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Gas Pipeline Inspection Checklist


Use this complete gas pipeline inspection checklist to perform quality and safety checks regarding the existing standards, comply with laws regarding gas safety records and keep your building and everyone in it safe.

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Gas Pipeline Inspection Checklist

Main Line Audit

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
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