It is necessary that any material or component designed to transport gas be approved for use in the application for which it will be used. An approved material (or component) is any material (or component) that has a City stock room carries has been approved by the Office of the Gas Superintendent and the Warehouse Manager for use in the distribution.

Procedure for Having New Materials Approved for Use

Anyone desiring to have a new material approved for use shall forward the request in letter form to the Gas Superintendent. The letter should include the following:

(a)

A complete description of the material.

(b)

The purpose for which the material is to be used.

(c)

Any advantages it has over materials now in use.

(d)

Manufacturer literature describing the material (as applicable).

(e)

The name, address and phone number of manufacturer's representative.

(f)

Recommendation of whether the item should be stocked or ordered for each job and estimated annual usage.

The Gas Superintendent shall make a preliminary investigation to determine if the item should be tested. If it appears that the item would be beneficial to city operations, warehouse manager will perform all necessary steps to ensure that the material meets City gas standards.

If it is determined that the item would be beneficial but has only limited application, the item will be added to the approved manufacturer's list if it is determined that the approved item will be used in sufficient quantity to justify it being carried in inventory.

All materials furnished shall be manufactured in the United States and shall meet the applicable requirements of the Pipeline Safety Regulations, Code of Federal Regulations, Title 49, Latest Edition and any other applicable requirements and specifications listed in these specifications.

Cathodic Protection Test Station. Cathodic protection test station shall be constructed at the locations shown in the plans as shown on the detail in the plans. Each cathodic protection test station shall conform to the following.

Post: Post consist of super-tough polycarbonate plastic.

Conduit: Conduit and conduit straps shall be rigid steel and shall be zinc-coated (galvanized). Conduit shall be single tap and equal to those as manufactured by Crouse-Hinds. Conduit bushings shall be installed in the buried end of the conduit to properly protect the bond wire.

Plastic Cover: Plastic cover shall be yellow in color constructed from polycarbonate plastic with two or three binding posts as specified in the plans.

Wire: Wire shall be stranded or solid single conductor copper cable insulated with high molecular weight polyethylene (HMW/PE) and shall be No. 12 AWG.

Connection to Main: Connection of wire to mains shall be accomplished by the Cadweld connection process utilizing a weld metal of copper oxide and aluminum.

Protective Cap: Protective cap shall protect the connection of the wire to the steel pipe meeting the requirements of the Pipeline Safety Regulations, Code of Federal Regulations, Title 49, Latest Edition, Part 192,471 - External Corrosion Control: Test Leads.

Flanges. Flanges shall be raised face, carbon steel meeting the requirements of ASTM A105 and ANSI B16.5. Flanges shall be of the welding neck type and shall be ANSI Class 150. Studs, nuts and bolts shall be as specified by the flange manufacturer.

Insulation Spacers. Insulation spacers shall be constructed of a non-conductive material and shall prevent electrical shorts between the steel line pipe and metallic structures in close proximity. Insulation spacers shall be equal to the FRP insulation spacer-Type No. 120 as specified by the flange manufacturer.

Materials For Concrete.

Cement: All cement shall be standard Portland Cement Class B.

Fine Aggregate: The fine aggregate shall consist of clean, hard, durable uncoated particles of sand or stone. When incorporated in the concrete mixture, fine aggregate shall be free from frost, frozen lumps, injurious amounts of dust, mica, soft or flaky particles, shale, alkali, organic matter, loam or other deleterious substance.

Ninety-five percent (95%) of the fine aggregate shall pass a one-quarter inch (1/4") screen; not more than twenty-five percent (25%) shall pass a fifty (50) mesh sieve, and not more than five percent (5%) by weight shall pass a one hundred (100) mesh sieve.

In no case shall fine aggregate be accepted containing more than three percent (3%) by dry weight nor more than five percent (5%) by dry volume, nor more than seven percent (7%) by wet volume of clay, loam or silt. If any samples of fine aggregate show more than seven percent (7%) of clay, loam or silt, after twenty-four (24) hours settlement after shaking in an excess of water, the material represented by the samples will be rejected.

Fine aggregate shall be of such quality that mortar composed of Portland cement and the fine aggregate made into 2" x 4" cylinders in the same proportions as will be used in the concrete mixture shall show compressive strength at seven and twenty-eight days equal to or greater than the compressive strength at seven and twenty-eight days equal to or greater than the compressive strength of cylinders composed of mortar of the same proportions of Portland cement and the standard Ottawa sand. For proportioning test cylinder, Portland cement and fine aggregate and standard Ottawa sand shall be measure by weight, and the same Portland cement shall be used with the Ottawa sand as with the fine aggregate to be tested.

Coarse Aggregate: Coarse aggregate shall be clean and washed gravel or crushed stone. The gravel or crushed stone shall be clean, hard, durable uncoated particles. It shall contain no vegetable or other deleterious matter, and shall be free from soft, thin, elongated, or laminated pieces.

Water: Water for concrete work shall be fresh, clear and free from oil, acid, alkali, or organic matter.

Pavement Removed And Replaced. Pavement removed shall be replaced with pavement meeting the requirements of the State of Georgia Department of Transportation's Standard Specifications for Road and Bridge Construction for the type of pavement involved. Pavement shall be replaced as shown in the details on the plans. Traffic plates must be provided and maintained by the Contractor and shall remain in place until the pavement is replaced as required. Traffic interruption shall be minimal.

Seeding. Materials for grassing of public rights-of-way disturbed during construction shall meet the requirements of Section 890-SEEDS AND SOD of the State of Georgia Department of Transportation's Standard Specifications for Road and Bridge Construction, Latest Edition. Where grassing is disturbed adjacent to residential or commercial lawns or beyond public rights-of-way, the type of plant material shall match that of the adjacent areas meeting the following minimum requirements.

Seeds: All seeds shall meet the requirements of the Georgia seed laws, rules and regulations except that the requirements as to purify, germination and noxious weeds shall be:

Fertilizer: All fertilizer shall be 5-10-10 grade and shall meet all the requirements of the fertilizer laws of the State of Georgia. Fertilizer shall be undamaged at the time of application.

Agriculture Lime: Agriculture lime shall be pulverized limestone meeting the following requirements:

Total Carbonates, not less than 85%

Passing 10 mesh screen at least 100%

Passing 100 mesh screen at least 25%

Mulch: Mulching material shall be wheat, rye or oat straw, sericea lespedeza or other approved hay. Material shall be in good condition, dry enough to adhere to asphalt and free from weeds and foreign materials.

Steel Line Pipe. All steel line pipe shall be Electric Resistance Weld (ERW), Grade X42/ meeting the requirements of API 5L, Specifications for Line Pipe, 1988 and shall be new and unused. Steel line pipe shall be manufactured in the United States and shall bear the mark of the manufacturer. Before any work begins, the pipe manufacturer shall furnish the Superintendent mill test certificates on all steel line pipe delivered. Steel pipe shall have diameters and wall thicknesses as specified and shall be double random (42') lengths and beveled for welding.

Steel Line Pipe Coating

Plant Applied Coatings.

Buried Steel Line Pipe. All buried steel pipe must have plant applied coating shall be fusion bonded epoxy (F.B.E.) applied electrostatically to an average plant thickness of 14 mils with a minimum thickness at any point of 12 mils terminating six inches (6") from the ends of the pipe. Coating specifications, procedures and electrical inspection shall be in accordance with the National Association of Pipe Coating Applicators (NAPCA) Specifications and Plant Coating Guide, Latest Edition and as required by the coating manufacturer.

Directionally Drilled Steel Line Pipe. Plant applied coating of directionally drilled steel line pipe will be a multi-layer combination of the same coating application as specified above for buried steel line pipe plus an additional plant applied durable coating designed to be applied over fusion bonded epoxy coating for harsh to severe installation conditions. Additional coating will be applied electrostatically to an average plant thickness of 20 mils with a minimum thickness at any point of 20 mils terminating six inches (6") from the ends of the pipe. Total multi-layer coating system shall be an average plant thickness of 34 mils with a minimum thickness at any point of 32 mils. Coating specifications, procedures and electrical inspection shall be in accordance with the National Association of Pipe Coating Applicators (NAPCA) Specifications and Plant Coating Guide, Latest Edition and as required by the coating manufacturer.

Stenciling. The following minimum information shall be stenciled to the exterior of plant applied coatings.

Name of Coating Applier

Name of Pipe Manufacturer

Pipe O.D. in Inches

Pipe Wall Thickness in Inches

Type of Pipe Manufacture and Grade

Tape Coatings. Welded joints, fittings and damaged areas of the coating shall be wrapped with a tape coating having a minimum thickness of 35 mils and shall be compatible with the specified coating. Tape coatings shall be supplied with the necessary primer and of the type and grade recommended by the tape manufacturer. The applicator of the tape coatings must demonstrate his abilities to properly apply the selected type(s) of tape coating(s) in the presence of the Superintendent. The Superintendent may require the applicator to be qualified under his written procedures if it is questionable that his work produces unacceptable results.

Cold Applied Tape. Cold applied tape shall be equal to Tape Coat H35 Gray/Internal Primer as specified by manufacturer.

Heat Shrink Sleeves. Heat shrink sleeves shall be equal to those as manufactured by Canusa.

Heat shrink sleeves shall be used on weld joints subjected to pull-back during boring and drilling operations.

Temporary Silt Fence. Temporary silt fence shall meet the requirements of Section 171 - TEMPORARY SILT FENCE for the State of Georgia Department of Transportation's Standard Specifications for Road and Bridge Construction, Latest Edition for Type "C" or Type "B" Fences as called for.

Threaded Fittings. Threaded fittings shall be constructed of carbon steel meeting the requirements of ASTM A105 and ANSI B16.11. Threaded fittings shall be ANSI Class 3000.

Valve Boxes. Valve Boxes shall be of the cast iron roadway, sliding adjustable type. The boxes shall have a minimum inside diameter 5-1/4" and a minimum bottom bell inside diameter of 8". The length shall be adjustable from 36" to 48" and, if necessary the minimum thickness of metal at any point shall not be less than 5/16". The top section shall have a flange at the bottom to prevent external loads from being supported by the valve. Valve boxes shall be painted inside and outside with a good bit mastic paint.

Line Markers. Line markers will be made of a composite material, 4" width, in lengths ranging from 62-78 inches as needed and will be yellow in color, either single or double sided with all emergency information installed when received. Carsonite or its equal.

Welding Fittings. Welding fittings shall be butt weld, Grade B, seamless steel with a minimum yield strength of 35,000 psi meeting the requirements of ASTM A106 and ANSI B16.9. Welding fittings shall be Standard Weight, Pipe Schedule Number 40 in accordance with ANSI B36.10.

PE Plastic Pipe And Tracer Wire. PE Plastic Pipe must be SDR 11, PE 2406 or 3408 in 500 FEET ROLLS. Tracer wire will be #12 coated stranded or solid copper. Also, either 2" or 4" caution tape, with gas line buried below on tape will be installed.

Gas Meters. City of Tifton will use the following meters for residential customers; Sensus 275 and 415 or American 250 and 425

City of Tifton will use the following meters for small commercial customers;

Sensus 750 and 1000

American 800 and 1400

City of Tifton will use the following meters for large commercial / industrial customers; Dattus 5M and Up and American or Sense Turbine meters

Regulators/Relief Devices. City of Tifton will use the following regulators for residential customers;

Fisher 252 or equal

City of Tifton will use the following regulators for small commercial customers;

Sensus 143-80 and 243 and Fisher 202 ,102 or equal

City of Tifton will use the following regulators for large commercial / industrial customers;

Sensus, American or Fisher - 2" or Larger with associated relief valves when needed.

Relief Valves used:

Fisher 1805,627 or equal

Fisher EZR or equal

Plastic Pipe Fittings. Perma-Sert, Con-Stab, Tri-Fusion or similar fittings will be used in the City of Tifton's Natural Gas System

Scope of the work. All construction procedures and techniques used shall meet the applicable requirements of the Pipeline Safety Regulations. Operator shall meet the applicable requirements of the Pipeline Safety Regulations, Code of Federal Regulations, Title 49, Latest Edition. All such procedures and techniques shall be conducted in accordance with safe and accepted pipeline construction practices. Anyone performing work on the City of Tifton natural gas system must be B31Q qualified.

Service Installation. These standards set forth the requirements for installing services in the City's natural gas system. Generally, a single service shall be run to serve a single customer or group of customers.

(See Appendix E Procedures # 0861,0871-0911,0901,0941)

Location. The standard meter set location is three to five feet from the front building wall on the side of the house for a single-family residential structure and ten (10) feet from the front building wall for commercial buildings. Normally, the meter set and point of service entry should be on the side opposite the driveway of where vehicular traffic is predominant. Deviation from this location should only be considered due to site constraints. If deviation is required, consideration should be given to minimizing the amount of service line under pavement. Services should be run in a straight line at right angles to the street. That portion of a service paralleling a building should not be nearer than 2 feet to the foundation wall.

Septic tanks, large trees (and their accompanying root structures), heavily landscaped areas, storm water pipes, and sanitary sewer/septic lines should be avoided when running services. Services should be run in a walk or driveway only if no better route is available.

Prior to any excavating, a request for locates of other underground facilities should be made the 811 one call system. In addition, the City or its designated agent shall spot all gas facilities within the scope of the job site as required by appropriate state law.

Excavating. In general, the procedures for installing mains / services should be followed when excavation for service lines is performed. (See B31Q procedures # 0861 - Steel Pipe and # 0901 - For Plastic Pipe Installation).Trench bottoms should be free of rocks, cinders, sticks or other debris that might cause damage to the pipe and or its coating. (See B31Q procedure # 981 for proper back-filling of trench.)

When opening the paving over a main for tapping, the normal cut should not exceed 48" × 48" where possible. However, in unpaved areas, these dimensions may be more liberal.

Paved streets or walks should not be cut except over the main for tapping or where other underground facilities or construction conditions make it necessary.

Trenching in lawns must be performed with care to allow returning the surface to acceptable condition. Sod should be cut into blocks, carefully removed before the trench is started, and set aside for replacement upon completion of the backfill.

Service Depth. Services should be run with a minimum cover of 18 inches from the main to meter location. In the event that a service crosses a roadway drainage ditch, there should be a minimum of 24 inches cover measured from the bottom of the ditch. In all cases, adequate protection of the service from damage must be considered.

In addition, it may be necessary to provide additional cover from main to property line where required by state highway.

Service Construction Inspection. New service construction should be inspected by superintendent or his designee, as necessary, to assure compliance with Construction Standards.

Pressure Testing. Before being placed into operation, each new service shall be pressure tested in accordance with Procedures # 0561,0571,0591 located in Appendix E of operators O&M Procedures Manual. Services may be pressure tested together with a main extension when feasible.

Services and mains shall be purged when testing. When purging services, an ell should be used on the riser or standpipe to direct the flow of gas away from the building. When purging a main a purge stack must be used as required by Procedures # 1641-1651 located in Appendix E of O&M Procedures Manual.

Backfilling ( Appendix E Procedure # 0981- O&M Procedures Manual). When installing pipe in a trench, it shall be bedded to have a good bearing on undisturbed or well tamped soil. It is important that service risers be properly supported by bearing sufficient to minimize strain on meter set components.

Backfill shall be made to a level 8 inches above the service pipe with soil that is free of rocks, stumps, cinders, paving material or other debris that could damage the pipe or its coating. Backfill should be completed in layers to ensure proper compaction.

New Services Not in Use. When a service is not placed in operation upon completion of the installation, one of the following must apply until the customer is supplied with gas

(a)

The service cock or valve shall be locked.

(b)

The customer's piping must be physically disconnected from the gas supply and the open pipe ends sealed.

A record of each service installed shall be retained by using the all in one form. (See O&M Procedures Manual for form.) All location measurements shall be taken from the nearest intersecting street.

Services Equipped with an Excess Flow Valve (EFV). All new residential, single-meter services must be equipped with an excess flow valve (EFV).

An excess flow valve (EFV) shall be installed as close as practical to the service line connection to the main on all single residential service lines installed/inserted from the main.

These requirements apply to the design and installation of plastic and steel piping and components in the City of Tifton's Natural Gas System.

Joining of Plastic. Plastic pipes may be heat fused together or to fittings. Plastic pipe made from equivalent resins or the same color may be heat fused in accordance with the City's O/M Procedures Manual. Except for electro-fusion, plastic pipe of different colors (and thus different resins) may not be heat fused to each other, including fittings.

Plastic pipe may not be joined by a threaded joint or miter joint.

Tools and Equipment. Tools required for plastic fusion shall be specifically designed for that purpose. General use equipment, such as portable generators shall be of good quality.

Heating Tools. Heating tools shall be electric and have thermostatic controls. Heating tool faces shall match the dimensions of the pipe and fittings to be joined. Faces shall be coated with a Teflon coating or other approved non-stick coating.

The Teflon coating on all heating tools and faces shall be cleaned of the residual melted plastic after each use. The heating tools and faces shall be cleaned using a clean natural fiber rag, paper towel or soft wooden stick. The heating tool and faces shall be re-coated with Teflon by the manufacturer when the coating becomes scratched, wears thin or otherwise becomes unserviceable. Do not use Teflon sprays or abrasives on heater faces.

Each heating tool should be checked weekly. A pair of "tempil sticks" can verify that the thermometer is indicating accurately. With the thermometer indicating the desired temperature, 400-450 degrees Fahrenheit for most fusion work, the low temperature "tempil stick" (400 degrees Fahrenheit) is brushed across the heating tool (not on the surface which will contact pipe or fitting). A liquid smear will indicate that the low temperature limit has been exceeded. The high temperature "tempil stick" (450 degrees Fahrenheit) is used in a similar manner. A dry mark on the face will indicate that the upper temperature limit has not been exceeded. These indications prove that the heating tool faces are within the temperature range for proper heat fusion.

A pyrometer can also be used to check heating tools. To ensure proper calibration of the pyrometer simply touch the probe to a piece of ice. The LED should read 32 degrees Fahrenheit. To check the calibration of the heating tool, touch the probe to the iron's face. The desired temperature is 400-450 degrees for most fusion work.

Generators. Generators shall have sufficient capacity (10,000 kw required) to power the heating tools and other equipment to be used. Generally, the generator should have 25% more capacity than the power requirement of the largest heating source to be used.

Static Electricity. When plastic gas lines are broken or being purged, static electric charges can build up. Static electric charges are caused by particulate matter in the gas contacting the pipes inside wall and fittings at high flow rates. This static electric charge will "flow" down the pipe wall with the gas and collect on metal fittings or at the end of the pipe. The static electric charge must be conducted to the ground to remove any potential danger. A grounding method is a soapy water saturated cloth wrapped around the pipe and in contact with wet earth or a ground rod. A Static Electricity Eliminator Device may be used to provide the necessary grounding and static spray.

Steel Pipe. In general, steel mains shall be joined by welding using joint design and procedures set forth in the City of TIFTON Weld procedures manual.

Oxy-acetylene welding of pipe joints will normally be used for pipe sizes 1 inch O.D. and smaller. For pipe sizes larger than 1 1/2 inches O.D. shielded electric arc welding of pipe joints will normally be used.

Pipe ends prepared in the field for welding shall be beveled to the same angle as mill beveled pipe by using oxy-acetylene flame cutting or other approved means.

The factory applied coating cutback is normally adequate to prevent any welding difficulties when welding epoxy coated pipe. Precautions should be taken to insure ventilation is adequate during welding.

Only welders qualified to API 1104 or DOT standards will be permitted to weld.

Visual inspection shall be made to ensure that welding is performed in accordance with the specified welding procedure, and where considered necessary a weld should be cut out in order to test the quality of the welding.

Marking of Plastic Pipe Joints. To ensure quality control measures for jointing pipe, and to monitor the weld quality of each person the following steps will be performed. Every qualified person making a connection between pipe and or between pipe and fitting will mark on the pipe the following information:

(a)

The Name of the Company performing the work.

(b)

The initials of the person making the weld and the last six digits of their social security number or their employee number.
(Example - CITY TIFTON - TE - 123456)

Only a black/white permanent-type markers shall be used.

Joint Records. The location of each fitting and the type of fitting (excluding couplings) shall be recorded, along with the location of the joint. The measurements will consist of distance from paving edge, distance from the center line of the road in two directions (longitudinal & lateral), and depth as measured from the undisturbed ground level to the top of the fitting. When magnesium anodes are installed with uniform spacing, it is necessary to record only the number, size and spacing used.

Plastic Pipe Joints. No person may make a plastic pipe joint unless that person has been qualified.

No person may carry out the inspection of joints in plastic pipes required unless that person has been qualified by appropriate training or experience in evaluating the acceptability of plastic pipe joints made under the applicable joining procedure.

(A)

Heat-fusion Joints. Each heat-fusion joint on plastic pipe must comply with the following:

(1)

A butt heat-fusion joint must be joined by a device that holds the heater element square to the ends of the piping, compresses the heated ends together, and holds the pipe in proper alignment while the plastic hardens.

(2)

An electro-fusion joint must be joined utilizing the equipment and techniques of the fittings manufacturer or equipment and techniques shown, to be at least equivalent to those of the fittings manufacturer.

(B)

Mechanical Joints. The City will not use compression fittings as permanent repairs.

(C)

Requalification for Plastic Pipe Joints. A person must be re-qualified under an applicable procedure located in Appendix E of the O&M Manual if during any 12-month period that person:

(1)

Does not make any joints under that procedure; or has 3 joints or 3 percent of the joints made, whichever is greater, under that procedure that are found unacceptable by testing.

(2)

Or a person must be re-qualified under an applicable procedure by performing the appropriate qualification test at least once every 12 months.

All joints in polyethylene plastic piping systems shall be made in accordance with the procedures contained herein, or the "Generic Butt Fusion Joining Procedure for Polyethylene Gas Pipe," available separately and published by the Plastics Pipe Institute. All plastic joining procedures have been qualified in compliance with the U.S. Department of Transportation's Pipeline Safety Regulations Minimum Federal Safety Standards, Sub-part E, Part 192.283. These procedures have been proved by test or experience to produce strong gas-tight joints.

Three joining processes are approved for joining polyethylene plastic piping and fittings in the City's system. These processes are externally applied heat fusion joining, mechanical joining, and electro-fusion.

The City or its designated agent shall inspect the completed joint for proper installation.

Externally Applied Heat Fusion Joining Procedures. The following procedures apply to pipe and fittings made from medium density polyethylene (PE) 2406 and 3408 resin meeting ASTM specifications.

Plastic pipe and fittings manufactured from resins of different densities shall be joined by mechanical joining or electro-fusion methods.

Fusion joints should not be made where the pipe surface has been in contact with grease, diesel fuel, oil, diesel soot, or other petroleum hydrocarbons.

Safety Precautions. Electrical heating tools used for plastic fusion are potential sources of ignition. Therefore, appropriate precautionary measures shall be taken before using the equipment in areas where combustible mixtures may be present.

Heated tools shall be handled carefully to avoid injury to personnel or damage to plastic pipe surfaces.

Where necessary, suitable gloves should be worn when making fusion joints .

Butt Fusion Joints. All butt fusion joints shall be made by a fusion alignment machine designed for this application and approved by the City. The following steps shall be followed when making butt-fusion joints.

[a]

Ensure that the proper faces are on the heating tool and clean. The heating tool should be connected to the power source and pre-heated during preparation of pipe.

(b)

Where necessary, remove all frost, ice, or snow from O.D. and I.D. surfaces of areas to be fused by lightly tapping or gently scraping the solids until they flake off the pipe ends.

(c)

Wipe each pipe end (or fitting) clean with a clean dry non- synthetic cloth, inside and outside, to remove dirt, water, and other foreign materials.

(d)

Place pipe ends (fitting) into fusion machine clamps and tighten as appropriate. Ends should extend approximately one inch past clamps for facing. Bring pipe ends (fitting) together and check for alignment.

(e)

Insert the appropriate facing tool between the pipe ends (fitting) and close ends against rotating facing blades with adequate pressure. Ends should be machined square to smooth, flat surfaces. Operate facer until machine has bottomed out against stops on facing unit. Separate pipe ends (fitting). After power to facer has been turned off and the tool has stopped rotating, remove facer unit. Remove cuttings from pipe ends (fitting) and check ends for complete facing. If incomplete, repeat facing operation until ends is square.

(f)

Bring pipe ends (fitting) together and check for alignment, gap and out-of-roundness.

Ends should meet squarely and completely over the entire surface to be fused. Where necessary, adjust line-up clamps as appropriate. Proper alignment is necessary to obtain uniform heating of the pipe ends (fitting) and uniform bead at the fused joint.

Where necessary, the pipe ends (fitting) should be wiped with a clean dry non-synthetic cloth to remove moisture, dirt, or other foreign substances. Avoid touching the areas to be fused with hands.

Be sure the lineup clamp is sufficiently tightened to restrain the pipe (fitting). Verify that heating tool faces are clean. A tempil stick, thermo-couple probe, or equivalent may be used periodically to ensure that heating tool faces have reached the correct temperature (400-450°F±10°).

(g)

Insert the heating tool between the aligned pipe ends (fitting). Bring ends in contact with the heating tool without exerting pressure. The heating cycle starts when the pipe ends (fitting) are completely flush against the heating tool faces and a bead of molten material is first visible around the complete circumference of both pipe ends (fitting). As the melt bead develops, maintain contact with pipe ends (fitting) and heater face with zero pressure using the torque control handle. Keep both pipe ends (fitting) in contact with the heater for prescribed period of time or until the melt bead width is the appropriate size (see Table Below). A bead of molten polyethylene will form and expand as the polyethylene melts. Exerting pressure should be avoided because the molten plastic will be displaced from the fusion area resulting in an unsatisfactory joint.

a.

Heating time ranges are normally for ideal conditions at temperatures ranging from 55°F - 85°F and no wind. However, when fusing in cold weather conditions, the time required to form the initial melt bead will automatically extend the total melt time cycle. The upper range on the heating time should be used when fusing in temperatures below 55°F and the lower range used in temperatures above 85°F. When fusing pipe sizes 8 inch diameter and greater, it is preferred that sight fusion procedures be used.

b.

Joint must be held firmly in place.

c.

Time required before removing the fused joint from the equipment. Light handling and making an additional fusion on the same fitting may be performed after this cooling period.

d.

Time required after removing the joint from the fusion equipment before testing or subjecting the joint to bending, burying, pressure testing, or similar handling and backfill stresses.

(h)

Carefully move the pipe ends away from the heating tool and remove the tool. No melted plastic should remain on the tool. If melted plastic remains, cut off the melted pipe ends (or fitting where required) and perform the procedure again. Where necessary, a new fitting should be used.

(i)

Bring the heated pipe ends (fitting) together quickly to form a uniform bead around the entire circumference of the pipe. Do not slam together as this may cause excessive displacement of melt, resulting in a poor quality fusion. Sufficient pressure should be applied to roll back the melted material to produce a properly formed weld bead. The fused joint must be held steady, with no additional pressure, for the specified hold time (see Table Above). Over-pressuring the melt will cause the bead to overlay itself and could result in a sub-quality fusion. The melt would be pushed to the outside diameter and inside diameter of the fusion, creating a possible non-fused area in the center of the fusion joint. Under-pressure could result in inadequate fusion due to insufficient contact in the melt area. Also, extreme care should be exercised to maintain contact pressure during fusion cooling even if the bead exceeds the desired width (see Table Above for the appropriate thickness of each bead after fusion). Reversing the pressure will cause porosity in the fused area. Allow the joint to cool during the prescribed cooling time (see Table Above). Inspect the joint for a uniform, nonporous appearance. If for any reason there is a question regarding the quality of the joint, cut it out and start over. Remove the lineup clamps and allow the joint to cool to air temperature as indicated. The fused joint should be allowed to cool for the appropriate cooling time for rough handling before applying stress (see Table Above).

Saddle Fusion Joints. Service connections using multi-saddles and punch tees shall be heat fused to plastic mains using the following procedure. The fusion procedure should be performed with the aid of an application tool designed for this procedure. Manufacturer's operating instructions shall be followed for the appropriate application tool.

High volume punch tees and branch saddles are heat fused to mains in the same manner as the service size fittings. Be sure that the proper heater aces are used for the particular fitting being used.

(a)

Ensure that heating tool faces are the correct size for the joint to be made and clean. The heating tool should be connected to the power source and preheated during preparation of pipe.

(b)

Where necessary, remove all frost, ice, or snow from surface areas to be fused by lightly tapping or gently scraping the solids until they flake off the pipe.

In cold weather, It may be necessary to condition fittings to a more appropriate temperature by keeping them in the cab of the truck or other suitable means. This will reduce exposure to extremely low temperatures making it easier to heat the area to be fused.

(c)

Wipe surface of the main with a clean dry cloth to remove moisture, dirt, or other foreign substances. The saddle fitting also must be clean and dry.

(d)

Lightly roughen the surface of the main and the inside base of the saddle fitting in line with the pipe with a clean 60- to 80-grit emery cloth. Take care not to alter the contours of either the main or the saddle fitting. Wipe roughened surfaces with a clean dry non-synthetic cloth.

(e)

Place application unit on the prepared surface area of the pipe according to manufacturer's instructions and secure. Where necessary, a bolster plate should be used for pipe 6" and smaller in diameter.

(f)

Insert fitting in application unit and lower until fitting base rests on the pipe. Secure fitting tightly in unit.

(g)

Verify that the heating tool is clean and the vents in the saddle fusion heater faces are open. A tempil stick, thermocouple probe, or equivalent may be used periodically to ensure that heating tool faces have reached the correct temperature (400-450°F±10°).

(h)

When the appropriate temperature has been reached, place the heating tool on the heating iron before placing the fitting onto the iron). Within approximately 3 seconds, lower fitting against heating tool. Apply and maintain continuous pressure accordingly during the heating cycle. Make sure the force is evenly distributed and square to the axis of the pipe during the heating cycle. The heating tool may be rocked slightly assure full contact with the pipe (approximately 2 degrees). Do not interrupt the heating cycle to inspect the melt pattern on the pipe.

(i)

Heating cycle begins after fitting and pipe are firmly seated against heater faces. Heat for prescribed period of time or until the appropriate melt bead size is visible on crown of pipe (see Table Below). Heating cycle is complete when the appropriate time or bead size is reached. Heating time ranges in Table Below are normally for ideal conditions at temperatures ranging from 55°F - 85°F and no wind. When fusing in cold weather conditions, the time required to form the proper melt will vary as ambient temperatures and wind conditions change. The areas to be fused should be shielded with a wind break or cover to reduce these effects. Pipe end and fitting should be heated for the maximum time specified for the range in Table below. When fusing in ambient temperatures above 85°F,the lower heating time range should be used.

(j)

When the heating cycle is complete, snap the fitting off the heating tool first, then snaps the heating tool off the pipe, making sure the heating tool corners do not dig into the pipe wall.

(k)

Quickly inspect both melt patterns before fusing the fitting to the main. Heated surfaces on fitting and pipe should be 100% melted with no cold spots. If patterns are incomplete, continue the fusion process. However, after the appropriate cooling times have been allowed, abandon the fitting in place by cutting off the stack or outlet. Repeat process with a new fitting and a different area of pipe.

Quickly (within approximately 3 seconds after removing the heater) lower the fitting on the pipe with firm pressure until the appropriate fusion bead (see Table below) appears around the entire base of the fitting.

(l)

Constant pressure shall be applied to the fitting for the appropriate hold time listed in Table below. During the hold time the joint should be held firmly in place.

(m)

After the appropriate cooling time (see Table below), remove the application tool and inspect the fusion bead around the entire base of the fitting. A three roll bead will be present on a good fusion - one on the pipe, one on the fitting and one between these two.

(n)

If the fusion beads are not acceptable, allow for the appropriate cooling time for rough handling as indicated in Table Below. Cut off the top of the fitting to prevent future use. Relocate application tool and install a new fitting using proper procedure.

Mechanical Joining Procedures. The fitting to be used should be checked to ensure that it is appropriate for the size and type pipe(s) to be joined. For additional information refer to the appropriate fitting manufacturer's installation instructions.

Anchoring and blocking may be necessary where some mechanical fittings are used especially where little or no restraint is obtained from soil.

Bolt Type Compression Couplings and Sleeves (See B31Q Procedures # 1011 Appendix E of O&M Manual). Bolt type compression couplings and sleeves such as Dresser Style Couplings or similar fittings shall be installed as follows:

(a)

Before assembling joint, pipe ends must be clean, dry and cut square. Do not apply soap solution to plastic pipe or gaskets before installing coupling. Any defect such as a scratch or gouge in the joining area that would affect the sealing of the gasket should be eliminated. Where necessary, remove burrs from end of pipe using clean emery cloth.

(b)

A "metal insert stiffener" must be inserted into the end of the plastic pipe and the compression fitting gasket must bear on the "metal insert stiffener".

(c)

For the purpose of centering the fitting, each pipe shall be marked an equal distance back from pipe ends. Separation of pipe ends shall be no more than 1/2 inch.

(d)

Tighten bolts evenly to a uniform tightness. See manufacturer's specifications for recommended torque.

Stab Type Fittings (See B31Q Procedures # 0711 Appendix E of O&M Manual). Stab type fittings such as Permasert, Con-Stab, Tri-Fusion or similar fittings shall be installed as follows:

(a)

Before assembling joint, pipe ends must be clean, dry and cut square. Any defect in the area to be covered by the fitting should be eliminated so as to eliminate possible leaks. Where necessary, remove burrs from end of pipe using clean emery cloth.

(b)

Using a chamfering tool, chamfer the end of the pipe according to manufacturer's instructions.

(c)

Using the fitting as a reference, mark the appropriate stab length on the pipe.

(d)

Stab pipe into fitting until pipe bottoms out in the fitting. Verify stab depth of fitting to the previous mark made on the pipe. Repeat procedure to connect other pipe end.

Nut Type Bottoming-Out Fitting: (See B31Q Procedures # 0691-0701 Appendix E of O&M Manual).

(a)

Before assembling joint, the end of the pipe must be cut square, clean, dry and free of scratches or gouges that would affect the sealing of the gasket. Where necessary, remove burrs from end of pipe using clean emery cloth.

(b)

Using the fitting as a reference, mark the appropriate stab length on the pipe.

(c)

Loosen nut according to manufacturer's instructions and make sure gasket is free. Do not remove nut or lubricate gasket.

(d)

Stab pipe into fitting through the nut and gasket and onto the internal stiffener until it bottoms on stiffener flange or base. Verify stab depth of fitting to the previous mark made on the pipe.

(e)

Tighten nut until it is properly secure against the body of the fitting. Visual verification of proper application and installation is attained through bottom-out tightening of the nut against the body. Repeat procedure to connect other pipe end.

Nut Type Non-bottoming-Out Fittings (See B31Q Procedures # 0691-0701 Appendix E of O&M Manual). Nut type non-bottoming-out fittings such as Dresser Style 90 or similar fittings shall be installed as follows:

(a)

Fittings with separate or loose stiffener:

(1)

Before assembling joint, pipe ends must be cut square, deburred, clean, dry and free of scratches or gouges that would affect the sealing of the gasket. Where necessary, remove burrs from end of pipe using clean emery cloth.

(2)

Remove nut, retainer, gasket and metal insert stiffener from fitting. Also remove lock ring from fitting of that type.

(3)

Assemble nut, retainer and gasket (also lock ring, if required) over end of plastic pipe before installing metal stiffener.

(4)

Do not lubricate gasket.

(5)

Install metal insert stiffener into plastic pipe until flange is against pipe end. Due to the amount of friction the insert may encounter, care shall be exercised not to bend the insert flange when using force.

(6)

Stab plastic pipe into fitting until insert flange is against stop in fitting body or pipe ends are centered in coupling. The compression gasket must bear on metal insert stiffener.

(7)

Tighten nut to achieve sufficient gasket pressure. See manufacturer's specifications for recommended torque and wrench size.

[b]

Fittings with built-in stiffener:

(1)

Before assembling joint, pipe ends must be cut square, clean, dry and free of scratches or gouges that would affect the sealing of the gasket. Where necessary, remove burrs from end of pipe using clean emery cloth.

(2)

Using the fitting as a reference, mark the appropriate stab length on the pipe.

(3)

Loosen nut about one-quarter turn and make sure gasket is free.

(4)

Do not lubricate gasket.

(5)

Stab pipe into fitting through nut and gasket and onto stiffener until it bottoms on stiffener flange or base. Verify stab depth of fitting to the previous mark made on the pipe.

(6)

Tighten nut to achieve sufficient gasket pressure. See manufacturer's specifications for recommended torque and wrench size.

Mechanical Saddle Tee. Plastic mechanical saddle tees for use on plastic pipe shall be installed as follows:

(a)

Before assembling fitting, pipe surface must be clean, dry, round and free from gouges or scratches.

(b)

Place the body of the fitting on the pipe and the bottom section underneath making sure all bolt holes line up before inserting bolt.

(c)

Insert bolts and tighten evenly with appropriate wrench until top and bottom of saddle tap come together. See manufacturer's specifications for recommended torque and wrench size recommended torque and wrench size.

(d)

Where necessary, install service pipe as appropriate in accordance with the procedure for the fitting being used.

(e)

Remove O-ring cap and insert tapping wrench into tapping punch. Screw tapping punch clockwise until tap is made and continue turning to set the punch on the bottom of the tee body. Do not over-tighten.

(f)

Turn wrench counterclockwise until punch head is level with, but not above, the edge of the tee molding.

(g)

Replace O-ring cap. Tighten only manually so that the cap is hand tight. Do not over-tighten or use pipe wrench on cap.

Other Mechanical Fittings. Where plastic pipe is to be joined using approved mechanical fittings not specifically covered by this section, the installation shall be in strict accordance with the manufacturer's written installation instructions.

Electro-fusion. Electro-fusion procedures have been qualified for installing couplings and saddle fittings when connecting polyethylene mains and services. Electro-fusion is most beneficial when making fusion joints in emergency repair situations and for making tie-ins in confined areas where it is difficult to use other fusion equipment.

Additionally, electro-fusion may be used to join polyethylene pipe manufactured from resins of different densities. Electro-fusion equipment, when properly used, will adjust its settings to make proper connections for the type of polyethylene being fused. These standard procedures describe the steps necessary to join similar or dissimilar polyethylene piping materials.

Electro-fusion joints should not be made where the pipe surface has been in contact with grease, diesel fuel, oil, diesel soot, or other petroleum hydrocarbons.

Safety Precautions.

(a)

Electrical equipment used for electro-fusion are potential sources of ignition. Therefore, appropriate precautionary measures shall be taken in accordance with Hazard section, Division 4, Section 5 before using the equipment in areas where combustible mixtures may be present.

(b)

When making electro-fusion joints, the power source, control box, and supply line junction shall be located out of the trench or bell hole

(c)

For protection against electric shock, electro-fusion equipment shall be connected to properly grounded outlets only.

(d)

Manufacturer's guidelines and safety precautions should be followed to ensure proper operation of electro-fusion equipment.

Electro-fusion Couplings and Reducers (See B31Q Procedure # 0781 Appendix E of O&M Manual). The following steps shall be followed when joining polyethylene mains and services with electro-fusion couplings and reducers.

(a)

The end of the pipe shall be cut squarely, being sure to remove any gouges from the fusion zone, using tubing cutters approved for cutting plastic pipe or equivalent. Pipe ends that are not square may result in over-heating and uncontrolled flow of molten plastic. Where necessary, a dry cloth should be placed in the pipe to keep polyethylene fragments out of the pipe. After cutting, burrs should be removed from inside the pipe wall using clean emery cloth or equivalent.

(b)

The end of the pipe should be wiped with a clean dry non-synthetic cloth to remove moisture, dirt, or other foreign substances. The electro-fusion coupling should be protected in the plastic wrapper as long as possible until procedures require its assembly. Do not touch cleaned surface(s) with your hands.

(c)

Using the electro-fusion coupling as a reference, mark the fusion zone on both pipe ends with an appropriate marker. Generally, for most couplings, it is the distance between the end and the middle of the coupling. This will measure the stab depth of the pipe into the coupling.

(d)

Scrape the outside diameter of the pipe end(s) accordingly up to the marking(s) (area to be fused) with a tubing scraper, main scraper, hand scraper, or equivalent. Scraping should continue until the thin oxide layer, which forms on polyethylene during storage is removed. Do not scrape the inside of the electro-fusion fitting.

(e)

After scraping, burrs should be removed from the inner and outer edges of the pipe wall using the scraper, emery cloth, or equivalent. Wipe off excess polyethylene with a clean dry non-synthetic cloth and protect the prepared surface(s) from dirt and contamination. Where necessary, a suitable cleaning agent (isopropyl alcohol base, where alcohol content is a minimum of 96% by volume) may be used with an absorbent lint free, non-dyed, non-synthetic disposable cloth to clean the prepared surface(s) and the inside of the electro- fusion fitting. The solvent on the pipe or fitting must be completely dry before proceeding. Do not touch the scraped pipe surface(s) or fusion area on electro- fusion fitting with your hands.

(f)

Where necessary, mark the fusion zone on the pipe end(s) again to ensure the proper stab depth of the fitting (original mark may have been removed during scraping and cleaning). If necessary, use rounding clamps where the pipe may have lost its circular form.

(g)

Remove the electro-fusion coupling from the package and slide over the prepared pipe end being careful not to contaminate the inside surface of the fitting. Where necessary, use an appropriate alignment clamp to secure the ends of the pipe to be joined. Center coupling over the joint using the stab depth marks as a guide.

(h)

The coupling is now ready for the fusion process. Follow electro-fusion box manufacturer's operating procedures for connecting the control box output leads and fusing the coupling. Do not disturb the control box output leads during the fusion cycle.

The control box will indicate when the fusion cycle is complete and a recommended cooling time will be displayed. Disconnect the control box output leads from the coupling and do not move or disturb the fused joint until the specified cooling time has elapsed. Remove alignment clamps where necessary.

Electro-fusion Tapping Tees and Saddle Fittings. The following steps shall be followed when fusing electro-fusion tapping tees and saddle fittings to polyethylene pipe.

(a)

Wipe the surface area of the main to be fused with a clean dry cloth to remove moisture, dirt, or other foreign substances. The entire circumference of the pipe should be cleaned. Care should be taken to select an area free of gouges in the fusion zone. The electro-fusion fitting should be protected in the plastic wrapper as long as possible until procedures require its assembly.

(b)

Using the electro-fusion fitting as a reference, mark the fusion zone on the pipe with an appropriate marker. Scrape the appropriate surface area of the pipe to be fused accordingly with a main scraper, hand scraper, or equivalent. Scraping should continue until the thin oxide layer, which forms on polyethylene, is removed. Do not scrape the fusion area of the electro-fusion fitting.

(c)

Wipe off excess polyethylene with a clean dry non-synthetic cloth and protect the prepared surface from dirt and contamination. Where necessary, a suitable cleaning agent (acetone or alcohol base, where alcohol content is a minimum of 90% by volume) may be used with an absorbent lint free, non-dyed, non-synthetic disposable cloth to clean the prepared surface and the inside of the electro-fusion fitting. The solvent on the pipe or fitting must be completely dry before proceeding. Do not touch the scraped pipe surface with your hands.

(d)

Remove the electro-fusion fitting from the package and install on the properly prepared pipe surface according to the fitting manufacturer's instructions (some fittings may require the use of a clamp). Do not touch the fusion area on the electro-fusion fitting with your hands. The fitting must be located completely within the scraped area on the pipe. Evenly tighten fitting until it has bottomed out or is tight against the main according to manufacturer's instructions.

(e)

The fitting is now ready for the fusion process. Follow electro-fusion box manufacturer's operating procedures for connecting the control box output leads and fusing the fitting. Do not disturb the control box output leads during the fusion cycle.

(f)

The control box will indicate when the fusion cycle is complete and a recommended cooling time will be displayed. Disconnect the control box output leads from the coupling and do not move or disturb the fused joint until the specified cooling time has elapsed. Where necessary, tap the main as appropriate and remove alignment clamps.

QUALIFYING PERSONS TO JOIN PLASTIC PIPE. Each city employee engaged in joining plastic pipe and fittings by externally applied heat fusion or mechanical fittings must make acceptable sample joints following approved joining procedures for the kind of plastic pipe and type of joints used. The sample joints must be inspected and tested in accordance with this section.

Each city employee engaged in joining plastic pipe and fittings by electro-fusion shall demonstrate competence in following the required procedures. However, the fusion process does not have to be performed and the joint does not have to be destructively tested.

Appropriate training or experience in the use of plastic joining procedures is required.

Approved joining procedures are procedures which have been qualified by the manufacturer of the pipe and/or fittings or qualified by company tests in accordance with Paragraph 192.283 of the Minimum Federal Safety Standards. Refer to Joining Procedures for Plastic Pipe.

Qualification Inspection. Sample joints must be visually inspected while being made and after completion to assure that the correct procedure is followed and that the completed joint has acceptable appearance. Electro-fusion procedures shall be visually inspected to ensure that the person qualifying for Electro-fusion has demonstrated competence in following the procedure for the type joint to be made.

Inspection must be performed by a city representative who has been qualified by training or experience in evaluating the acceptability of plastic pipe joints made under the applicable joining procedure.

Externally Applied Heat Fusion Qualification. A person shall qualify for externally applied heat fusion on plastic pipe and fittings by successfully completing, in the presence of the Gas Superintendent or his designee, a sample joint for each joining procedure being used and the joint passing the appropriate destructive test.

Butt Fusion.

(a)

Pipe nipples should be of the same material as those used in normal pipeline installations.

(b)

Pipe ends must be prepared as specified in approved written procedures.

(c)

Make butt fusion joint according to approved procedures. Since the tools used for butt fusing plastic pipe 2" IPS and greater differ from pipe sizes less than 2" IPS. A person making a butt fusion joint greater than 2" IPS shall be qualified for the size joint made during qualification down to 1" IPS.

(d)

Test of Butt Fusion:

(1)

Visually inspect joint for acceptable appearance. Bead shall have uniform appearance, and no incomplete fusion is allowed.

(2)

Cut joint out with approximately 8" of pipe on each side of the joint. Split the pipe and joint by sawing in half lengthwise and inspect for complete fusion. Incomplete fusion or misalignment of pipe ends will disqualify test.

(3)

Cut three approximately 1" wide by approximately 16" long test strips from the fusion joint. Bend test each sample toward inside of the pipe. Bend test each strip toward outside of the pipe. No separation shall appear in the fusion joint.

Saddle Fusion.

(a)

Pipe nipple and fitting should be of same material as those used in normal pipeline installations.

(b)

Pipe surface and fitting should be prepared as specified in approved written procedures.

(c)

Fuse a 2" x 5/8" saddle service tee to a 2" pipe nipple according to approved procedures. Saddle service tees without the tapping bit, cap, and protective sleeve are available in stock for plastic joining qualifications.

(d)

Test of the Saddle Fusion Joint:

(1)

Visually inspect the joint for complete fusion. Incomplete fusion will disqualify test.

(2)

Cut fitting out leaving about 8" of pipe on either side.

(3)

Saw saddle and pipe into three longitudinal strips approximately 1" wide with approximately 8" of pipe on each side of fitting. Bend, torque, or impact test each strip toward inside of pipe. No separation shall appear in the fusion joint.

Mechanical Joining Qualification.

A person shall qualify for joining plastic pipe with mechanical joints by successfully completing, in the presence of a qualified city representative, a sample joint for each type of mechanical fitting being used as follows:

(a)

Pipe ends must be prepared as specified in approved written joining procedures.

(b)

Assemble joint in accordance with approved procedures.

(c)

A mechanical joint must be visually inspected during and after assembly to assure that the correct procedure is followed and that the completed joint has an acceptable appearance.

Electro-fusion. A person shall qualify for electro-fusion on plastic pipe and fittings by successfully demonstrating, in the presence of a qualified city representative, competence in following the procedure for the type joint to be made.

Electro-fusion Couplings and Reducers.

(a)

Pipe surface and fitting shall be prepared as specified in approved written procedures.

(b)

Install coupling and connect control box output leads according to approved procedures. The coupling does not have to be fused to the pipe, however the individual shall demonstrate competence in following the appropriate manufacturer's operating procedures.

Electro-fusion Tapping Tees and Saddle Fittings.

(a)

Pipe surface and fitting shall be prepared as specified in approved written procedures.

(b)

Install fitting on pipe nipple and connect control box output leads according to approved procedures. The fitting does not have to be fused to the pipe however the individual shall demonstrate

Requalification. A person who is qualified under externally applied plastic heat fusion, mechanical joining or Electro-fusion shall be re-qualified by performing the appropriate qualification test at least once every 12 months.

The Gas Superintendent or his designee should visually inspect the initial set up for requalification and ensure that pre-fused joints are not used. The Gas Superintendent or his designee should also periodically inspect the sample joint(s) while being made to assure that the correct procedure is being followed. The completed joint shall be visually inspected for an acceptable appearance before performing the appropriate destructive test.

A person qualifying or re-qualifying for electro-fusion should demonstrate, in the presence of Gas Superintendent or his designee, competence in following the procedure for the type joint to be made.

A record shall be maintained of each person qualified to join plastic pipe including the dates of their qualification or requalification. Externally applied heat fusion and electro-fusion qualification/requalification tests shall be recorded.

Mechanical joining qualification/requalification tests shall be recorded.

Qualification Card. The Qualification Card shall be completed for each person successfully completing plastic joining qualification/requalification tests. Persons joining plastic shall have the Plastic Joining Qualification Card in their possession at all times while on the job.

Approved Joining Procedures. A copy of each applicable joining procedure must be available locally to the persons making and inspecting joints on plastic pipe. Procedures in Appendix E of the O&M Manual.

MECHANICAL JOINING PROCEDURES - STEEL. This section outlines the procedures that shall be used to mechanically join segments of steel pipe to other segments of steel pipe, as well as to fittings, valves and other pipeline components.

Flanged Fittings. The following procedure should be used for assembling flanged joints at valves or other fittings:

(a)

The flange shall be a standard unit manufactured in accordance with approved specifications, and of the proper design for the type of service and intended use.

(b)

The flange faces shall be brushed clean of all rust, dirt or other foreign material which could interfere with the proper make-up of joint.

(c)

Flange gaskets shall be clean, free of defects and selected for the pressure rating of the flanges with which they will be used.

(d)

Bolt sizes and specifications will be as required for the fitting being joined. All bolts shall be placed in the bolt holes before any bolt is tightened.

(e)

Flanges shall be checked for proper line-up before tightening the bolts.

(f)

Four bolts, spaced 90 degrees apart shall be tightened so that a uniform pressure is exerted on the flanges and gasket initially. The opposite bolts shall be tightened uniformly in sequence until all bolts are tight.

(g)

Only suitable wrenches, such as open end, box or socket wrenches shall be used.

(h)

City or its designated agent shall inspect the completed joint for proper installation.

Compression Type Fittings. The following procedures should be used when joining steel pipe with couplings, sleeves, or other fittings of the compressions type. The City of TIFTON will only use this type fitting as a temporary repair.

Bolt Type Compression Couplings and Sleeves (See B31Q procedure # 1041 in Appendix E of the O&M Manual.). Bolt type compression couplings and sleeves should be installed as follows:

(a)

Before assembling joint, pipe ends must be cleaned by removing oil, dirt, loose scale, and rust. Gaskets should seat on bare metal.

(b)

For the purpose of centering the fitting, each pipe should be marked an equal distance back from pipe end.

(c)

Gaskets and seating surfaces must be clean. Lubricate pipe, gaskets, and flares of middle ring with soap solution before making up joint.

(d)

Tighten bolts evenly to a uniform tightness of about 80 lbs. pull on a 12- inch wrench.

(e)

Where pipe movement out of a compression fitting might occur, reinforcement by strapping or weld-over sleeve, or suitable anchorage must be provided.

(f)

The Gas Superintendent or its designee shall inspect the completed joint for correct installation.

Style 90 Type Compression Fittings.

(a)

Pipe ends and fitting must be clean before assembling joint.

(b)

Loosen nuts to relieve gasket pressure.

(c)

Apply soapy solution to gaskets.

(d)

Push pipe ends into coupling or fitting. Center coupling over joint.

(e)

Tighten each nut separately to a pull of about 75 pounds on the wrench.
(See Table below for required wrench size.)

(f)

Where pipe movement out of compression fitting might occur, proper reinforcement or anchorage of the pipe must be provided.

(g)

The Gas Superintendent or his designee shall inspect the completed joint for correct installation.

Table: Wrench Sizes For Style 90 Fittings

Other Compression Fittings. Joining of pipe by means of proprietary compression fittings, not specifically covered by this section shall be strictly in accordance with the manufacturer's installation instructions.

Threaded Joints (See B31Q procedure # 0721 in Appendix E of the O&M Manual.). Pipe shall be threaded with clean cut threads and shall be free of cutting burrs or other obstructions which would cause stoppage or restrict the flow of gas.

Pipe shall be threaded in accordance with the following table.

Pipe or fittings with threads which are stripped, chipped, corroded, or otherwise damaged shall not be used.

Threaded joints should be made up using an approved joint compound (pipe dope or equivalent) which is applied sparingly only to the male thread of the joint, and the joint tightened with a wrench of an appropriate size.

Tap Sleeves or Service Sleeves.

(a)

Clean dirt and rust from surface of the pipe where gaskets will make contact.

(b)

Separate sleeve body into halves by removing the nuts from the side bolts. Do not remove the bolts, gaskets or other parts.

(c)

Lubricate the gaskets with soapy water and assemble sleeve on the pipe. Replace nuts on side bolts and tighten to a uniform tightness. For 3" through 8" sleeves, the side bolts should be tightened to a pull of 100 pounds on a 12-inch wrench.

(d)

Next, tighten the follower screws a little at a time until all screws at each end of the sleeve are uniformly and securely tightened. Use the small wrench supplied, or a socket wrench having at least a 7-inch handle. Do not use an open-end wrench.

(e)

The Gas Superintendent or his designee shall inspect the completed assembly for proper installation.

Service Saddles.

(a)

Remove straps from saddle. Do not disturb gasket as it is cemented in place.

(b)

Clean dirt and rust from surface of pipe where the gasket will seat.

(c)

Lubricate gasket and pipe surface with soapy water.

(d)

Assemble saddle on pipe and tighten straps evenly until gasket starts to extrude from under saddle.

(e)

The Gas Superintendent or his designee shall inspect the completed assembly for proper installation.

Special Tap Fittings.

The use of tap fittings not specifically covered by this section, shall be strictly in accordance with the manufacturer's written installation instructions.

These instructions are intended to be carried out by, or under the direction of, persons qualified by experience and training in pipeline corrosion control methods.

Minimum Requirements for External Corrosion Control. All new steel pipelines, mains and services including station piping and replacement sections shall be properly coated, and have cathodic protection installed within one year after installation. Normally, such cathodic protection should be installed at the time of construction.

All bare or ineffectively coated distribution system piping, including station piping shall be cathodically protected where active corrosion is found. Active corrosion is defined as continuing corrosions which, unless controlled, could result in a condition that is detrimental to public safety.

Determining Active Corrosion. Areas of active corrosion are to be determined by electrical survey, or where electrical survey is impractical, by the study of corrosion and leak history records, and records of exposed pipe examinations.

In some cases, electrical surveys are considered impractical in urban areas because they present great difficulty in the application and interpretation of the data. In such areas, leak surveys and review of the records listed above will normally be the most effective and appropriate methods of determining areas of corrosion.

Cathodic Protection of Existing Systems. Existing systems constructed with coated pipe should be isolated as necessary into practically-sized systems and completely cathodically protected rather than attempting to identify specific areas of "active corrosion" by electrical surveys.

It has been demonstrated that cathodic protection of bare or ineffectively coated bare or ineffectively coated systems is by the installation of magnesium anodes at corrosion leak repairs or other known "hot spots." When such measures fail to control corrosion, replacement of the pipe should be considered.

Periodic Re-evaluation. A re-evaluation shall be made of any remaining unprotected lines at intervals not exceeding three (3) years in areas in which active corrosion is found. Areas of active corrosion shall be determined by study of corrosion and leak history records, by inspection of underground facilities or by leak detection surveys. After each evaluation, piping found to have active corrosion should be cathodically protected (or replaced) in accordance with standard company practices. The City of TIFTON has no isolated services. All services have been inserted.

THEORY OF CORROSION AND CATHODIC PROTECTION

Corrosion. In nature, metallic systems seek the stable or balanced condition of equilibrium.

Commercial iron being unstable takes advantage of the corrosion process to return to its original metal oxide state of equilibrium.

Decomposition of a metal (corrosion) occurs when there is an anode (negatively charged area) and a cathode (positively charged area) bonded by a metallic path and in contact with an electrically conductive media (soil, water).

The electrochemical process of the anode supplying electrons through the metallic path to the cathode and the corresponding ion migration through the electrolyte results in the decomposition of the metal at the anode only.

Cathodic Protection. An unprotected pipeline will contain numerous local anodes and local cathodes.

Corrosion will occur at the local anodes. By forcing the entire pipeline or segment of pipeline to act as a cathode, corrosion is significantly curtailed. This is known as cathodic protection and can be accomplished in basically two ways, galvanic anode and impressed current.

Cathodic protection using galvanic anodes takes advantage of dissimilar metal corrosion to protect the pipeline. An electrochemical potential exists between the pipe and the magnesium anode significantly enough to cause a segment of pipe to act as a cathode. The driving voltage existing between the steel pipe and galvanic anode metals is limited to relatively low values, so if the anode is to discharge a useful amount of current, resistance of the current path between the anode and the pipe must be relatively low. For this reason, galvanic anodes are more effectively used in low resistivity soils.

Cathodic protection using impressed current relies on a dc power source for the driving voltage. This allows for a wider variety of anode material since you are not dependent on dissimilar metals for the driving voltage. The materials most commonly used for impressed current anodes are a high silicon cast iron and graphite.

An impressed current anode bed or ground bed is only as good as the contact resistance to earth; for that reason carbonaceous backfill material is used not only to give the lowest contact resistance possible but also, being carbonaceous in composition, this material acts as an anode itself, thus giving greater life and efficiency to the ground bed installation.

SURVEYS. A survey utilizing pipe-to-soil potentials and current readings is to be conducted on each cathodically protected system to demonstrate that at least one of the criteria for cathodic protection found has been achieved initially and is being maintained annually as required.

RECTIFIER INSTALLATION. New and existing piping are protected with rectifier (impressed current) systems on the Cities natural gas system. These systems may be utilized where current requirements are large, in areas of high soil resistivity, or where the use of galvanic anodes may be impractical. Rectifier installations should also be considered when more economical than galvanic anode systems. However, the use of a rectifier requires the availability of a suitable ground bed location.

Rectifier systems should be designed with output voltages limited to the least amount of current needed to protect the system, therefore minimizing excessive ground potentials or interference with other foreign structures.

Location. The primary consideration in determining a location for a rectifier is soil resistivity. The ground bed must be installed in an area with acceptable soil resistivity. Lower soil resistivity results in more efficient ground beds, and usually lower output voltage requirements. Other considerations should also be taken into account when selecting a rectifier location. These include the following:

(1)

Other underground metallic structures within the area that may be affected by stray current interference.

(2)

Right-of-way procurement.

(3)

Availability of A.C. power.

(4)

Accessibility for construction and maintenance.

(5)

Future development plans for the area near the rectifier and ground bed location.

Rectifier Specifications. Rectifier units for general use should be of the air cooled type, single phase, with silicon rectifying elements, such as the Goodall model CSAWSA, or Universal model ASAI. Lightning protection should be provided against lightning surges coming into the unit from either the A/C or D/C side.

Rectifier Installation. For an effective impressed current system, rectifiers should be installed properly to eliminate future problems. For proper installation the following steps should be considered.

(1)

Rectifier condition upon receipt - Check rectifier immediately for damage. Check all electrical connections to make sure that bolts have not vibrated loose during shipping.

(2)

Rectifier location - Consider accessibility, vandalism, livestock, hunters, ventilation, high ambient temperatures and proper cooling. Install rectifiers away from other equipment that create heat. Do not coat rectifier cabinet with mastics or tar, or any insulating materials and, if possible, install rectifier in a shaded area.

(3)

Rectifier Protection - Follow all local electrical and wiring codes. Most codes require fused disconnect switches ahead of all rectifiers even though the rectifiers are equipped with circuit breakers. Rectifiers are screened at the top and bottom to allow air flow which cools the components.

Make sure air flow is not obstructed by clogged screens. Do not place the rectifier manual in the bottom of the rectifier as it may obstruct air flow.

(4)

Personal Safety - All rectifier cabinets should be connected to a ground rod. Grounding lugs are placed on the rectifier for this purpose.

Do not attempt any interior repairs or maintenance to a rectifier while the A.C. power supply is on. Always have power supply in the off position before work is started.

Cabinets and disconnect boxes shall be locked to discourage vandalism and tampering.

(5)

Proper Input Voltage - Before energizing the unit, read rectifier manual, and check the voltage available. It should be within 10% of that which is required by the rectifier. A.C. input leads should be long enough to allow for inspection of rectifiers equipped with slide-out racks.

(6)

Correct Polarity of Output Connections - The negative (pipe) and positive (ground bed) leads should be permanently marked. Verify that the pipe potential shifts negatively when the rectifier is energized.

Ground Bed Design. Only outside Consultants/Engineers will design ground beds for the City of TIFTON Natural gas system. Designs for ground beds may be prepared once their locations have been selected by considering information listed in Location.

The following is a list of items which should be analyzed when designing a ground bed:

(a)

Anode to electrolyte resistance: This often controls the entire circuit resistance, and therefore, the following factors must be carefully considered:

(1)

Resistivity of the soil;

(2)

Resistance between a single anode and the soil;

(3)

Configuration of the anodes, particularly the spacing;

(4)

Location of anodes with respect to the pipeline and foreign structure; and

(5)

Anode position such as vertical or horizontal.

(b)

Resistance of positive and negative cables.

(c)

Vulnerability to physical damage: anodes, cables and connections must be carefully placed to minimize this possibility. Ground beds should be designed with a resistance which will permit the required current output with an impressed voltage to be within the rating of the D.C. power supply. However, due to the variables involved, it is recognized that the design figure for completed ground bed resistance may not be exact, necessitating some over sizing of the rectifier or sizing of the rectifier after the ground bed has been installed.

Horizontal Anode Ground Bed. A horizontal anode ground bed should be considered when soil resistivity tests indicate low resistivity at the ground surface which increases with depth. This ground bed is probably the easiest to install since a continuous trench may be dug and the carbonaceous backfill and anodes are placed in the open trench.

Deep Well Anode Ground Bed. Deep Well anode ground beds should be installed only when no other means of protection is economically feasible. This type of ground bed should be considered when surface level resistivities are extremely high and subsurface (50 feet - 100 feet) resistivities very low.

Cable Specifications and Data. In most cases, single conductor stranded copper cables are used. The size usually attached to the anode is No. 6 stranded with header cables being larger such as No. 6 .

Connections and Splices. The best type of connections is from the anode to the junction box but the following methods could be used as well. The design details in an impressed current system should keep connections and splices to a minimum. This is primarily because the wiring is most often buried or submerged in an electrolyte where even the smallest pinhole in insulation will mean rapid failure. Every connection should be inspected by a Crew Foreman before backfilling. Brazing, soldering or split bolt connection kits may be used. The header cable to anode connection is a critical point. Improper insulation could result in a loss of anodes.

Anode Specifications:

Graphite Anode. Graphite anodes are 3 inches in diameter by 60 inches long, Linseed oil impregnated, and center connected with 12 feet of No. 8 AWG stranded copper HMWPE insulated lead wire. The anodes are prepackaged in an 8 inch × 84 inch galvanized steel canister filled with 3/16-0 metallurgical grade coke breeze, with a rubber grommet to protect the lead wire exit from the canister.

Initial surveys shall be completed for each rectifier system and recorded.

Each pipeline that is under cathodic protection must be tested at least once each calendar year to determine whether the cathodic protection meets the requirements set forth in Part 192 Appendix D of the Pipeline Safety Regulations. The standard criterion used by the City of TIFTON is the negative 0.85 volt, with reference to a saturated copper sulphate electrode. These annual pipe-to-soil potentials and current readings must be recorded.

Each cathodic protection rectifier or other impressed current power source must be inspected six times per year but with intervals not exceeding 2 1/2 month and recorded on appropriate City of TIFTON form or whenever possible, on the corrosion control mainframe computer systems.

TEST STATIONS: Test stations enable the City to determine the effectiveness of cathodic protection installations while also providing a means of pinpointing trouble areas through potential and current monitoring. Each pipeline or distribution system under cathodic protection shall have a sufficient number of test stations or other contact points for electrical monitoring.

Test Station Installation. Test stations shall consist of lead wires (size as specified) attached to the pipe by the thermite weld process and terminated in either a valve box type terminal box or above ground terminal box. The wire connection to the pipe shall be carefully coated with an approved coating material. Enough lead wire should be provided such that no stress is placed on the wire-pipe connection and sufficient slack is available for making connection in the terminal box. Extreme care should be used so as not to "nick" the copper conductor or damage the lead wire in any way. Test stations shall be installed so they will not present a hazard to pedestrian traffic, or be subject to damage by vehicles, mowing machines, etc. Above ground test stations may be installed adjacent to pipeline markers, fence posts, utility poles, etc., to provide the necessary protection. In addition, marking to denote City property should be made by a durable adhesive label affixed to the above ground terminal boxes. Each test station must be located precisely with respect to property lines or permanent land marks and the location information recorded where it will be available when tests are to be made.

Test Station Location. Test stations should be installed at the following locations:

(a)

All casing installations.

(b)

All suspected foreign line interference locations.

(c)

Selected insulated fitting locations.

(d)

Locations where lowest protective potentials are expected.

(e)

At sufficient intervals to determine the adequacy of cathodic protection.

Service risers that are not electrically isolated from the main may be used as test points on distribution lines.

Where such service risers are not available, potential test stations must be installed. In systems protected with galvanic anodes, test stations should be located at approximately 1,000 foot intervals. Generally, in rectifier protected systems, fewer test points are required to monitor cathodic protection. Where pipelines are installed on private R/W, test stations should be installed at road crossings so they are accessible for testing.

Thermite Welding Procedure. Test leads, anode wires, bond wires, or other wire connections to a steel pipe surface shall be made by the thermite welding process (Cadweld or Thermo-weld) using the proper graphite mold and a powder cartridge. Wet or damp molds will produce porous welds. The mold should be dried out if it has become wet or has been out of use for a length of time sufficient to absorb moisture. This may be done by firing a powder cartridge in the mold before making the actual weld.

Preparation of Steel Service. To obtain a good weld, surface must be bright-clean and dry. After removing pipe coating, the metal surface should be filed, using a coarse file or rasp, to remove all mill scale, rust, grease, and dirt.

Welding Procedure.

(1)

Strip insulation from wire and insert wire into mold. Wire should protrude 1/8" beyond end of sleeve. The sleeve may be crimped onto the wire in order to hold it in place.

(2)

Insert steel disc in mold to hold powder.

(3)

Dump cartridge into powder crucible being careful not to upset the steel disc. Tap bottom of cartridge to loosen all fine starting powder and spread evenly over the coarser welding powder. Place a small amount of starting powder on top edge of mold under cover opening for easy ignition.

(4)

Cover opening should face away from operator for safety. Before firing, check for proper positioning of wire.

(5)

Close cover, and holding welder firmly in place, ignite with flint gun at cover opening. Jerk gun away quickly to prevent fouling. Keep hands and face away from flash of ignition powder.

(6)

Remove all slag from mold before making the next weld. Clean cover every 6 to 10 welds.

(7)

After weld has cooled, remove slag with hammer, carefully coat the weld, and repair the pipe coating.

CRITERIA FOR CATHODIC PROTECTION AND PIPE-TO-SOIL POTENTIAL MEASUREMENTS. Each cathodic protection installation must provide a level of cathodic protection that meets the requirements contained in Subpart I, Appendix D, of Minimum Federal Safety Standards. The criteria for cathodic protection that follow are applicable to steel systems.

Potential. A cathodic potential of at least -0.85 volts as measured between the structure and a saturated copper-copper sulfate reference electrode in contact with the soil. Measurement of this potential shall be made with the protective current applied.

This criterion will generally be used on the following installations:

(a)

Effectively coated steel piping.

(b)

Poorly coated or bare steel pipe where other listed criteria cannot be effectively used.

Negative Potential Shift. A minimum cathodic potential shift (negative) of 300 millivolts, produced by the application of protective current. The potential shift from its "negative state" shall be measured between the structure and a saturated copper-copper sulfate reference electrode in contact with the soil. "Native state" shall be designed as the potential of the structure before cathodic protection is applied.

This criterion will generally be used on poorly coated or bare piping systems that do not contain dissimilar metals (such as steel and copper).

Polarization Potential Shift. A minimum cathodic polarization potential shift (negative) of 100 millivolt measured between the structure and a saturated copper-copper sulfate reference electrode in contact with the soil. The polarization voltage shift must be determined by interrupting the protective current and measuring the polarization decay. When the current is initially interrupted, an immediate voltage shift occurs. The voltage reading after the immediate shift must be used as the base reading from which to measure the 100 millivolt depolarization. This criterion will normally apply to piping systems where the source of protective current may be readily disconnected to establish the polarization potential shift.

Protective Current Flow. A net protective current flow from the surrounding soil into the structure surface is measured by an earth current technique applied at points on the structure that were previously known to be current discharge points. This criterion will normally be used where cathodic protection is applied only at "hot spot" or anodic areas in a system coupled with high soil resistivity which make other criteria impractical.

Pipe-to-Soil Potential Measurements. When making pipe-to-soil potential measurements, instruments of the following types should be used in order to minimize the effects of external circuit resistance upon the indicated potential readings:

(a)

Potentiometer - voltmeters.

(b)

Electronic voltmeters.

Pipe-to-soil measurements to determine the level of protection will normally be made with the reference electrode (half cell) placed on the soil directly over the pipe or other structure in question. The porous plug of the half cell must be in form contact with moist earth. If necessary, moisten the soil to be contacted or dig the electrode into moist soil.

Location of the half cell and voltage (IR) drops other than those across the structure-electrolyte boundary must be considered when interpreting indicated pipe-to-soil potentials. This is of particular importance on bare or poorly coated structures.

Half cells shall be properly maintained. The copper rod should be routinely cleaned, water added when necessary, a saturated solution of copper sulfate maintained and the porosity of the plug checked periodically.

Potential meters are delicate instruments and should be handled with care. Calibration of instruments should be checked periodically or whenever, because of abnormal readings, the calibration is suspected to have changed.

Below Ground Coatings. All steel gas piping including associated valves and fittings to be buried below ground or submerged shall have an external protective coating applied over a properly prepared surface so that all exposed areas are properly covered.

Coatings used shall have the following characteristics:

(a)

Low moisture absorption;

(b)

High electrical resistance;

(c)

Sufficient adhesion to effectively resist underfilm migration of moisture;

(d)

Sufficient ductility to resist cracking;

(e)

Resistance to damage from normal handling and soil stress; and

(f)

Compatibility with cathodic protection.

The City's standard coating for buried or submerged steel pipe is a minimum of 12 mils green factory-applied fusion bonded epoxy (FBE) with a yellow spiral band. Pipe ends are not coated to within 1-1/2 inches (+/- 1/2") from the ends of the pipe joint.

External protective coating must be protected from damage that could result from adverse ditch conditions or supporting blocks. If sand or rock-free backfill is not available or economical, a rock shield or protective material should be used. The rock shield shall completely encircle and be securely fastened to the pipeline.

Metallic valves and fittings used in plastic systems shall also be coated using coatings having the above characteristics.

It is preferred that fittings of irregular shape that are difficult to coat in the field be factory coated where suitable factory-applied coatings are available.

Coatings for Pipe to be Bored. An abrasive resistance overlay must be used on all coated pipe installed by boring, driving, or other similar method. The approved overlays are the Powercrete and Foster tough coat. The corrosion protection coating should be a minimum of 12 mils and the overlay a minimum of 35 mils. If the bore is more than 500 feet long, consideration should be given to the increasing of the abrasive resistance overlay thickness. Pipe coated with an abrasive resistance overlay should not exceed manufacturer's bend radius; it should be used only for straight line applications.

Coatings on Risers. Pipe coating shall extend at least 6 inches above ground on pipe risers.

Above Ground Coatings

Bridge and End-Wall Piping Coating Specifications. Bridge piping and end-walls should be coated to prevent corrosion. The preferred coating for pipelines installed on bridges is fusion bonded epoxy covered with Powercrete, Naprock, 3M 6352 or equals.

Other Above Ground Applications. All piping or pipeline components that are installed above-ground should be coated to prevent corrosion. It is preferred that all coatings be factory-applied if possible. In addition, a field-applied coating may be necessary to ensure that components scratched or nicked during transport to the site or during installation are adequately protected from atmospheric corrosion.

Field Application of Coatings. All uncoated sections of pipe, welded joints, fittings, valves and damaged areas of factory applied coating to be installed underground shall be coated in the field. Approved field coatings should be applied over a properly cleaned and primed surface.

Surface Preparation. The area to be coated should be cleaned until the area is free of dirt, grease, weld slag, and any loose coating. Visible oil and grease spots should be removed by approved safety solvents that do not leave a residue. For example, high pressure steam or detergent and warm water can thin the oil and move it around. An oxygenated cleaning agent or common dish soap will emulsify oil and make it water soluble so that it can be removed by a flood rinse of water.

Weld spatter, slag, sharp edges, burrs and knurls on the pipe surface shall be removed. Grinding or filing may be used. An effort should be made to preserve the established anchor pattern by wire brushing or similarly effective methods.

If pipe surface is sweating, the pipe surface shall be dried, heated and maintained above the dew point (dry) and must be above the minimum application temperature according to the manufacturer's specifications before the coating may be applied.

Field Coatings:

Tapes. Petrolatum tape, 70 mils thick, covered with a polyethylene backing or one of the approved cold-applied tapes, is also allowed. The coating should be applied in accordance with manufacturer's instructions to ensure that the coating is free of voids, wrinkles and entrapped air.

Approved cold-applied tapes should be applied over a dry primer by removing the plastic separator, if used. The method of wrapping may be spiral. Tension on tape while wrapping should be enough to obtain conformability to the surface being coated. A minimum overlap of approximately 1/4 inch should be used. When wrapping a weld, the tape should overlap the pipe coating at least 2" on either side of the weld.

Mastics (Royston Roskote Mastic R-28). Mastics should be used only on the visible areas of fittings or pipe without factory coating; for example, the coating on the top of a valve that has been damaged by excavation.

Mastics should not be used to repair the underbody or non-visible areas of pipelines or pipeline fittings.

Mastic should be applied liberally over a cleaned and primed surface by brush or glove. A generous amount of mastic should be kept on the brush or glove at all times. Mastic should never be brushed thin. Mastic must be allowed to dry completely before backfilling.

Final Preparation. The field-coated piping should not be covered with backfill until the coating has completely set, dried or cured. The field-applied coating must extend over the existing coating and adhere to it, including an allowance for shrinkage where appropriate.

Storage and Handling of Factory-Coated Pipe:

Storage. Factory-coated pipe should be stored clear of the ground surface on three or four padded skids, approximately 12 inches wide, placed on solid ground not more than 20 feet apart. The skids should be approximately level so the weight of the pipe will be equally distributed.

Pipe should be stacked on the skids in pyramid fashion and suitable stops provided to prevent the stack of pipe from avalanching.

Coated pipe should be stacked according to the following table:

Fusion bonded epoxy and Pritec coated pipe shall be shaded from direct ultraviolet light during storage.

Finally, all coated pipe shall be stored out of the way of vehicular traffic at the maximum possible distance from adjacent roadways. Where a sufficient distance from a road cannot be achieved, consideration shall be given to installing physical barriers to prevent damage to the pipe by errant vehicles.

Handling. When transporting coated pipe, sufficient padding must be used at points of support to prevent damage to the coating. The pipe shall be protected from binder chains by padding or by boards placed parallel to the pipe so that the chains cannot touch pipe coating.

Pipe sizes 4 inch and larger should be loaded and unloaded with pipe slings or end hooks operated by a side-boom tractor, crane or hoist. Pipe 2 inch and smaller may be loaded or unloaded by hand. Pipe should never be permitted to roll or fall from the truck or trailer. Care shall be taken to avoid dropping pipe or hitting one joint of pipe with the end of another.

Abandonment of Pipelines and Distribution Facilities. These procedures apply to the abandonment in place of pipelines, mains, services, control lines, vaults or pits, and appurtenances for which there is no further planned use. Prior to any abandonment, pressure gauges must be used to monitor surrounding dwellings to ensure that existing pipelines maintain adequate pressure while depressurizing the proposed abandoned facilities. Also an adequate records search should be perform prior to any abandonment in order to reduce the possibility of outages to non-targeted facilities.

Physical Abandonment of Distribution Mains. If a representative party requests the removal of gas facilities and it has been determined that it is necessary to physically disconnect the lines from the gas distribution system to prevent damages to the gas facilities and/or danger to the excavator, the following steps shall be taken:

(a)

The line shall be physically disconnected from the piping system to eliminate all sources and supply of gas. Where necessary, the open ends shall be sealed with cement or other effective means. In the case of offshore pipelines, filled with water or inert materials; and sealed at the ends.

(b)

The abandoned facility must be purged of gas to prevent the development of a potentially hazardous condition. However, the pipeline need not be purged when the volume of gas is so small that there is no potential hazard.

A "representative party" includes, but is not limited to, the owner of a property, the owner's official representative, the property developer, and state, county or municipal public works departments. In addition:

(a)

Service lines connected to an abandoned main shall be sealed at the customer end of the service.

(b)

If the service line to be abandoned passes through a building foundation wall, a gap shall be cut out outside the wall and the remaining pipe ends sealed.

(c)

Vaults and pits abandoned in place shall be filled with a suitable compacted material.

Physical Termination of Service. Whenever service to a customer is discontinued, one of the following must be complied with:

(a)

The valve that is closed to prevent the flow of gas to the customer must be provided with a locking device or other means designed to prevent the opening of the valve by persons other than those authorized by the City.

(b)

A mechanical device or fitting (such as a blind disc) that will prevent the flow of gas must be installed in the service line or in the meter assembly.

(c)

The customer's piping must be physically disconnected from the gas supply or main and the open pipe ends sealed.

Discontinuance of service to the customer means that a service line is "not currently being used to provide gas service," and it does not mean "temporary closure for some purpose other than termination of service to the customer." Thus, "discontinuance" implies the customer will no longer be provided gas. A brief lapse in gas delivery, as during an outage, would not indicate an intent to "discontinue" service.

Inactive Services. Gas service lines become inactive when:

(a)

The customer has submitted a formal request for service to be terminated to a premise.

(b)

The customer has been be shut off for non-payment of the gas bill.

(c)

The premise has been abandoned. In this case, gas service may or may not be shut off.

Procedure for Verifying Abandoned Pipelines. In the course of operations, it occasionally becomes necessary in the field to verify if a particular facility is abandoned. In these instances a small hole may be cut into a section of the pipe with a hacksaw to make that determination. However, before any action, a thorough records search of the drawings must be performed to verify the facility is shown as an abandoned facility.

Where the pipeline is coated metallic steel, the crew foreman should check the pipeline with a volt meter to determine if the main is still indicating a level of protection as generated by rectifiers in the area, which may indicate that the pipe is not abandoned, before resorting to this procedure. If an adequate protection reading is indicated, then a more thorough investigation should be performed to identify why or if the pipe is still being protected. If the investigation concludes that the pipe is still active, then no further action is necessary. However, if the investigation is inconclusive, then the verification process should continue.

A section of pipe long enough to install a band clamp of adequate size should first be cleaned and properly prepared should the band clamp be needed. To reduce the time necessary to stop a leak if the pipe is still active, the band clamp should be partially installed adjacent to the area after cleaning, but before cutting the pipe. Before cutting on the pipe, all persons in the excavation must have on all personal protective equipment and have taken the necessary precautions required for working in a gaseous atmosphere, i.e., fire proof coverall, respirator, fire extinguisher nearby, static eliminator device, etc. In addition, cutting equipment (hacksaw) should be properly grounded to reduce the possibility of arcing.

Cut the pipeline in the center of the cleaned area with the hacksaw only deep enough to penetrate the pipe wall. If the pipeline is still under continuous pressure, slide the band clamp over the center of the hole and tighten. Take all the appropriate measurements to locate the clamp and record this information on Work Order. However, a band clamp should only be utilized on plastic pipe as temporary measure. The damaged section of pipe should then be replaced utilizing appropriate methods of replacement.

If the pipeline is not under continuous pressure, remove the band clamp for future use. Where an investigation above indicated that an abandoned pipe is still protected by a rectifier, remedial measures shall be taken to disconnect this pipe from the system.

If the maximum allowable operating pressure of the main is greater than 60 PSIG, a weld-over, or clamp of suitable design and pressure rating, must be installed.

However, where conditions indicate that the use of a hacksaw may not be appropriate, a self-tapping tee may be used as an alternative.

Hazardous leaks or other damage creating a hazardous condition must be repaired or otherwise made safe promptly upon discovery. If necessary, immediate temporary measures should be used to protect the property and the public. Any temporary repairs made must be followed up with permanent repairs as soon as feasible.

Whenever it is determined by means such as inspections, failures, leak history, corrosion, substantial changes in cathodic protection requirements, and other unusual operating and maintenance conditions that a segment of pipeline or distribution facility is in unsatisfactory condition, but no immediate hazard exists, the unsatisfactory portion shall be scheduled for replacement or reconditioning within a reasonable length of time. Refer to Corrosion Section for required repair or replacement of facilities damaged by corrosion. If the segment cannot be reconditioned or retired, the maximum allowable operating pressure (MAOP) shall be reduced in accordance with this manual.

Repair of Steel Pipe. A gouge, groove, arc burn, or dent may not be repaired by insert patching or by pounding out. Each gouge, groove, arc burn, or dent that is removed from a length of pipe must be removed by cutting out the damaged portion as a cylinder.

Imperfections or Damages. Each imperfection or damage that impairs the serviceability of a length of pipeline of steel pipe must be repaired or removed. If a repair is made by grinding, the remaining wall thickness must a least be equal to either:

(a)

The minimum thickness required by the tolerances in the specification to which the pipe was manufactured; or

(b)

The nominal wall thickness required for the design pressure of the pipeline.

Dents. Each of the following dents must be removed from steel pipe to be operated at a pressure that produces a hoop stress of 20 percent, or more, of SMYS, unless the dent is repaired by a method that reliable engineering tests and analyses show can permanently restore the serviceability of the pipe:

(a)

A dent that contains a stress concentrator such as a scratch, gouge, groove, or arc burn.

(b)

A dent that affects the longitudinal weld or a circumferential weld.

(c)

In pipe to be operated at a pressure that produces a hoop stress of 40 percent or more of SMYS, a dent that has a depth of:

(1)

More than 1/4 inch in pipe 123/4 inches (324 millimeters) or less in outer diameter; or

(2)

More than 2 percent of the nominal pipe diameter in pipe over 12 3/4 inches.

For the purpose of this section a "dent" is a depression that produces a gross disturbance in the curvature of the pipe wall without reducing the pipe-wall thickness. The depth of a dent is measured as the gap between the lowest point of the dent and a prolongation of the original contour of the pipe.

Repair of Plastic Pipe. Each imperfection or damage that would impair the serviceability of plastic pipe must be repaired by a patching saddle or removed.

Inspection and Testing of Pipeline Repairs. Replacement sections of pipe shall be tested to the pressure required for a new pipeline installed in the same location as required under (Pressure Testing) in the O/M Manual. The pressure test may be made on a pipe section before it is installed in the line. Additionally, this task can be accomplished by pretesting segments or pipe rolls. The pressure test record of the pretested pipe shall be maintained as appropriate and documented on the work order when the segment of pipe is installed.

Protective Coating of Repairs and Replacements. All replacements and repaired areas of steel pipelines, mains and services must be coated and properly protected.

A record(s) of all repair work and pressure test shall be made on the appropriate work order ( all in one form). Records shall be maintained.

All appropriate employees shall be instructed when initially employed and cautioned periodically thereafter as to sources of ignition, theory of combustion explosive limits, hazardous atmospheres and use of fire extinguishers, combustible gas indicators, and other safety equipment.

Prevention of Accidental Ignition:

Sources of Ignition. Before working on any City facility used in transporting natural gas it is of utmost importance that all ignition sources be eliminated. The various sources may be represented by the classifications given below:

(A)

Flames

(1)

Open lights, such as pilot lights, blow torches and various smoking apparatuses (i.e., cigarettes, smoking pipes, cigars, etc.).

(2)

Matches and cigarette lighters.

(3)

Lanterns.

(4)

Fire in boilers; water heaters.

(5)

Burning materials; incinerators.

(B)

Sparks and Arc

(1)

Non-approved flashlights.

(2)

Torch ignitors.

(3)

Sparks from engines, stacks, etc.

(4)

Static electricity.

(5)

Electrical Shorts.

(6)

Lightning.

(7)

Electronic devices: mobile phones, pagers, personal digital assistants (a.k.a. Palm Pilot, Blackberry, Pocket PC), two- way radios.

(8)

Sparks from tools; cutting or welding equipment.

(9)

Solids traveling at high velocity within a pipe.

(C)

Heated Materials

(1)

Glowing metals, cinders and filaments.

(2)

Electric lights.

(D)

Materials that can ignite spontaneously in the presence of a gas-air mixture.

Safety Precautions. All smoking, open flames, or other sources of ignition will be prohibited in or around regulator building or vaults, border stations, large volume metering installations, or other locations where volumes of gas may be vented to the atmosphere or combustible mixtures may be present.

Only after suitable precautions have been taken to determine that combustible mixtures or a hazardous atmosphere are not present will routine maintenance, repairs or construction work begin.

Welding or the use of a cutting torch will not be permitted on piping or piping components containing a combustible mixture of gas and air in the area of work.

In no case shall active gas piping within a building or other enclosed location be opened unless the gas flow is controlled by a valve or other positive means, and all suitable precautions are taken to eliminate hazards from the release of gas.

Accidental Electric Arcing:

(A) Use of Equipment. Where a hazardous atmosphere exist, only approved flashlights, portable flood lights, extension cords and any other electrically powered tool or equipment should be used. Electrical connections and disconnections should be made outside the designated area. Also, internal combustion engines that power trucks, cars, compressors, pumps, generators, and other equipment should not be operated.

(B) Bonding Cables or Grounding Cables on Metallic Pipe. Bonding to provide electrical continuity should be installed across the point of connection during tie-ins or cuts separating metallic pipes which have natural gas present. This bond should be installed prior to cutting and maintained until all reconnections are completed or a gas free environment exists. Bonding cables should be installed in such a manner to assure that they do not become dislodged during construction and that they provide minimal electrical resistance between pipe sections.

(C) Static Electricity on Plastic Pipe. Individuals should ensure proper earth bonding or grounding of all metal parts of equipment and pipe so that hazardous quantities of charge cannot be accumulated where they are available for easy and rapid discharge. All instrumentation and portable equipment should be grounded before introduction into hazardous atmospheres. Where necessary, appropriate clothing and footwear should be worn to prevent charge buildup on personnel.

The potential ignition of gas that can be caused by static electric charges induced on the outside surface of plastic piping should be eliminated during routine cutting operations. Acceptable methods that should be used to provide the necessary grounding include but are not limited to:

(1)

A Static Electricity Eliminator Device, Static Spray or a cloth saturated with soapy water wrapped around the pipe and in contact with wet earth or a ground rod.

(2)

Thoroughly spraying the exposed pipe with compatible electrically conductive liquid or soapy water.

Static electric charges induced on the inside surfaces of plastic piping by gas flow cannot be eliminated by the methods outlined above. Appropriate steps, such as flow control from a location a safe distance from the location of the escaping gas, should be taken to minimize the escape of gas and to protect personnel from the potential hazards. When repairing plastic pipe under pressure that has been broken or damaged, squeeze off points should be located approximately 20 feet upstream of the point of rupture, where practical. Plastic piping shall be grounded as indicated above before installing squeeze off equipment. All squeeze units and metal fittings should also be grounded.

Plastic vents or blow-downs should not be used due to the possibility of internal static electric charge causing ignition of the escaping gas.

Fire Extinguishers. Fire extinguishers shall be selected by type and rating for each area based on the character of fires anticipated, and the construction and occupancy of the individual property/location or hazard to be protected.

Fire extinguishers should be located at construction and maintenance work in such a manner that they will be easily accessible in the event they are needed.

When a hazardous amount of gas is being vented into open air, each potential source of ignition must be removed from the area and a fire extinguisher must be provided. Fire extinguishers should be positioned and manned on the up-wind side of the leak or discharge at a distance that provides protection for the user and adequate coverage for repair personnel.

Warning Signs and Barricades. Warning signs or barricades should be posted, where appropriate, if danger of ignition of escaping gas is present. The area should be cleared except for essential personnel and instruct everyone in the area not to perform any actions that would cause the gas to ignite. Some possible ignition sources are: operating mechanical equipment, electrical switches, open flames, static electricity, cell phones, cameras, pagers or other portable electronic and electrical equipment not approved for hazardous atmospheres.

Working in Confined Spaces:

Hazardous Atmosphere. An oxygen deficient or flammable atmosphere may exit in vaults, pits or excavations due to leakage from components within the space itself, or from seepage (natural gas, other gases, gasoline or other vapors) from outside the space.

The hazards to be guarded against are fires, explosions, and suffocation. Therefore, it is vitally important that employees recognize these situations and exercise care when entering such confined spaces.

Where a hazardous atmosphere exists, all employees working in the confined space shall wear proper respirator equipment designed to be used for the situation at hand, flame retardant clothing and hood, retrieval harness with lifeline, hard hat, gloves and any other personal protective equipment deemed necessary. Persons who have not been properly instructed and fit tested or approved for the respirator in use shall not be allowed in the designated area.

This requirement extends to persons working in an area of a gas leak or a distribution operation where the uncontrolled release of gas has created a hazardous atmosphere.

Life Protective Equipment. In conducting maintenance, repairs or construction work, every reasonable precaution shall be taken to protect employees and the general public. Work in potentially hazardous atmospheres may require the use of life protective equipment such as fire extinguishers, safety harnesses and/or hose masks or other breathing apparatus, flame retardant clothing, hood and glove inserts, ear protection devices, combustible gas detectors, oxygen deficiency indicators, and other such equipment. At least annually, affected employees should be shown what life protective equipment is available locally the procedure for getting it to the job site, and reminded of the circumstances in which it should be used.

The employee in charge of the specific job site is responsible for ensuring that use of life protective equipment is adhered to where applicable. Only persons who have been properly instructed and approved for the respirator in use are allowed to use them.

Where required, the appropriate respirator shall be used for the work place atmosphere at hand.

Self-Contained Breathing Apparatus (SCBA). SCBAs should be used as designated for respiratory protection against atmospheres that may be immediately dangerous to life and health, or for entering an atmosphere where the hazard is unknown. The necessity of this type of respirator will be determined on an individual need basis.

SCBAs are bulky and heavy, making them unsuitable for strenuous work or use in confined areas. The quantity of air supply is limited to the amount in the compressed air cylinder/tank. Therefore, SCBAs cannot be used continuously for extended periods (typically over 30 minutes duration) without replacing the cylinder.

If a SCBA is used in atmospheres immediately dangerous to life and health, at least one additional person shall stand by with suitable rescue equipment. Communications shall be maintained (voice, visual, or signal line) between all individuals present.

Rescue. Should a person become unconscious in a pit, vault or other confined space from suffocation, he should be removed as soon as possible but not before the confined space is vented and made safe for entry by a rescuer or rescue team. As necessary, a combustible gas indicator (CGI) shall be used to check for the presence of gas. Maintaining the safety of the rescuer(s) shall be of upmost importance during the rescue operation. After removal from the confined space, the unconscious employee should be taken immediately to fresh air and given artificial respiration. The condition of the rescuer(s) should also be monitored and addressed as necessary.

A rescuer shall not enter a vault having a manhole entrance to remove a victim without a safety harness. There should also be at least one other person above-ground to assist in raising both the victim and the rescuer through the opening. The victim should be left in the vault until a safe way to rescue him is available. This is the surest way to save the lives of both the victim and the rescuer.

If an employee is overcome by gas in a sidewalk pit with full opening cover, a rescuer may not enter the pit without first making sure it is safe for entry by using a CGI. After verifying that an explosive atmosphere does not exist and that the level of oxygen is sufficient, the rescuer may enter the pit. A safety harness and stand-by employee is desirable, but not required.

Inspection of Station. Each pressure limiting station, relief device (except rupture discs), and pressure regulating station and its equipment must be subjected at intervals not exceeding 15 months, but at least once each calendar year, to inspections and tests to determine that it is:

(a)

In good mechanical condition;

(b)

Adequate from the standpoint of capacity and reliability of operation for the service in which it is employed;

(c)

Set to function at the correct pressure; and,

(d)

Properly installed and protected from dirt, liquids, or other conditions that might prevent proper operation.

Testing of Relief Devices. If feasible, pressure relief devices must be tested in place, at intervals not exceeding 15 months, but at least once each calendar year, to determine that they have enough capacity to limit the pressure on the facilities to which they are connected to the desired maximum pressure.

If a test is not feasible, review and calculation of the required capacity of the relieving device at each station must be made at intervals not exceeding 15 months, but at least once each calendar year, and these required capacities compared with the rated or experimentally determined relieving capacity of the device for the operating conditions under which it operates. After the initial calculations, subsequent calculations are not required if the review documents that parameters have not changed in a manner which would cause the capacity to be less than required.

If the relieving device is of insufficient capacity, a new or additional device must be installed to provide the additional capacity required.

Annual Inspection:

Inspection of Pressure Limiting or Regulating Stations not Equipped with Service Type Regulators.

(a)

Station equipment will be inspected for leaks, particularly when gas was found in a vault or regulator house, and after performing maintenance. All leaks found will be repaired.

(b)

Each station will be reviewed from the standpoint of capacity, reliability, proper installation, correct pressure settings, and protection from dirt, water, or other conditions that might prevent proper operation.

(c)

When necessary, pressure regulating, monitoring, and relief valve equipment shall be overhauled, strainers, pilot filters, orifices, etc., cleaned, and all unserviceable parts replaced.

(d)

An examination will be made to determine that the regulating equipment is operating properly and maintaining satisfactory pressure control. If there is evidence of unsatisfactory operation of balanced valve or other large regulators, or operating experience makes it advisable, the internal parts exposed to the flowing gas stream should be inspected for wear or deterioration. Mechanical linkage by which the main valve is actuated should be examined.

(e)

Pressure recorders will be tested for accuracy using a pretested gauge and adjusted if necessary. Where pressures are not continuously recorded, a pressure recorder or gauge should be installed temporarily, when considered advisable, to determine that satisfactory pressures are being maintained.

(f)

Each relief valve should be tested for correct pressure setting by applying gas pressure to the test connection.

(g)

Each monitor regulator should be tested for proper operation and correct pressure setting by allowing it to take over the pressure control.

(h)

Each standby regulator in parallel installations should be tested for proper operation by allowing it to supply the gas load.

(i)

Valves should be inspected for proper operation and greased or packed as required.

(j)

Regulator pits, vaults, and houses shall be inspected for good physical condition. Vault covers should be installed so that they will not present a hazard to public safety. Vaults having an internal volume of 200 cubic feet or more must be inspected to insure that the required ventilation equipment is adequate and functioning properly.

(k)

Where necessary, station equipment will be cleaned of rust or corrosion and repainted.

(l)

Relief valve isolation valves and, if applicable, control line valves on the relief will be locked open and bypass valves locked closed upon completion of the inspection.

(m)

Inspect station for appropriate markers where necessary. Pipeline markers may be used to identify City facilities in addition to or instead of stickers.

Telemetering, Recording Gauges and/or Pressure Charts. Telemetering, recording gauges, and pressure charts will be monitored regularly. If there are indications of abnormally high or low pressure, the regulator and the auxiliary equipment must be inspected and the necessary measures employed to correct any unsatisfactory operating conditions.

Appropriate records should be kept to indicate that pressure limiting and regulating stations are inspected and relief capacities maintained accordingly.