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Checklist for the Operation of Gas Pipelines

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Checklist for the Operation of Gas Pipelines

1.0 - Project Set Up

Project Set Up

Tie in plan properly prepared

Corrosion recommendation

Proper traffic control plan

Pre-job safety briefing held

Line locates

Inspector on site, OQ Valid, demonstrated access to gas standards, facility maps, and required permits

Primary contributor to unsatisfactory results.

2.0 - Pipe Joining

Welding

OQ Valid / Welding certification card

Demonstrated the ability to interpret and carry out the specific requirements of the welding process being used (in accordance with Procedure Qualification Record (PQR) and Welder Test Record (WTR), API Standard 1104, ASME B31.8)

Used an approved welding process for the type weld being performed

Properly prepared the welding surfaces prior to welding (machining, grinding, cutting, brushing)

Properly aligned and secured facing surfaces and ensured the proper root openings (pipe-to-pipe or pipe- to-fitting)

Inspected the area to be welded to ensure proper dimensions as per API Standard 1104; verified permissible mismatch for pipe wall thickness or out-of-round pipe and used machined fittings to eliminate mismatch where required

Protected the others near the welding area from the arc rays by use of a non-reflecting curtain (as applicable)

Ensured that the work area had adequate ventilation and plenty of fresh air

Used caution when working in the vicinity of combustible gasses or liquids

Kept electrodes dry

Kept equipment in good condition and any electrical connections used were tight, clean, dry, and properly insulated

Kept area where welding was performed as clean and dry as possible

Used correct size welding cable

Properly attached the ground clamp to the pipe or fitting to insure sound e,ectrical connection and in such a way as to prevent arc burn to the adjoining pipe or fitting surfaces

Demonstrated the ability to recognize/react (physically or verbally) to adverse weather conditions

Located and staggered the start of each weld pass at a different point of initiation

Demonstrated (physically and verbally) the ability to recognize an unacceptable weld and to remove and/or repair the weld

Applied welder identification number as specified in company procedure

Butt Fusion

OQ Valid

Properly inspected/prepared pipe surfaces

Pipe properly aligned

Followed manufacturer's instructions

Equipment in good condition

Verified proper heater plate temperature (400-450 degrees F)

Hydraulic machine pressure set correctly

Hydraulic machine controls operated in correct sequence

Maintained fusion pressure while allowing joint to cool

Allowed joint to cool for the specified time before removing clamp

Inspected joint for quality; removed if unacceptable

Socket Fusion

OQ Valid

Properly inspected/prepared pipe surfaces

Followed manufacturer's instructions

Chamfered pipe ends with proper tool

Properly positioned cold ring clamp

Verified proper heater plate temperature (500 degrees +/- 10 degrees)

Applied heat for the specified time

Quickly checked the melt to ensure it was complete

Inserted pipe into fitting until cold ring was flush with the fitting, being careful not to torque or rotate the pipe or fitting during insertion

Allowed joint to cool for the specified time before removing clamp

Inspected joint for quality; removed if unacceptable

Electrofusion

OQ Valid

Properly inspected/prepared pipe surfaces

Followed manufacturer's instructions

Scraping satisfactory

Fitting and prepared surfaces clean and dry

Fitting positioned and clamped correctly

Proper marking

Used proper extension cord

Conditioned fittings and control box to work-site temperature

Verified that the control box identified the correct connected fitting

Employee was out of the excavation prior to starting the fusion process

Allowed joint to cool for the specified time before removing clamp

Inspected joint for quality; removed if unacceptable

Mechanical Fitting

OQ Valid

Compression / Bolted Type Fittings

Properly inspected/prepared pipe surfaces

Followed the manufacturer's installation instructions

Marked stab depth

Checked the proper alignment/stab depth

Inspected joint for quality; removed if unacceptable

Stab Type Fittings

Properly inspected/prepared pipe surfaces

Followed the manufacturer's installation instructions

Chamfered/shaped the pipe ends with correct tool for the fitting being used

Marked stab depth

Stabbed the pipe into the fitting to the proper depth

Inspected joint for quality; removed if unacceptable

Primary contributor to unsatisfactory results.

3.0 - Pipe Installation

OQ Valid

Material inspection and Proper Pipe Handling/Storage

Inspected pipe for defects, damage and age requirements as applicable

Rejected pipe for deficiencies found or made necessary repairs

Steel pipe joints 6" and greater in diameter were mechanically lifted using slings, other approved method (no bare cables, chains, metal bars, etc.)

Pipe protected from damage

Pipe properly tiered when stacking joints

Pipe stored away from high-voltage areas

Open Cut Installation

Located all underground facilities prior to excavating/boring

Installed pipe with the proper cover

Installed to withstand anticipated external loads whenever minimum cover requirements cannot be met

Maintained proper clearance with other underground structures

Plastic pipe located away from buried power cables or steam lines

Maintained proper trench width

Damage tile, etc. repaired or replaced

Trench bottom properly prepared (smooth surface, padded as required)

Piping properly placed in trench

Prevented damage to coatings, pipe wall

Plastic piping was not supported by blocking

Steel piping that was supported by blocking insulated (rock shield, fiberglass)

Bore Installation

Proper boring methods used

Consideration given to secondary damage

Consideration given to pipe or coating damage during insertion

Annular space between pipe and bore hole kept to a minimum

Filled unsuccessful bore holes 6" and larger

Closed open pipe ends prior to insertion

Used a "weak link" on pulls 100' or greater

Joints welded or fused

Pipe examined for damage

Casing Installation

Properly inserted main in casing

Plastic used as casing only when authorized

Vents installed only when required

Vents properly sized (no less than 2" in diameter)

Carrier pipe not permitted in above ground casing

Cut casing windows for services whenever possible prior to insertion (used "window cutter" to remove casing)

Insulating spacers used on coated pipe (maximum recommended spacing @ 10' apart)

At least 5' of leading end of carrier pipe inspected after insertion

Plastic pipe continuously supported where it enters and leaves the casing

End seals installed on steel carrier pipe following the manufacturer's installation instructions

Cathodically protected

Casing filler installed as applicable

Insertion Method

Used plastic main as carrier (unless steel is authorized)

Maintained approved "pipe cover" requirements

Carrier pipe electrically inspected for holidays prior to insertion

Leading end of carrier pipe closed prior to insertion

At least 5' of leading end of carrier pipe inspected after insertion

Provided restraint at tie-ins to metallic mains

Pipe continuously supported where it enters and leaves the casing

Support shims installed (between pipe sections removed to enable insertion of plastic)

Valve Installation

Recognized valve installation requirements

Metal valve boxes may not be installed in contact with the main and must be supported

Valves installed per manufacturer's installation instructions

Steel valves installed in plastic systems must be installed to minimum torsional or shearing loads

Tracer Wire Installation

Installed tracer wire/electronic markers

Installed with all non-cased plastic main

Made accessible for above-ground connection (free ends coated)

Wire connections properly made and protected against corrosion (dielectric tape or material covered with plastic tape)

Installed warning tape

Properly placed line markers

Steel Pipe Bending

Used proper bending methods

Followed the maximum deflection guidelines (per procedure)

Used a number of bends whenever larger degrees are needed to met needs

Recognized that wrinkle bends are prohibited

Recognized that the bend must be at least 1 1/2 pipe diameters from the pipe end

Properly placed pipe seam prior to bending

Applying Corrosion Control

OQ Valid

Followed design and manufacturer's instructions for installation of corrosion control materials

Backfilling

Special fill was used as appropriate

Excavated rocks removed or proper padding used

Rock shield used as appropriate

Backfill was thoroughly compacted, especially at branch connections, to prevent additional pipe stress

Hydrohammers used only when at least 24" of cover was maintained

Backhoes we're not used for tamping

Primary contributor to unsatisfactory results.

4.0 - Install/Replace/Repair Meter & Regulator Sets

Meter and Regulator Set

OQ Valid

Installed meter and regulator set to minimize anticipated stress on connecting pipe and meter

Ensured that materials met the pressure rating standards for the application

Located regulator vent at a place where gas from the vent can escape freely into the atmosphere and way from any opening into the building

Verified that the regulator vent faced downward and was protected with an insect screen

Ensured that the vent pipe was sized no smaller than the manufacturer's vent connection

Located meter set in a position to minimize exposure to hazards from traffic

Installed the meter set in an easily accessible location

Locked/Disked as applicable

Verified regulator output pressure was correct for the system served

Verified that the meter setting was properly insulated

Checked for leakage

Primary contributor to unsatisfactory results.

5.0 - Pressure Testing/Tie-in/Purging

Pressure Testing

OQ Valid

Backfilled ditch (if practical)

Determined the safety procedures to be used prior to testing

Determined the testing medium and the disposal method to be used

Used an appropriate test gauge and fitting(s)

Gauges calibrated (as applicable)

Tested mains and services at the appropriate pressure and duration

Included the tap connection in the test (unless an existing tap hole was utilized)

Tested service line valves for leak-through (as applicable)

Tested temporarily disconnected service lines from the point of disconnection to the meter valve

Administered a leakage test at the operating pressure at connections not included in the pressure test

Documented test results

Tap Pipelines Using a Self-tapping Tee

OQ Valid

Rotated the punch (internal cutter device) clockwise, tapping piping according to the manufacturer's instructions

Rotated the punch counter-clockwise to the proper position

Replaced the cap, tightened according to the manufacturer's instructions

Tap Pipelines Using Drilling Machine

OQ Valid

Lubricated cutter (as applicable)

Verified that the equipment being used was within the proper design range

Followed manufacturer's instructions to ensure the correct drill size, hole saw and pilot holder, tapping valve, cutting speed

Took necessary measurements according to MFG instructions

Monitored pressure as applicable

Used correct tapping speed

Verified valve operation

Depressurized before equipment removal

Drilled to full tapping depth

Verified coupon retained

Plugging Device Used

Followed the equipment manufacturer's installation instructions

Visually examined equipment for defects prior to use

Cleaned the interior of the pipe after tapping and before inserting stopper into the main

Did not exceed equipment pressure ratings

Verified proper plug/effectiveness

Monitored line pressure

Purged equipment housings as applicable

Controlled vented gas and sources of ignition

Maintained sufficient distance from stopper when welding

Stop Pipelines (1 psig or less) Using an Inflatable Bag/Diaphragm Stopper

OQ Valid

Followed the equipment manufacturer's installation instructions

Visually examined equipment and tested for defects prior to use

Calibrated gauge on inflatable bags

Monitored line and bag pressures

Cleaned the interior of the pipe after tapping and before inserting bag into the main

Did not exceed maximum bag or line pressures

"Double bagged" line

Was careful not to tear bag or stopper during insertion

Controlled vented gas and sources of ignition

Maintained sufficient distance from stopper when welding

Stop Pipelines Using a Squeeze Off Device

OQ Valid

Followed the equipment manufacturer's installation instructions

Visually examined equipment for defects prior to use

Monitored line pressure

Maintained at least 3 pipe diameters or 12", whichever is greater from a socket, butt, or saddle fusion

Static electricity removed prior to cutting or squeezing off a plastic main

Squeeze off performed in separate excavation whenever escaping gas was present, or if impractical, employees entering excavation must use approved entry suit with safety line

Properly grounded squeeze-off tools with a #12 AWG wire

Squeeze off properly performed

Recognized that squeeze-off is a temporary measure that should not be used for more than 8 hours

Squeezed just until the flow of gas is controlled

Marked squeeze-off with filament, duct or electrical tape upon completion

Tie-in Piping Remediation

Bare Steel Pipe

OQ Valid

Bonding used whenever a steel pipe is separated (prior to separation); correct size bonding cables; grounding rod used as required

Visually examined exposed piping for evidence requiring remedial action; recognized "localized" or "generalized" corrosion; notified the appropriate personnel (when required)

Examined exposed piping to determine installation requirements for an anode

Took pipe-to-soil readings on metallic pipe

Verified safe atmosphere before installing anode

Installed an anode when required according to gas standards

Properly cleaned area on piping to ensure a good connection

Positioned wires to minimize strain or breakage during the backfill operation

Installed protective coatings following the manufacturer's installation instructions

Inspected the interior pipe wall for evidence of internal corrosion when the pipe was separated

Cast Iron Pipe

OQ Valid

Visually examined exposed piping for evidence requiring remedial action; recognized "localized" or "generalized" graphitization; notified the appropriate personnel (when required)

Recognized that any bell and spigot joint that has been exposed must be sealed

Used appropriate repair method

Properly supported exposed cast iron piping

Insulated steel pipe from cast iron pipe

Purging

OQ Valid

Capital design job orders had a purging plan attached and employee followed the plan

Properly installed and grounded purging stack

Extended 7' or more above ground level

Plastic pipe was not used as purge pipe

Provided fir extinguishers at each activated vent point

Properly vented purged gas

Removed and controlled potential ignition sources

Flared gas only when conditions were safe

Injected the purging medium at a continuous rate to prevent extensive mixing of air and gas

Provided vent points at appropriate locations

Purged mains until a sustained reading of 95% Gas or 0% Gas as applicable was obtained

Purged services to remove pockets of air that could cause pilot outages

Monitored the pressure of the supply piping

Notified dispatcher for pressure control issues; involved pressure control personnel when adjustments in the system or monitoring at regulator stations was required

Conducted odorant level testing after the purging of long and large diameter pipelines

Used a purging medium for abandoning services when natural venting did not work

Used air movers, if required, to remove gas from an existing line

After purging was complete, sealed the open ends of the piping being abandoned

Primary contributor to unsatisfactory results.

5.0 - Project Closeout/Documentation

Project Closeout/Documentation Inspection

WMS/DIS Updates; Ensures all conversations in WMS are completed and DIS service line information has been updated accurately.

Open text (SLR); Verify accurate data on service line cards.

Mapping/GIS; Review maps for updated and accurate information. Swing tie measurements when needed.

Method of Installation - Mains/Services; Verify method of installation for all facilities installed ( I.e. open trenching, directional drill, other boring methods, or inserted). If service was bored, check sewer camera report for post inspection record.

Facility Locates; Verify facilities have been installed and are 100% locatable in accordance with Damage Prevention Plan . Marker balls used and locatable.

Meter Settings; Ensure all meter settings are in best possible location for Damage Prevention and meter protection is provided where needed. Verify meters are fabricated according to Meter Setting Standards/Guidelines.

Line Markers; Verify the markers/ vent pipes have proper company information and phone numbers. Ensure line markers are upright and straight.

Restoration; Verify that all restoration mets or exceeds local codes and requirements. Check all meters to make sure concrete was completed. Make sure ADA requirements were met for curb ramp installations.

Signatures; Ensure all paperwork is signed and dated by appropriate personnel.

Directional Bores; If directional boring was used, ensure copy of sketch from contractor is in work order pouch.

EFV's; Ensure all new service lines have EFV installed and meter is tagged accordingly.

OQ Cards; Verify copies of OQ records are contained within job order pouch.

Material; Correct units applied to job and material reconciled.

Contract Item Numbers; Correct item numbers used.

Pressure Verification; Testing procedure followed according to Gas Standard.

Primary contributor to unsatisfactory results.

Sign Off

On site representative

Auditor's signature