropriately communicated.

7. Identification of intervals at which re-evaluation of the individual’s qualification is needed.

This OQ Program was also developed following the guidance provided by the Guidance Document for the Qualification of Liquid Pipeline Personnel, American Petroleum Institute (API) Publication 1161, First Edition, August 2000. In accordance with the API Guidance, this Program document includes the following chapters:

1. Introduction

2. Premises and Definitions

3. List of Covered Tasks

4. Evaluation Methods and Ongoing Evaluation

5. Non-Qualified Individuals

6. Contractor Personnel

7. Record Keeping

1.2 Program Administration

This Program shall be administered by the OQ Administrator. For the purposes of this program, the OQ Administrator is an employee of DESC HQ. The OQ Administrator shall designate an on-site government employee (such as a Quality Assurance Representative (QAR) or a Facility Engineer) to implement the OQ Program at their associated DFSP.

1-2 August 2009

The DESC will provide funding and oversight of the implementation of the OQ Program. The DESC Contracting Officer Representatives (CORs) are responsible for implementing specific components of the Program. The CORs and the on-site designee will work closely with the OQ Administrator to ensure that the OQ Program is implemented and effective.

The OQ Administrator should review the program at least once every calendar year (not to exceed 15 months) to evaluate the Program’s performance and implement improvements to enhance the effectiveness of the Program.

August 2009 2-1

2 PREMISES AND DEFINITIONS

2.1 Premises

The pipeline assets covered by this OQ Program includes all regulated pipelines operated by Defense Fuel Support Points (DFSP) and under the control of the DESC. These include, but are not limited to, the pipelines identified in Appendix B. All pipelines regulated by 49 CFR 195 and operated by the DESC or a DFSP are covered by this Program. If it is unclear as to whether a government pipeline should be included in this program, consult with the OQ Administrator.

2.2 Definitions

In order to appropriately develop and implement the OQ Program, it is important to understand the terms used in 49 CFR 195 and in the API guidance. Key definitions are presented below.

2.2.1 Regulatory Definitions

The definitions below are from 49 CFR §195.2 and 49 CFR §195.503:

2.2.1.1 Abandoned

Abandoned1 means permanently removed from service.

2.2.1.2 Breakout Tank

Breakout tank2 means a tank used to (a) relieve surges in a hazardous liquid pipeline system or

(b) receive and store hazardous liquid transported by a pipeline for reinjection and continued transportation by pipeline.

2.2.1.3 Abnormal Operating Condition

Abnormal operating condition3(AOC) means a condition identified by the operator that may indicate a malfunction of a component or deviation from normal operations that may:

(a) Indicate a condition exceeding design limits; or

(b) Result in a hazard(s) to persons, property, or the environment.

2.2.1.4 Evaluation

Evaluation4 means a process, established and documented by the operator, to determine an individual's ability to perform a covered task by any of the following:

1 49 CFR §195.2

2 49 CFR §195.2

3 49 CFR §195.503

2-2 August 2009

(a) Written examination;

(b) Oral examination;

(c) Work performance history review;

(d) Observation during:

(1) performance on the job,

(2) on the job training, or

(3) simulations;

(e) Other forms of assessment.

(See also the API definition of evaluation, below.)

2.2.1.5 Hazardous Liquid

Hazardous liquid5 means petroleum, petroleum products, or anhydrous ammonia.

2.2.1.6 Operator

Operator6 means a person who owns or operates pipeline facilities.

2.2.1.7 Operating Contractor

In this OQ Program, an Operating Contractor is a private firm or military organization under contract or agreement to operate a DFSP. This includes Navy, Army, and Air Force personnel who operate a government-owned government-operated DFSP.

2.2.1.8 Person

Person7 means any individual, firm, joint venture, partnership, corporation, association, State, municipality, cooperative association, or joint stock association, and includes any trustee, receiver, assignee, or personal representative thereof.

2.2.1.9 Qualified

Qualified8 means that an individual has been evaluated and can:

(a) Perform assigned covered tasks and

(b) Recognize and react to abnormal operating conditions.

4 40 CFR §195.503

5 49 CFR §195.2

6 49 CFR §195.2

7 49 CFR §195.2

8 49 CFR §195.503

August 2009 2-3

(See also the API definition of qualified, below.)

2.2.1.10 Work Performance History Review

(Note: The definition of work performance history review is not defined in 49 CFR 195, but is published by the Pipeline and Hazardous Materials Safety Administration (PHMSA) in their glossary at http://primis.phmsa.dot.gov/oq/glossary.htm.)

Work performance history review is a process established by the Operator to ascertain the previously demonstrated competency of an individual to perform a covered task. Evaluation parameters should include:

• A search of existing records for documentation of an individual’s satisfactory performance of the covered task in the past.

• Verification that the individual’s work performance history contains no indications of substandard work or involvement in an incident or accident or incident to which the individual may have contributed by committing an error in the performance of a covered task.

• Verification and documentation that the individual has satisfactorily performed the covered task on a regular basis prior to October 26, 1999. (Note: Verification and documentation that the individual has satisfactorily performed the covered task on a regular basis can no longer be used as a sole evaluation method.)

2.2.2 API Definitions

The definitions below are from API 1161, API Guidance Document for the Qualification of Liquid Pipeline Personnel, Appendix B.

2.2.2.1 Abnormal Operating Condition

Abnormal operating condition (AOC) means a condition identified by the DESC or DFSP that may indicate a malfunction of a component or a deviation from normal operations that may indicate an operating condition that could exceed design limits or result in hazards(s) to persons, property, or the environment. A deviation from normal operation does not necessarily mean an abnormal operating condition exists. The following examples of conditions may be indications of an AOC or may create an AOC related to a specific task:

• Unexpected hazardous liquid encounter (unauthorized release, vapors, hazardous atmosphere, and contamination)

• Unexplained pressure deviations (increase, decrease, high, low, absence)

• Activation of a safety device (pressure relief, emergency shut downs, high pressure shut downs, high temperature shutdowns, seismic shut off)

• Unexplained flow rate deviations (high flow, low flow, no flow)

• Unexplained status change (unit start-up, unit shut-down, valve open, valve close, gravity change, tank level, temperature, flash, haze, co-mingling of product, etc.)

• Fire or explosion

2-4 August 2009

• Interruption or failure of communications, control system or power.

• Pipeline system damage (line hit, lightning strikes, tornado, flood, earthquake, damaged pipeline support, etc.)

• Abnormal facility condition (exposed pipe, low cathodic protection levels, missing line markers, frayed or broken test lead wires, line crossing, excessive atmospheric corrosion, exposed river crossing, etc.)

• Component failure or malfunctioning component (field and SCADA components including meter failure)

2.2.2.2 Activity

Activity means physical, visual, or mental effort directed at achieving a result.

2.2.2.3 Covered Task

A covered task:

• Is a discrete activity performed by an individual or group of individuals

• Has a beginning and an ending point

• Has two or more steps

• Can be observed and measured

• Is identified by the DESC, and

• Meets all four of the conditions discussed below.

Condition 1: Task is performed on a pipeline facility. A covered task is performed on a pipeline facility, meaning that an activity is performed by an individual or group of individuals whose performance directly impacts the pipeline facility.

Condition 2: Task is an operations and maintenance (O&M) task. O&M tasks are activities done by an individual or group of individuals (1) to perform a function on a pipeline facility, or (2) to provide upkeep of a pipeline facility. A “new construction task” changes to an O&M task when the pipeline facility is being commissioned or during the act of connecting to an active pipeline facility. The following are not O&M tasks:

• Activities on pipelines that have never been in service and not physically attached to an operating pipeline

• Fabrication of new installations

• Emergency response activities

Condition 3: Task is required by 49 CFR Part 195. Activity required by 49 CFR Part 195 means only those tasks specifically required to be addressed in 49 CFR Part 195. State and local requirements are not applicable to this rule.

Condition 4: Task affects the operation or integrity of the pipeline system. A task affects the operation or integrity of the pipeline system if the activity could directly or indirectly cause the

August 2009 2-5 release of hazardous liquid to the environment or result in a hazard to persons or property. An effect can be either immediate (direct) or delayed (indirect). The integrity of the pipeline refers to the pipeline’s ability to operate safely and to withstand stresses imposed during operations.

2.2.2.4 Evaluation

Evaluation means a process, established and documented by the DESC, to determine an individual’s ability to perform a covered task.

2.2.2.5 Individual

Individual means a person who, on behalf of the DESC or DFSP, performs one or more covered tasks on a pipeline facility operated by the DESC or DFSP.

2.2.2.6 Operate

Operate means starting, stopping, or monitoring.

2.2.2.7 Pipeline Facility

A pipeline facility is new and existing pipe, rights-of-way, and any equipment, facility, or building used in the transportation of a hazardous liquid.

2.2.2.8 Pipeline System

Pipeline system means all parts of a pipeline facility through which a hazardous liquid moves in transportation (line pipe, valves, appurtenances, pumps, meters, tanks, etc.)

2.2.2.9 Qualified

Qualified means:

• That an individual has passed an evaluation,

• The individual can perform assigned covered tasks,

• The individual can recognize and react to abnormal operating conditions, and

• Compliance documentation is completed.

2.2.2.10 Removed from the System

Removed from the system means that a part of the pipeline system is physically removed from the pipeline system.

2-6 August 2009

August 2009 3-1

3 TASK IDENTIFICATION, ANALYSIS, AND

ASSIGNMENT

3.1 Task Identification and Analysis

DESC has identified activities which are covered tasks for DESC’s pipeline facilities.9 A generic covered task list was obtained from API and was modified specifically for DESC and DFSP activities for this OQ Program. DESC’s and DFSP’s manuals and plans (Operation, Maintenance, Environmental, and Safety (OMES) Plan; Spill Prevention, Control, and Countermeasures (SPCC) Plan; Facility Response Plan (FRP), etc.) were reviewed to ensure all covered tasks performed by DESC, DFSP employees and contractors were included in the covered task list. The covered tasks are shown in Table 3-1. The expanded list of tasks, including task descriptions, the results of the four-part test, and AOC analyses, is included as Appendix C of this Plan.

The covered task list was developed with three principles in mind.

• First, the list should include all covered tasks that may be performed by DESC/DFSP employees, operating contractors, and other contractors.

• Second, the list should identify not only normal and routine tasks that are performed on existing DESC pipeline systems, but also tasks that may be performed on an existing DESC/DFSP pipeline system.

• Third, the tasks should be general enough so that personnel are qualified to perform all steps and subtasks involved.

In this DESC OQ Plan, the fourth condition of the four-part test (Does the task affect the operation or integrity of the pipeline?) was broken into two questions:

1. If the task is performed on a pipeline, does it affect the operation or integrity of the pipeline?

2. If the task is performed on a breakout tank, does it affect the operation or integrity of the pipeline?

Bulk storage tanks at the DFSPs can be considered to be breakout tanks. In all cases, the bulk storage tanks are located within secure and fenced government property and are managed in compliance with appropriate API standards. All bulk storage tanks are isolated from the regulated pipeline by a pumphouse, which provides the flexibility to select the tank to be used for a specific operation. That is, if a task is performed on a bulk storage tank, it is removed from service or the valves between the tank and the pumphouse are closed so that the tank will not affect the operation of the pipeline and the remaining operations.

9 49 CFR §195.505(a)

3-2 August 2009

Table 3-1. Covered Task List

Task ID Covered Task Name

Person Performing Task

DESC/

DFSP

Gov't

Employee

Operating Contractor

Other Contractor, Subcontractor, or Entity

1 Inspection activities for tie-ins, pipe replacements, or other components connecting to an existing pipeline - √ √

3 Welding on existing pipeline √

4 Inspect welds and welding √

5 Remove or repair welds √

6 Test welds √

20 Conduct pressure tests √

21 Operations of pipeline system √

22 Repair valves √ √

23 Repair overfill protective devices √

24 Repair relief valves √

25 Abandoning, safe disconnect, purging and sealing of pipeline facilities √

26 Protect breakout tanks from static electricity, lightning, and stray electrical currents √

27 Place and maintain line markers √

28 Inspect surface conditions of ROW √

29 Inspect navigable waterway crossing √

33 Inspect valves √

34 Maintain valves √

35 Provide security for pipeline facilities √

August 2009 3-3

ID Covered Task Name

Person Performing Task

DESC/

DFSP

Gov't

Employee

Operating Contractor

Other Contractor, Subcontractor, or Entity

36 Perform general pipeline repair activities √

37 Moving in-service pipe √

38 Operate pressure relieving devices for launching and receiving facilities √

39 Inspect, test, and calibrate pressure limiting devices √

40 Inspect, test, and calibrate relief valves √

41 Maintain relief valves √

42 Inspect, test, and calibrate pressure switches and transmitters √

43 Verify or set protection parameters for programmable controllers and/or instrumentation control loops √

44 Test, inspect, and calibrate overfill protective devices √

45 Inspect breakout tanks √

47 Provide temporary marking of buried pipeline prior to excavation √

48 Leak survey after excavation activities and leak survey after blasting √

49 Inspection during and after excavation activities and blasting √ √

50 CPM leak detection √

55 Inspect pipe coating √

56 Repair pipe coating damage √

57 Install cathodic protection √

58 Install cathodic protection test leads √

3-4 August 2009

ID Covered Task Name

Person Performing Task

DESC/

DFSP

Gov't

Employee

Operating Contractor

Other Contractor, Subcontractor, or Entity

59 Examine buried pipe when exposed √

60 Test cathodic protection system √

61 Perform electrical survey (or other test) of unprotected pipe √

62 Check rectifiers √

63 Inspect cathodic protection system on breakout tanks √

64 Cathodic protection corrective action √ √

65 Install insulating device on pipeline system √

66 Inspect and electrically test electrical isolation √

67 Maintain test leads √

68 Identify, test, and minimize interference currents √

70 Investigate corrosion effect of hazardous liquid on pipeline √

71 Inject and monitor corrosion inhibitor into pipeline √

72 Inspect removed pipe for internal corrosion √

73 Install lining in breakout tank √

74 Clean and coat pipeline exposed to atmosphere √

75 Inspect pipeline or portion of pipeline exposed to atmosphere for atmospheric corrosion √

76 Replace damaged or corroded pipe √

August 2009 3-5

3.2 Assignment of Covered Tasks

Covered tasks may be performed by the Operating Contractor, subcontractors, other contractors, other entities, or government employees. Table 3-1 identifies the types of personnel that might perform a specific covered task. The OQ Administrator shall maintain a list of contractors, subcontractors, other entities, and government personnel who perform a covered task. A form (Contractor Assignment List) that can be used for this list is included in Appendix D.

3-6 August 2009

August 2009 4-1

4 EVALUATION METHODS AND ON-GOING

EVALUATION

4.1 Evaluation Methods

Operators are required to evaluate individuals to determine whether they are qualified to perform covered tasks.10 The rule provides several acceptable methods of evaluation. These are:

• Written exam

• Oral exam

• Work performance history

• Observation during performance on-the-job

• Observation during on-the-job training (OJT)

• Simulations

• Certification by vendors or industry organizations

• Other forms of assessment

Each of these methods is described in greater detail below. All evaluations will be performed in English. Sufficient command of the English language is required for all personnel performing covered tasks.

If the DESC requires that a DESC employee perform a covered task, then the method of evaluation must be task specific and applied uniformly across all personnel performing the covered task. All evaluation methods must also include the recognition of abnormal operating conditions (AOCs), specific to the covered task.

4.1.1 Knowledge Test

An Individual responds in writing to a written evaluation question. The preferred type of question is multiple choice, but other types of questions are acceptable. This evaluation may be either computer-based or paper copy.

4.1.2 Oral Exam

An Individual responds orally to questions appropriate to the covered task. The exam evaluator or proctor will transcribe the individual’s answers onto the appropriate form.

10 49 CFR §195.505(b)

4-2 August 2009

4.1.3 Work Performance History Review

A work performance history evaluation demonstrates an Individual’s history of performing a covered task. The information supplied should include the task performed, whether the task was performed correctly and safely, the frequency the task was performed, and the length of time the Individual performed the task. A form to document work performance history is included in Appendix D.

An Individual will not pass a work performance history evaluation if an indication of unsatisfactory performance has been identified.

4.1.4 Observation During Performance on the Job

Qualified Individuals may observe an unqualified Individual performing a covered task to ensure that the unqualified Individual has the knowledge and skill necessary to perform the task safety and properly. If the unqualified Individual performs any task in a way that compromises safety or quality of the job, the person will not be certified until further training on the covered task is achieved.

4.1.5 Observation During OJT

Qualified Individuals may observe an unqualified Individual perform a covered task during OJT to ensure that the individual has the knowledge and skill necessary to perform the task safety and properly. If the unqualified Individual performs any task in a way that compromises safety or quality of the job, the unqualified Individual will not be qualified until further training on the covered task is achieved.

4.1.6 Simulations

A Qualified Individual or trained evaluator will utilize a validated, step-by-step skills checklist to evaluate the Individual’s performance on a simulation of a covered task. The simulation may be computer based or a hands-on performance.

4.1.7 Certification by Vendors or Industry Organizations

Numerous vendors and industry organizations such as, API, National Center for Construction Education and Research (NCCER), National Association of Corrosion Engineers (NACE), or American Society of Mechanical Engineers (ASME), and Midwest Energy Association (MEA) have existing programs which pertain to specific covered tasks. The OQ Administrator will review all requests to utilize vendor and industry organization programs. If a vendor or an industry organization qualification is to be used for DESC’s evaluation, the OQ Administrator will obtain a copy of the training program and review it with appropriate DESC personnel familiar with the covered task before that qualification can be accepted as part of this OQ Program.

Once the vendor or industry organization program is approved by the OQ Administrator, an Individual will be considered qualified for that specific covered task when the qualification documentation is received.

August 2009 4-3

4.2 Types of Qualifications

API RP 1161 requires that the OQ program address transitional qualification, initial qualification, subsequent qualification, and re-evaluation. Each of these is described in greater detail in the following sections.

4.2.1 Transitional Qualification

49 CFR §195.509 allowed for Transitional Qualification before October 28, 2002. The deadline for transitional qualification has passed.

4.2.2 Initial Qualification

Initial qualification is for Individual(s) who are not qualified for a particular covered task.

4.2.3 Subsequent Qualification

Each covered task has a subsequent qualification period. The intervals for subsequent evaluation are identified on the Covered Task List in Appendix C of this Plan.

An Individual must be re-evaluated within this interval in order to maintain qualification.

The determination of the interval for subsequent qualification is based on:

• The frequency of performance of the covered task

• The complexity of the task

• The risk and consequences involved if the task is incorrectly performed.

Tasks that are performed frequently and have low risk may have longer re-evaluation periods than tasks performed infrequently and have high risk. For example,

• A covered task that is performed infrequently, is highly complex, and may have severe consequences (such as welding on existing pipe) will have a more frequent evaluation interval.

• A covered task that is performed weekly or daily and has a low degree of complexity with moderate to low consequences (e.g., line riding) will require less frequent evaluation intervals.

4.2.4 Re-Evaluation

Re-evaluation of an individual must occur when any of the following occur:

• The time interval for subsequent qualification, as established by the applicable OQ Program, has expired;

• There is reason to believe that the individual’s performance of a covered task contributed to an accident or incident; or

• There is reason to believe an individual is no longer able to perform a covered task.

4-4 August 2009

Each of these conditions is discussed in greater detail below.

4.2.4.1 Interval for Subsequent Qualification

See Section 4.3 and Appendix C.

4.2.4.2 Accident-Related Actions

DESC or the Contractor will re-evaluate an individual if the DESC, Operating Contractor, or other contractor, has reason to believe the individual’s performance of a covered task contributed to an accident or incident as defined in 49 CFR §195.50 An accident or incident investigation should be performed as part of the reporting required by 49 CFR §195.50 and

195.54. The individual will be considered to be unqualified until the completion of the investigation. If the investigation indicates that the individual’s actions contributed or may have contributed to the accident or incident, then the individual should be trained and re-evaluated, as appropriate. If the investigation determines that the individual’s actions did not contribute to the accident or incident, then the individual will be considered to be qualified (unless that person’s qualification has lapsed due to other factors).

The re-evaluation will sufficiently address both the knowledge and skill components of the covered task to ensure that the individual has been properly re-evaluated. The root cause analysis may also indicate if other individuals performing the same covered task need additional training to prevent recurrence of the same error. Finally, all re-evaluations must be documented.

If an individual’s actions while performing a covered task have contributed to an accident or incident, the individual will not be allowed to perform the covered task on a DESC pipeline until he/she has passed a re-evaluation and proof of re-evaluation has been submitted to, and accepted by, the OQ Administrator.

4.2.4.3 Ability to Perform Covered Task

When there is reason to believe that an individual may no longer be able to perform a covered task, the individual shall be re-evaluated and re-qualified prior to performing the covered task.

For example:

• The individual has spent excessive time away from the job due to a disability, special assignment, or a change in job duties. DESC considers excessive time to be 12 months.

• The individual displays unsatisfactory performance of a covered task. This includes not only unsatisfactory performance of the covered task, but also unsatisfactory safety performance while performing the covered task (e.g., not wearing required personal protective equipment or performing the covered task while under the influence of drugs or alcohol).

49 CFR §195.50 Reporting Accidents

An accident report is required for each failure in a pipeline system subject to this part in which there is a release of the hazardous liquid or carbon dioxide transported resulting in any of the following:

(a) Explosion or fire not intentionally set by the operator.

(b) Release of 5 gallons (19 liters) or more of hazardous liquid or carbon dioxide, except that no report is required for a release of less than 5 barrels (0.8 cubic meters) resulting from a pipeline maintenance activity if the release is:

(1) Not otherwise reportable under this section;

(2) Not one described in §195.52(a)(4);

(3) Confined to company property or pipeline right-of-way; and

(4) Cleaned up promptly;

(c) Death of any person;

(d) Personal injury necessitating hospitalization;

(e) Estimated property damage, including cost of clean-up and recovery, value of lost product, and damage to the property of the operator or others, or both, exceeding $50,000.

August 2009 4-5

• There are significant changes to the equipment or procedures since the individual’s last qualification.

4.3 DESC Employee Qualification

If the DESC requires that a DESC employee perform a covered task, then the method of evaluation must be task specific and applied uniformly across all personnel performing the covered task. All evaluations must include the recognition of abnormal operating conditions (AOCs), specific to the covered task.

4.3.1 Transitional Qualification

49 CFR §195.509 allowed for Transitional Qualification before October 28, 2002. The deadline for transitional qualification has passed.

DESC requires that all DESC personnel performing a covered task comply with this OQ Program immediately or prior to performing a covered task.

4.3.2 Initial Qualification

DESC will provide for training (per 49 CFR §195.505(h)), as appropriate, to ensure that individuals performing a covered task have the necessary knowledge and skills to perform the task in a manner that ensures the safe operation of the pipeline facility. 11

DESC requires that initial qualification consist of at least two or more of the evaluation methods below:

• Work performance history

• Observation during performance on-the-job

• Observation during on-the-job training

• Certification by vendors or industry organizations

• Other forms of assessment approved by the OQ Administrator

Individuals with a relevant work performance history of 5 years or more that are to be qualified for the first time will be evaluated by passing a work performance history review and one of the following:

• Observation during performance on-the-job

• Observation during on-the-job training

• Certification by vendors or industry organizations

• Other forms of assessment approved by the OQ Administrator

11 49 CFR 505(b); 49 CFR §195.505(h)

4-6 August 2009

Individuals with a relevant work performance history of less than 5 years that are to be qualified for the first time must be evaluated by providing documentation of appropriate training, plus two of the following:

• Work performance history review

• Observation during performance on-the-job

• Observation during on-the-job training

• Certification by vendors or industry organizations

• Other forms of assessment approved by the OQ Administrator

Qualification of a DESC employee is recorded on the Operator Qualification Individual Certification form in Appendix D of this Plan. The completed forms and supporting documentation are maintained by the OQ Administrator.

4.3.3 Subsequent Evaluation

For DESC employees, each covered task has been assigned a subsequent OQ qualification interval. This interval will initially be the interval identified for each covered task in Appendix C of this Plan. However, the interval can be modified by the OQ Administrator based on periodic studies of covered task variables; such as, critical nature, how often performed, complexity, and safety sensitivity.12

4.3.4 Re-Evaluation

An Individual must be re-evaluated when any of the following occur:13

• The time interval for subsequent qualification, as established in Appendix C of this Plan, has expired;

• There is reason to believe that the individual’s performance of a covered task contributed to an accident or incident; or

• There is reason to believe an individual is no longer able to perform a covered task.

DESC will re-evaluate an individual if the DESC has reason to believe the Individual’s performance of a covered task contributed to an accident or incident as defined in 49 CFR §195.50 (see Section 4.2.4.2). If an individual’s actions while performing a covered task have contributed to an accident or incident, the individual will not be allowed to perform the covered task on a DESC pipeline until he/she has passed a re-evaluation and proof of re-evaluation has been submitted to, and accepted by, the OQ Administrator and DESC.

If an individual fails a re-evaluation, the individual may be re-evaluated after additional on-the-job training under the supervision of a qualified individual or additional classroom training.

12 49 CFR §195.505(b), (g) 13 49 CFR §195.505(d), (e), (g)

August 2009 4-7

4.4 Operating Contractor Qualifications

A DFSP Operating Contractor shall submit its OQ Program to the DESC COR as part of the bid documents. The COR will conduct an audit of the contractor’s OQ Program using the Contractor OQ Program Audit Checklist and the PHMSA (OQ) Inspection Form 14 (included in Appendix D of this Plan). The Operating Contractor’s OQ Program must be in compliance with this OQ Program Plan. The OQ Program must pass the audit in order for the Operating Contractor to perform covered tasks.

The DESC requires:

• The method of qualification evaluation be task-specific and applied uniformly across all personnel performing the covered task.

• All evaluation methods include the recognition of AOCs, specific to the covered task.

• All operating contractors performing a covered task submit evidence of current qualifications to the COR prior to performing the covered task.

The OQ qualified individuals must be able to effectively communicate regarding the covered task activities and reactions to abnormal operating conditions. This may require the ability to communicate with workers who speak and comprehend languages other than English either directly or through the use of a translator.

4.4.1 Transitional Qualification

DESC requires that all Operating Contractor personnel comply with this OQ Program immediately upon Program finalization.

4.4.2 Initial Qualification

DESC requires initial qualification consist of training (per 49 CFR §195.505(h)) and another evaluation method at the discretion of the contractor’s employer. The training must ensure that the individual performing the covered task has the necessary knowledge and skills to perform the tasks in a manner that ensures the safe operation of the pipeline facilities.14

An Operating Contractor’s OQ program will identify the initial qualification methods available to their personnel. The following methods are acceptable to the DESC OQ Administrator:

• Written exam

• Oral exam

• Work performance history (not to be used as the sole method)

• Observation during performance on-the-job

• Observation during on-the-job training

• Certification by vendors or industry organizations

14 49 CFR §195.505(b), (h)

4-8 August 2009

• Simulations

• Other forms of assessment approved by the OQ Administrator

4.4.3 Subsequent Qualification

The interval for subsequent qualification is at the discretion of the Contractor, but must, at a minimum, be the interval specified in the covered task list (Appendix C of this Plan) unless an alternate interval has been approved by the OQ Administrator. More frequent subsequent qualification is acceptable.15

An Operating Contractor’s OQ program will identify the subsequent qualification methods available to their personnel. The following methods are acceptable to the DESC OQ Administrator:

• Written exam

• Oral exam

• Work performance history (not to be used as the sole method)

• Observation during performance on-the-job

• Observation during on-the-job training

• Certification by vendors or industry organizations

• Simulations

• Other forms of assessment approved by the OQ Administrator

4.4.4 Re-Evaluation

The Operating Contractor’s OQ Plan will identify the circumstances for and methods for re-evaluation. The Operating Contractor’s OQ Plan will also identify the period for re-evaluation and steps to take before re-evaluation can occur in the event an individual fails an evaluation.

At a minimum, an Operating Contractor Individual must be re-evaluated when any of the following occur:16

• The time interval for subsequent qualification, as established by the Operating Contractor, has expired;

• There is reason to believe that the individual’s performance of a covered task contributed to an accident or incident; or

• There is reason to believe an individual is no longer able to perform a covered task.

If an individual’s actions while performing a covered task have contributed to an accident or incident, the individual will not be allowed to perform the covered task on a DESC pipeline until he/she has passed a re-evaluation and proof of re-evaluation has been submitted to, and accepted by, the COR.

15 49 CFR §195.505(b), (g) 16 49 CFR §195.505(d), (e), (g)

August 2009 4-9

4.5 Other Contractors, Subcontractors, and Other Entities

“Other contractors” and “subcontractors” are those who are not considered to be a DFSP Operating Contractor and are under contract to the DESC, DFSP, other government agency, or other party who has authority to work on the pipeline (such as an Operating Contractor).

“Other entities” may be any other organization that works on the pipeline, such as another governmental agency or other pipeline company.

A DFSP contractor, subcontractor, or other entity shall submit its OQ Program to the DESC COR before performing a covered task. The COR will conduct an audit of the submitted OQ Program using the Contractor OQ Program Audit Checklist and the PHMSA (OQ) Inspection Form 14 (included in Appendix D of this Plan). The OQ Program must be in compliance with this OQ Program Plan. The OQ Program must pass the audit in order for the Operating Contractor to perform covered tasks.

The DESC requires:

• The method of qualification evaluation be task-specific and applied uniformly across all personnel performing the covered task.

• All evaluation methods include the recognition of AOCs, specific to the covered task.

• All operating contractors performing a covered task submit evidence of current qualifications to the COR prior to performing the covered task.

The OQ qualified individuals must be able to effectively communicate regarding the covered task activities and reactions to abnormal operating conditions. This may require the ability to communicate with workers who speak and comprehend languages other than English either directly or through the use of a translator.

4.5.1 Transitional Qualification

Other contractors under contract as of [finalization date of this document] who will perform a covered task must comply with OQ Program immediately. All other contractors must comply with this OQ Program upon receipt of the contract or task order (or before performing a covered task, in some cases).

4.5.2 Initial Qualification

DESC requires initial qualification consist of training (per 49 CFR §195.505(h)) and another evaluation method at the discretion of the contractor’s employer. The training must ensure that the individual performing the covered task has the necessary knowledge and skills to perform the tasks in a manner that ensures the safe operation of the pipeline facilities.17

A contractor’s OQ program will identify the initial qualification methods available to their personnel. The following methods are acceptable to the DESC OQ Administrator:

17 49 CFR §195.505(b), (h)

4-10 August 2009

• Written exam

• Oral exam

• Work performance history (not to be used as the sole method)

• Observation during performance on-the-job

• Observation during on-the-job training

• Certification by vendors or industry organizations

• Simulations

• Other forms of assessment approved by the OQ Administrator

4.5.3 Subsequent Qualification

The interval for subsequent qualification is at the discretion of the contractor, but must, at a minimum, be the interval specified in the covered task list (Appendix C of this Plan) unless an alternate interval has been approved by the OQ Administrator. More frequent subsequent qualification is acceptable. 18

A contractor’s OQ program will identify the subsequent qualification methods available to their personnel. The following methods are acceptable to the DESC OQ Administrator:

• Written exam

• Oral exam

• Work performance history (not to be used as the sole method)

• Observation during performance on-the-job

• Observation during on-the-job training

• Certification by vendors or industry organizations

• Simulations

• Other forms of assessment approved by the OQ Administrator

4.5.4 Re-Evaluation

The contractor’s OQ Plan will identify the circumstances for and methods for re-evaluation. The contractor’s OQ Plan will also identify the period for re-evaluation and steps to take before re-evaluation can occur in the event an individual fails an evaluation. At a minimum, a contractor Individual must be re-evaluated when any of the following occur: 19

• The time interval for subsequent qualification, as established by the contractor, has expired;

18 49 CFR §195.505(b), (g) 19 49 CFR §195.505(d), (e), (g)

August 2009 4-11

• There is reason to believe that the individual’s performance of a covered task contributed to an accident or incident; or

• There is reason to believe an individual is no longer able to perform a covered task.

If an individual’s actions while performing a covered task have contributed to an accident or incident, the individual will not be allowed to perform the covered task on a DESC pipeline until he/she has passed a re-evaluation and proof of re-evaluation has been submitted to, and accepted by, the COR.

4.6 Program Review and Management of Changes

4.6.1 Program Review

The OQ Administrator will review this program at least once a year, not to exceed 15 months, and make changes to the program to monitor program and contractor performance. The Program review will assemble and evaluate feedback on effectiveness and consider and implement suggested improvements, as appropriate. DESC employees and contractors are encouraged to provide feedback and suggest changes to the OQ Program. The OQ Program Feedback Form in Appendix D of this Plan should be used to document and communicate suggested changes. Submit completed forms to the OQ Administrator via email or mail. All changes and suggestions for changes shall be communicated in English.

Program reviews will be documented. A form for documenting the review is included in Appendix D.

Changes made to the program will be managed and communicated as described in Section 4.6.2, Management of Changes.

4.6.2 Management of Changes

Changes may be made to the covered tasks or to the OQ Program at the discretion of the OQ Administrator.

The DESC OQ Administrator will monitor the following to ensure changes to covered tasks or the OQ program are made and communicated to DESC employees and contractors in a timely manner:

• Modifications to Department of Defense (DOD), Defense Logistics Agency (DLA), and DESC policies and procedures

• Changes in state and federal regulations affecting the pipeline operation (see sidebar)

• Utilization of new equipment and/or technology

• New information from equipment or product manufacturers

As part of the management of change process, applicable training documentation and evaluation materials will be updated, as necessary, to reflect the changes.

State-specific information on pipeline regulations and jurisdictional responsibilities can be found at the PHMSA web site:

http://primis.phmsa.dot.gov/comm/

4-12 August 2009

For changes to covered tasks, the OQ Administrator will determine if the changes are substantive enough to require requalification of OQ qualified individuals already performing the task being modified. The OQ Administrator will immediately notify all affected CORs and DESC personnel of the change; the CORs will immediately communicate the change to their contractors.20 Record changes on the OQ Program Notice of Change form in Appendix D and maintain copies of the completed Notice of Change form.

The OQ Program may be modified by the OQ Administrator as a result of experience with the OQ Program (for both content and format), as covered tasks are added or deleted, as specific employee’s responsibilities change, and as regulations change. When such a change is made, a modified copy of the Program will be made available by the OQ Administrator to all affected individuals and PHMSA or the appropriate designated regulatory agency (as indicated in Appendix B). Changes will be identified in the body of the Program in order to facilitate the awareness of the changes. The OQ Administrator will maintain a list of all personnel who have an authorized copy of the OQ Plan.

20 195.505(f)

August 2009 5-1

5 NON-QUALIFIED INDIVIDUALS

Non-qualified individuals may include new employees in training, temporary employees assisting full-time employees, and contractor personnel. A non-qualified individual may perform a covered task only if a Qualified Individual is directing and observing the non-qualified individual.21

DESC will allow individuals that are not qualified to perform a covered task on a regulated DESC pipeline provided the following conditions are met:22

• The non-OQ qualified worker(s) must be directed and observed by an individual that is qualified in that specific covered task. A qualified person may observed multiple non-qualified individuals in a close proximity area.