UTILITY SPECIFICATIONS

UTILITY SPECIFICATIONS
STATE OF TENNESSEE
DEPARTMENT OF TRANSPORTATION
UTILITY SPECIFICATIONS
FOR THE CONSTRUCTION OF
Contract No. CNM080
BEDFORD COUNTY
Project No. 02950-3566-04
The grading, drainage, and paving on a S.I.A. route serving Newell Rubbermaid Corporation
in Shelbyville.
Project Length - 0.840 mile
1
ATMOS ENERGY CORPORATION
KENTUCKY - MID STATES DIVISION
810 CRESCENT CENTRE DRIVE
SUITE 600
FRANKLIN, TENNESSEE 37067
SPECIFICATIONS for CONTRACTORS
PREPARED BY:
ATMOS ENERGY CORPORATION
TECHNICAL SERVICES DEPARTMENT
JULY, 2011
(615) 771-8311
FAX (615) 771-8302
i
TABLE OF CONTENTS
SPECIFICATIONS for CONTRACTORS
PART ONE: OPERATOR QUALIFICATIONS
PART TWO: GENERAL CONSTRUCTION PROCEDURES
PART THREE: WELDING PROCEDURES
PART FOUR: MATERIAL SPECIFICATIONS
ii
APPENDIX A
Covered Task Qualification Matrix
Initial Release Date: February 16, 2009
Appendix A - “Covered Task Qualification Matrix” was initially published to reference
accepted qualification methods to each Covered Task identified by Atmos Energy
(“matrix”). This matrix is now available at ISNetworld (“ISN”) and any changes made to
this matrix by Atmos Energy will be communicated to Contractors by ISN. Visit
www.isnetworld.com for the latest Covered Task Qualification Matrix.
The accepted qualification programs or methods referenced in ISN are subject to
change without notice to Atmos Energy. If a Contractor becomes aware of a change in
any of these qualification programs which may impact the qualification of any of its
personnel to perform any of the Covered Tasks, that Contractor shall promptly notify
Atmos Energy of that change.
Contractors using qualification programs other than those listed in the matrix must have
those programs approved by Atmos Energy prior to performing a Covered Task on
Atmos Energy facilities.
Contractor and its employees shall reference any manuals provided by Atmos Energy for
further information that may be required before performing a Covered Task.
IMPORTANT NOTICE
ALL PERSONNEL QUALIFIED UNDER THE OPERATOR QUALIFICATION PLAN MUST AT A MINIMUM BE
QUALIFIED UNDER TASKS M 16 AND M 8 IN ADDITION TO OTHER TASKS AS REQUIRED BY THE
SPECIFIC JOB REQUIREMENTS.
Task M 16
Task M 8
Recognize and React to Abnormal Operating Conditions (AOC)
Preventing Accidental Ignition
APPENDIX B
Abnormal Operating Conditions
REACTION LEVEL TO ABNORMAL OPERATING CONDITIONS
LEVEL 1
LEVEL 2
1. Call 911 for any Abnormal Operating
Condition that represents an existing
or probable hazard to persons or
property.
2. Immediately remove all persons
(including members of the public) to a
safe distance upwind from the
location of the Abnormal Operating
Condition, and eliminate any potential
ignition sources.
3. Call Atmos Energy at 1-866-322-8667
with the following information:
• State you have a Level 1 condition
• State location and details of the
condition
LEVEL 3
1. Call Atmos Energy at 1-866-322-8667
with the following information:
1. Immediately notify the Atmos
Energy Representative
responsible for the assigned
work activity.
• State you have a Level 2 condition
• State location and details of the
condition
2. Call 911 as directed by Atmos Energy or
should conditions represent a hazard to
persons or property.
2. Continue to monitor the situation
if conditions warrant, elevate
level as appropriate.
3. Continue to monitor the situation if
conditions warrant elevate to Level 1.
ABNORMAL OPERATING CONDITIONS
Covered
Task
Task Title
Abnormal Operating Conditions
(General)
Unplanned
pipeline
M-16
Recognize and React to
Abnormal Operating Conditions
NOTE
Abnormal Operating Conditions
identified in Covered Task M-16
may also apply to many of the
other Covered Tasks further
contained in this Appendix B.
Initial Release Date: February 16, 2009
Escape
of
product
from
Reaction Level
a
1
Fire or Explosion
1
Unexplained / Unplanned pressure deviation
(increase, decrease, high, low, absent)
2
Unexplained / Unplanned flow rate deviation
(high flow, low flow, no flow)
2
Pipeline damage ( line hit, lightning strikes,
tornado, flood, earthquake, etc)
2
Activation of a safety device (pressure relief,
emergency shut down, high pressure shut
downs, case pressure shut downs, high
temperature shutdowns, etc)
2
Unexplained / Unplanned status change
(unit start-up, unit shut-down, valve open, valve
close, etc., without being directed to do so)
3
Communications, control system or power
interruption or failure
3
Inadequate Odorization or reports of gas odor
3
1 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
E-1
E-2
E-3
E-4
Task Title
F-1
F-2
F-3
F-4
F-5
3
E-1 Welding in a Fixed Position
using Manual Metal Arc Weld
Arc Burns
3
E-2 Welding Branch
Connections using Manual
Metal Arc Weld
Weather conditions
3
Welding surface oily or contaminated
3
Welding undercutting
3
Stringer bead evaluation
3
Welding under high voltage electrical power
line
3
Invasion Tubing
3
Contamination by Test Medium
3
Defective welds and flaws in welds
3
Defect on pipe surface
3
F-1 Joining of Polyethylene Pipe
with Electrofusion (Coupling
Fusion)
Insufficient Power
3
Surface Contamination
3
F-2 Joining of Polyethylene Pipe
with Electrofusion (Saddle
Fusion)
Pipe ends out of alignment
3
Unexpected weather conditions
3
Defect on electrofusion
3
Defect on pipe surfaces
Incomplete face off (F-3)
Improper pipe preparation (F-4, F-5)
Improper alignment
Excessive Melt and/or Excessive Pressure
Incomplete roll back
Different pipe densities (F-3)
Unexpected weather conditions
Contaminates present (F-4, F-5)
Improper heater plate temperature
3
3
3
3
3
3
3
3
3
3
E-3 Welding Metal using OxyAcetylene in the Fixed Position
Perform non-destructive Test on
Steel Welds
F-3 Joining of Polyethylene
Pipe with Heat Fusion (Butt
Fusion)
F-4 Joining of Polyethylene
Pipe with Heat Fusion (Sidewall)
F-5 Joining of Polyethylene
Pipe with Heat Fusion (Socket)
Defect on pipe surface
F-6
F-7
Reaction Level
Pitted Pipe Surface
E-4 Welding Metal using OxyAcetylene on Steel Branch
connections
E-5
Abnormal Operating Conditions
(Task Specific)
F-6 Joining of Polyethylene Pipe
with mechanical coupling 1/2”
CTS through 1” IPS
Surface contamination
F-7 Joining of Polyethylene Pipe
with mechanical coupling 1 ¼”
and 2” IPS
Angled cut pipe / pipe preparation
3
3
Leaking Fitting
SDR on pipe and fitting not compatible
Stiffener improperly sized or installed
Initial Release Date: February 16, 2009
3
2 of 8
3
3
3
APPENDIX B
Abnormal Operating Conditions
Covered
Task
F-8
F-9
Task Title
F08 Joining of Polyethylene
Pipe with Mechanical Tapping
Tee (1 ¼” and above)
F-9 Joining of Polyethylene Pipe
with Mechanical Coupling (Bolt
Style)
F-8 & F9
F-10
F-11
F-12
G-1
G-2
G-3
Joining of Polyethylene Pipe
with Compression type coupling
Repairing Non PE Plastic Pipe
Joining Dissimilar Pipe Types
Repairing Steel Pipe Distribution
Installing of Underground
Casing
Installation / Excavation of
Pipeline
Initial Release Date: February 16, 2009
Abnormal Operating Conditions
(Task Specific)
Reaction Level
Defect on pipe surface
3
Surface contaminated
3
Leaking fitting
3
Improperly sized stiffener
3
Improper alignment
3
SDR on Pipe and fitting not compatible
3
Defect on pipe surface
3
Surface contamination
3
Leaking Fitting
3
Improperly sized stiffener
3
SDR on pipe and fitting not compatible
3
Improper alignment
3
Defect on pipe surface
3
Surface contaminated
3
Leaking fitting
3
Improperly sized stiffener
3
Improper alignment
3
Hazardous situation
2
Irregular shaped pipe
3
Non Standard pipe (off-size)
3
Hazardous situation
2
Extremely deteriorated pipe
3
Possible ignition sources
3
Unexpected pipe type, pipe size, or pressure
3
Unexpected elevation change from one side of
bore to the other prior to casing installation.
3
Found casing shorted during installation.
3
Found damage on carrier pipe
3
Indications of a presence of non-located Buried
Facilities
3
Damage to third party facilities
3
Shifting or unstable soil which may allow
pipeline(s) to become unsupported
3
Damaged Coating
3
Aboveground facility exposed to vehicular
traffic
3
3 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
H-1
H-2
H-3
H-4
I-1
Task Title
Installing / Replacing Meters
Abnormal Operating Conditions
(Task Specific)
Reaction Level
Regulator venting gas
3
No regulator installed on service line (above
utilization pressure)
3
Operating above or below proper pressure
3
No relief valve on excess pressure setting
3
Regulator vent in wrong position
3
Meter not level
3
Meter in hazardous location
3
Meter in contact with inlet or outlet riser or
ground surface
3
Inlet pressure of regulator is higher or lower
than expected
3
Regulator venting gas
3
Operating above or below proper pressure
3
Regulator vent in wrong position
3
Regulator installation conflicts with building
code
3
Regulator in contact with meter
3
Inlet pressure is higher or lower than expected
3
Improper pipe size
3
Blowing gas (Uncontrolled Release of Gas)
1
Damaged Pipe or pipe coating
3
Fitting defect
3
Failed pressure test
3
Blowing Gas (Uncontrolled Release of Gas)
1
Damaged Pipe or pipe coating
3
Fitting defect
3
Failed pressure test
3
Improper voltage reading
3
No reading
3
Shorts to foreign structures
3
External corrosion on exposed pipe
3
Installing / Replacing Regulators
Installing / Replacing Service
Lines
Installing / Replacing Service
Valves
Conduct Pipe to Soil
Measurements
Initial Release Date: February 16, 2009
4 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
I-2
I-3
Task Title
Monitoring Rectifiers
Monitoring Interference Bonds
I-4
Installing/Repairing Impressed
Current Systems or Interference
Bonds
I-5
Installing/Replacing CP Test
Leads to Pipe
I-6
Installing Anodes and Insulating
Devices
I-7
I-8
I-9
I-10
Inspecting, Installing and
Repairing Pipe Coating
Install, Inspect and Test
Electrical Isolation Devices
Internal Corrosion Control
Atmospheric Corrosion
Abnormal Operating Conditions
(Task Specific)
No voltage present
3
No amperage present
3
Improper voltage / amperage present
3
Voltage not present
3
Bond broken
3
Improper reading
3
Damage to device(s)
3
Improper operations
3
Pitted pipe wall
3
Shorted Insulating Device
3
Abnormal anode voltage output
3
External Corrosion
3
Internal Corrosion
3
External Corrosion
3
Improper meter installation
3
Shorted to foreign pipelines / structures
3
Interference currents
3
Internal Moisture and or Bacteria
3
Improper location of Company facilities
3
Hot tap fitting not designed for
operating pressure
L-1
L-2
L-3
Tapping Steel Pipelines under
Pressure
Activating and Purging /
Blowdown Pipelines
pipeline
3
Coupon recovery
3
Pressure above MAOP
3
Wall thickness not compatible with tapping unit
3
Improper pipe surface
3
Ignition
1
Sudden decrease in flow rate
3
Moisture or other contaminants
3
Presence of H2S
2
Improper odorant level
3
Leakage of odorant
3
No gas pressure, off at test point
3
Operating pressure out of range
3
Perform Odorization Test
Initial Release Date: February 16, 2009
Reaction Level
5 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
L-4
M-1
M-2
M-3
M-4
M-5
Task Title
Tapping Pipelines under
Pressure with Self-tapping Tee
Surveying Leaks
Conducting Pipeline Patrolling
Surveys
Locating and Marking Lines
Testing Service Lines (New and
Reinstating)
Abnormal Operating Conditions
(Task Specific)
Pressure above MAOP
3
Improper pipe surface
3
Coupon recovery
3
Pipe and fitting not compatible
3
Leaking fitting
3
Structure built over gas line
3
Abnormal stress on pipeline
3
Exposed plastic pipe
3
Unexpected weather conditions
3
Unauthorized taps or vandalism to pipeline
3
Structure built over or in direct vicinity of gas
line
3
Abnormal stress on pipeline
3
Unauthorized taps or vandalism to pipeline
3
Exposed plastic pipe
3
Contacts to foreign structures
3
Shorted casing
3
Indication of potential leak
3
Above ground transmission line exposed to
vehicular traffic without protection
3
Pipeline markers that are improperly located
3
When required, pipeline markers are missing
3
Damaged, improper or unreadable markers
3
When service line tests indicate leakage
3
When leaks are located
3
Pipe surface condition
3
Pressure test not within parameters
3
Leaks on connection
3
Improper recording of pressure and test period
3
Improper surface conditions.
3
Testing Mains and Transmission
Lines
Initial Release Date: February 16, 2009
Reaction Level
6 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
M-6
Task Title
Inspecting, Testing Pressure
Limiting, Telemetering
Recording Gauges and Relief
Control Devices
Abnormal Operating Conditions
(Task Specific)
Reaction Level
Regulator will not lock-up per manufacturer
specifications
3
Internal Relief Regulator does not relieve at
appropriate level
3
Caps missing
3
Regulator not operating properly
3
Abnormal pressures
established MAOP
M-7
M-8
M-9
Performing Valve Inspection
and Maintenance
or
pressures
above
3
Verified telemetry signal if appropriate
3
Stuck Valve
3
Broken Valve Stem
3
Leaking
3
Uncontrolled escaping natural gas
1
Sources of ignition
3
Gas Leak
3
Surface Conditions
3
MAOP Factors
3
Preventing Accidental Ignition
Making Permanent Repairs on
Transmission Lines
M-10
Inspect, Repair, Tap and Protect
Cast Iron Pipe
Gas Leak or presence of cracks in cast iron
3
M-11
Abandoning/Deactivating or
Shutting Down Gas Pipelines
Discover illegal tap
3
Indications of abnormal pressure
3
M-12
Monitor and Regulate the flow
and pressure of gas from
remote locations
Loss of telemetry signal
3
Loss of power
3
Unplanned Outage
3
Access to Gas Facilities is denied
3
Indications of a Presence of non-located Buried
Facilities
3
Damage to Buried Facilities
3
M-13
M-14
Emergency Response
Damage Prevention during
Excavation or Encroachment
Initial Release Date: February 16, 2009
7 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
M-15
M-17
M-18
M-19
M-20
O-1
O-2
O-3
Task Title
Abnormal Operating Conditions
(Task Specific)
Reaction Level
No gas pressure, where expected
3
Gas venting where no gas lines exists
3
Pipeline markers that are improperly located
3
When required, pipeline markers are missing
3
Damaged, improper or unreadable markers
3
Hazardous atmosphere within the vault
3
Operational failure of any existing ventilation
equipment
3
Failure of the vault covers to the point where
they are a potential hazard
3
Changes in pressure
operating limits
normal
3
Emergency Shutdown Device (ESD) system
fails to properly operate during testing
3
Unintended operation of
Shutdown Device (ESD)
3
Leak Classification
Installing / Maintaining Pipeline
Markers
Inspect Vault Conditions
Inspect & Test Relief Devices at
Compressor Stations
Operating Within Established
MAOP
Conducting Indirect Inspections
External Pipe Inspection for
Anomalies
Internal Corrosion Inspection
(Non-destructive)
Initial Release Date: February 16, 2009
outside
an
of
Emergency
Visual damage to above ground facility
3
Inoperable valve
3
Cannot access pipe to be evaluated
3
Cannot locate pipe to be assessed
3
Unexpected barriers
3
Cannot directly observe pipe surface
3
Cannot determine geometry of anomalies
3
Unexpected barriers
3
Potential safety condition observed (i.e. pit
depth 70% of wall)
3
Cannot access pipe surface
3
Cannot access internal pipe condition
3
Unexpected barriers
3
Potential safety condition observed
3
8 of 8
APPENDIX B
Abnormal Operating Conditions
REACTION LEVEL TO ABNORMAL OPERATING CONDITIONS
LEVEL 1
LEVEL 2
1. Call 911 for any Abnormal Operating
Condition that represents an existing
or probable hazard to persons or
property.
2. Immediately remove all persons
(including members of the public) to a
safe distance upwind from the
location of the Abnormal Operating
Condition, and eliminate any potential
ignition sources.
3. Call Atmos Energy at 1-866-322-8667
with the following information:
• State you have a Level 1 condition
• State location and details of the
condition
LEVEL 3
1. Call Atmos Energy at 1-866-322-8667
with the following information:
1. Immediately notify the Atmos
Energy Representative
responsible for the assigned
work activity.
• State you have a Level 2 condition
• State location and details of the
condition
2. Call 911 as directed by Atmos Energy or
should conditions represent a hazard to
persons or property.
2. Continue to monitor the situation
if conditions warrant, elevate
level as appropriate.
3. Continue to monitor the situation if
conditions warrant elevate to Level 1.
ABNORMAL OPERATING CONDITIONS
Covered
Task
Task Title
Abnormal Operating Conditions
(General)
Unplanned
pipeline
M-16
Recognize and React to
Abnormal Operating Conditions
NOTE
Abnormal Operating Conditions
identified in Covered Task M-16
may also apply to many of the
other Covered Tasks further
contained in this Appendix B.
Initial Release Date: February 16, 2009
Escape
of
product
from
Reaction Level
a
1
Fire or Explosion
1
Unexplained / Unplanned pressure deviation
(increase, decrease, high, low, absent)
2
Unexplained / Unplanned flow rate deviation
(high flow, low flow, no flow)
2
Pipeline damage ( line hit, lightning strikes,
tornado, flood, earthquake, etc)
2
Activation of a safety device (pressure relief,
emergency shut down, high pressure shut
downs, case pressure shut downs, high
temperature shutdowns, etc)
2
Unexplained / Unplanned status change
(unit start-up, unit shut-down, valve open, valve
close, etc., without being directed to do so)
3
Communications, control system or power
interruption or failure
3
Inadequate Odorization or reports of gas odor
3
1 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
E-1
E-2
E-3
E-4
Task Title
F-1
F-2
F-3
F-4
F-5
3
E-1 Welding in a Fixed Position
using Manual Metal Arc Weld
Arc Burns
3
E-2 Welding Branch
Connections using Manual
Metal Arc Weld
Weather conditions
3
Welding surface oily or contaminated
3
Welding undercutting
3
Stringer bead evaluation
3
Welding under high voltage electrical power
line
3
Invasion Tubing
3
Contamination by Test Medium
3
Defective welds and flaws in welds
3
Defect on pipe surface
3
F-1 Joining of Polyethylene Pipe
with Electrofusion (Coupling
Fusion)
Insufficient Power
3
Surface Contamination
3
F-2 Joining of Polyethylene Pipe
with Electrofusion (Saddle
Fusion)
Pipe ends out of alignment
3
Unexpected weather conditions
3
Defect on electrofusion
3
Defect on pipe surfaces
Incomplete face off (F-3)
Improper pipe preparation (F-4, F-5)
Improper alignment
Excessive Melt and/or Excessive Pressure
Incomplete roll back
Different pipe densities (F-3)
Unexpected weather conditions
Contaminates present (F-4, F-5)
Improper heater plate temperature
3
3
3
3
3
3
3
3
3
3
E-3 Welding Metal using OxyAcetylene in the Fixed Position
Perform non-destructive Test on
Steel Welds
F-3 Joining of Polyethylene
Pipe with Heat Fusion (Butt
Fusion)
F-4 Joining of Polyethylene
Pipe with Heat Fusion (Sidewall)
F-5 Joining of Polyethylene
Pipe with Heat Fusion (Socket)
Defect on pipe surface
F-6
F-7
Reaction Level
Pitted Pipe Surface
E-4 Welding Metal using OxyAcetylene on Steel Branch
connections
E-5
Abnormal Operating Conditions
(Task Specific)
F-6 Joining of Polyethylene Pipe
with mechanical coupling 1/2”
CTS through 1” IPS
Surface contamination
F-7 Joining of Polyethylene Pipe
with mechanical coupling 1 ¼”
and 2” IPS
Angled cut pipe / pipe preparation
3
3
Leaking Fitting
SDR on pipe and fitting not compatible
Stiffener improperly sized or installed
Initial Release Date: February 16, 2009
3
2 of 8
3
3
3
APPENDIX B
Abnormal Operating Conditions
Covered
Task
F-8
F-9
Task Title
F08 Joining of Polyethylene
Pipe with Mechanical Tapping
Tee (1 ¼” and above)
F-9 Joining of Polyethylene Pipe
with Mechanical Coupling (Bolt
Style)
F-8 & F9
F-10
F-11
F-12
G-1
G-2
G-3
Joining of Polyethylene Pipe
with Compression type coupling
Repairing Non PE Plastic Pipe
Joining Dissimilar Pipe Types
Repairing Steel Pipe Distribution
Installing of Underground
Casing
Installation / Excavation of
Pipeline
Initial Release Date: February 16, 2009
Abnormal Operating Conditions
(Task Specific)
Reaction Level
Defect on pipe surface
3
Surface contaminated
3
Leaking fitting
3
Improperly sized stiffener
3
Improper alignment
3
SDR on Pipe and fitting not compatible
3
Defect on pipe surface
3
Surface contamination
3
Leaking Fitting
3
Improperly sized stiffener
3
SDR on pipe and fitting not compatible
3
Improper alignment
3
Defect on pipe surface
3
Surface contaminated
3
Leaking fitting
3
Improperly sized stiffener
3
Improper alignment
3
Hazardous situation
2
Irregular shaped pipe
3
Non Standard pipe (off-size)
3
Hazardous situation
2
Extremely deteriorated pipe
3
Possible ignition sources
3
Unexpected pipe type, pipe size, or pressure
3
Unexpected elevation change from one side of
bore to the other prior to casing installation.
3
Found casing shorted during installation.
3
Found damage on carrier pipe
3
Indications of a presence of non-located Buried
Facilities
3
Damage to third party facilities
3
Shifting or unstable soil which may allow
pipeline(s) to become unsupported
3
Damaged Coating
3
Aboveground facility exposed to vehicular
traffic
3
3 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
H-1
H-2
H-3
H-4
I-1
Task Title
Installing / Replacing Meters
Abnormal Operating Conditions
(Task Specific)
Reaction Level
Regulator venting gas
3
No regulator installed on service line (above
utilization pressure)
3
Operating above or below proper pressure
3
No relief valve on excess pressure setting
3
Regulator vent in wrong position
3
Meter not level
3
Meter in hazardous location
3
Meter in contact with inlet or outlet riser or
ground surface
3
Inlet pressure of regulator is higher or lower
than expected
3
Regulator venting gas
3
Operating above or below proper pressure
3
Regulator vent in wrong position
3
Regulator installation conflicts with building
code
3
Regulator in contact with meter
3
Inlet pressure is higher or lower than expected
3
Improper pipe size
3
Blowing gas (Uncontrolled Release of Gas)
1
Damaged Pipe or pipe coating
3
Fitting defect
3
Failed pressure test
3
Blowing Gas (Uncontrolled Release of Gas)
1
Damaged Pipe or pipe coating
3
Fitting defect
3
Failed pressure test
3
Improper voltage reading
3
No reading
3
Shorts to foreign structures
3
External corrosion on exposed pipe
3
Installing / Replacing Regulators
Installing / Replacing Service
Lines
Installing / Replacing Service
Valves
Conduct Pipe to Soil
Measurements
Initial Release Date: February 16, 2009
4 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
I-2
I-3
Task Title
Monitoring Rectifiers
Monitoring Interference Bonds
I-4
Installing/Repairing Impressed
Current Systems or Interference
Bonds
I-5
Installing/Replacing CP Test
Leads to Pipe
I-6
Installing Anodes and Insulating
Devices
I-7
I-8
I-9
I-10
Inspecting, Installing and
Repairing Pipe Coating
Install, Inspect and Test
Electrical Isolation Devices
Internal Corrosion Control
Atmospheric Corrosion
Abnormal Operating Conditions
(Task Specific)
No voltage present
3
No amperage present
3
Improper voltage / amperage present
3
Voltage not present
3
Bond broken
3
Improper reading
3
Damage to device(s)
3
Improper operations
3
Pitted pipe wall
3
Shorted Insulating Device
3
Abnormal anode voltage output
3
External Corrosion
3
Internal Corrosion
3
External Corrosion
3
Improper meter installation
3
Shorted to foreign pipelines / structures
3
Interference currents
3
Internal Moisture and or Bacteria
3
Improper location of Company facilities
3
Hot tap fitting not designed for
operating pressure
L-1
L-2
L-3
Tapping Steel Pipelines under
Pressure
Activating and Purging /
Blowdown Pipelines
pipeline
3
Coupon recovery
3
Pressure above MAOP
3
Wall thickness not compatible with tapping unit
3
Improper pipe surface
3
Ignition
1
Sudden decrease in flow rate
3
Moisture or other contaminants
3
Presence of H2S
2
Improper odorant level
3
Leakage of odorant
3
No gas pressure, off at test point
3
Operating pressure out of range
3
Perform Odorization Test
Initial Release Date: February 16, 2009
Reaction Level
5 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
L-4
M-1
M-2
M-3
M-4
M-5
Task Title
Tapping Pipelines under
Pressure with Self-tapping Tee
Surveying Leaks
Conducting Pipeline Patrolling
Surveys
Locating and Marking Lines
Testing Service Lines (New and
Reinstating)
Abnormal Operating Conditions
(Task Specific)
Pressure above MAOP
3
Improper pipe surface
3
Coupon recovery
3
Pipe and fitting not compatible
3
Leaking fitting
3
Structure built over gas line
3
Abnormal stress on pipeline
3
Exposed plastic pipe
3
Unexpected weather conditions
3
Unauthorized taps or vandalism to pipeline
3
Structure built over or in direct vicinity of gas
line
3
Abnormal stress on pipeline
3
Unauthorized taps or vandalism to pipeline
3
Exposed plastic pipe
3
Contacts to foreign structures
3
Shorted casing
3
Indication of potential leak
3
Above ground transmission line exposed to
vehicular traffic without protection
3
Pipeline markers that are improperly located
3
When required, pipeline markers are missing
3
Damaged, improper or unreadable markers
3
When service line tests indicate leakage
3
When leaks are located
3
Pipe surface condition
3
Pressure test not within parameters
3
Leaks on connection
3
Improper recording of pressure and test period
3
Improper surface conditions.
3
Testing Mains and Transmission
Lines
Initial Release Date: February 16, 2009
Reaction Level
6 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
M-6
Task Title
Inspecting, Testing Pressure
Limiting, Telemetering
Recording Gauges and Relief
Control Devices
Abnormal Operating Conditions
(Task Specific)
Reaction Level
Regulator will not lock-up per manufacturer
specifications
3
Internal Relief Regulator does not relieve at
appropriate level
3
Caps missing
3
Regulator not operating properly
3
Abnormal pressures
established MAOP
M-7
M-8
M-9
Performing Valve Inspection
and Maintenance
or
pressures
above
3
Verified telemetry signal if appropriate
3
Stuck Valve
3
Broken Valve Stem
3
Leaking
3
Uncontrolled escaping natural gas
1
Sources of ignition
3
Gas Leak
3
Surface Conditions
3
MAOP Factors
3
Preventing Accidental Ignition
Making Permanent Repairs on
Transmission Lines
M-10
Inspect, Repair, Tap and Protect
Cast Iron Pipe
Gas Leak or presence of cracks in cast iron
3
M-11
Abandoning/Deactivating or
Shutting Down Gas Pipelines
Discover illegal tap
3
Indications of abnormal pressure
3
M-12
Monitor and Regulate the flow
and pressure of gas from
remote locations
Loss of telemetry signal
3
Loss of power
3
Unplanned Outage
3
Access to Gas Facilities is denied
3
Indications of a Presence of non-located Buried
Facilities
3
Damage to Buried Facilities
3
M-13
M-14
Emergency Response
Damage Prevention during
Excavation or Encroachment
Initial Release Date: February 16, 2009
7 of 8
APPENDIX B
Abnormal Operating Conditions
Covered
Task
M-15
M-17
M-18
M-19
M-20
O-1
O-2
O-3
Task Title
Abnormal Operating Conditions
(Task Specific)
Reaction Level
No gas pressure, where expected
3
Gas venting where no gas lines exists
3
Pipeline markers that are improperly located
3
When required, pipeline markers are missing
3
Damaged, improper or unreadable markers
3
Hazardous atmosphere within the vault
3
Operational failure of any existing ventilation
equipment
3
Failure of the vault covers to the point where
they are a potential hazard
3
Changes in pressure
operating limits
normal
3
Emergency Shutdown Device (ESD) system
fails to properly operate during testing
3
Unintended operation of
Shutdown Device (ESD)
3
Leak Classification
Installing / Maintaining Pipeline
Markers
Inspect Vault Conditions
Inspect & Test Relief Devices at
Compressor Stations
Operating Within Established
MAOP
Conducting Indirect Inspections
External Pipe Inspection for
Anomalies
Internal Corrosion Inspection
(Non-destructive)
Initial Release Date: February 16, 2009
outside
an
of
Emergency
Visual damage to above ground facility
3
Inoperable valve
3
Cannot access pipe to be evaluated
3
Cannot locate pipe to be assessed
3
Unexpected barriers
3
Cannot directly observe pipe surface
3
Cannot determine geometry of anomalies
3
Unexpected barriers
3
Potential safety condition observed (i.e. pit
depth 70% of wall)
3
Cannot access pipe surface
3
Cannot access internal pipe condition
3
Unexpected barriers
3
Potential safety condition observed
3
8 of 8
APPENDIX C
Qualification Performance Table
This table identifies the allowance Atmos Energy has established for Covered Tasks performed by
unqualified personnel and any special conditions that may apply to that Covered Task. There are
several Covered Tasks that can “only be performed by a qualified person” and those
qualifications can be obtained from the Assessment Centers approved by Atmos Energy for that
Covered Task.
Covered
Task
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
Span of Control 1:0
Required Qualification
APPROVED ASSESSMENT CENTERS
FOR CERTIFICATION
- CALL FOR VARIOUS LOCATIONS MID-TEX DIVISION
E – 1 Welding in a Fixed Position using
Manual Metal Arc Weld.
E–1
E–2
E–3
E–4
E – 2 Welding Branch Connections
using Manual Metal Arc Weld.
E – 3 Welding Metal using OxyAcetylene in a Fixed Position.
E – 4 Welding Metal using OxyAcetylene on Steel Branch
Connections
192.235,
192.241,
192.245,
Sec 3&6 of
API Std
1104 and
Sec I & III of
49 CFR Part
192
Appendix C
DESERT INDUSTRIAL X-RAY, INC.
P.O. BOX 13988
Odessa, Texas 79768-3988
432-363-0669
NO
HI-TECH TESTING
35 FRJ Drive
P.O. BOX 12568
Longview, Texas 75607
903-753-1412
KXR INSPECTION, INC.
P.O. Box 149
Barker, Texas 77413
281-492-1694
TEXAS QA SERVICES INC.
2305 Doreen Street
Grand Prairie, Texas 75050
972-606-1218
MARCO INSPECTION SERVICES
1900 Industrial Blvd.
Kilgore, Texas 75662
903-984-8656
ACUREN INSPECTION, INC.
405 E. Eastman
Longview, Texas 75601
800-256-5442
E-5
Perform Non-destructive Tests on
Steel Welds
Release Date: February 16, 2009
Span of Control 1:0
192.243
NO
Required Qualification
1 of 10
APPENDIX C
Qualification Performance Table
Covered
Task
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
Span of Control 1:0
Required Qualification
APPROVED ASSESSMENT CENTERS
FOR CERTIFICATION
- CALL FOR VARIOUS LOCATIONS -
MID-TEX DIVISION
F-1
Joining of Polyethylene Pipe with
Electrofusion (Coupling Fusion)
192.281,
192.287,
192.311
NO
COOPER SUPPLY, INC.
2220 Carson, Street
Fort Worth, Texas 76117
817-222-9055
GAJESKE, INC.
2929 Antoine Drive
Houston, Texas 77092
713-688-2728
SECOR
2927 Westhollow Drive
Houston, Texas 77082
1-800-733-2455
EGW
1406 Hutton Drive
Carrollton, Texas 75006
972-446-1655
Span of Control 1:0
Required Qualification
APPROVED ASSESSMENT CENTERS
FOR CERTIFICATION
- CALL FOR VARIOUS LOCATIONS MID-TEX DIVISION
F-2
Joining of Polyethylene Pipe with
Electrofusion (Saddle Fusion)
192.281,
192.287,
192.311
NO
COOPER SUPPLY, INC.
2220 Carson, Street
Fort Worth, Texas 76117
817-222-9055
GAJESKE, INC.
2929 Antoine Drive
Houston, Texas 77092
713-688-2728
SECOR
2927 Westhollow Drive
Houston, Texas 77082
1-800-733-2455
EGW
1406 Hutton Drive
Carrollton, Texas 75006
972-446-1655
Release Date: February 16, 2009
2 of 10
APPENDIX C
Qualification Performance Table
Covered
Task
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
Span of Control 1:0
Required Qualification
APPROVED ASSESSMENT CENTERS
FOR CERTIFICATION
- CALL FOR VARIOUS LOCATIONS MID-TEX DIVISION
F-3
Joining of Polyethylene Pipe with Heat
Fusion (Butt Fusion)
192.281,
192.287,
192.311
NO
COOPER SUPPLY, INC.
2220 Carson, Street
Fort Worth, Texas 76117
817-222-9055
GAJESKE, INC.
2929 Antoine Drive
Houston, Texas 77092
713-688-2728
SECOR
2927 Westhollow Drive
Houston, Texas 77082
1-800-733-2455
EGW
1406 Hutton Drive
Carrollton, Texas 75006
972-446-1655
Span of Control 1:0
Required Qualification
APPROVED ASSESSMENT CENTERS
FOR CERTIFICATION
- CALL FOR VARIOUS LOCATIONS MID-TEX DIVISION
F-4
Joining of Polyethylene Pipe with Heat
Fusion (Sidewall Fusion)
192.281,
192.287,
192.311
NO
COOPER SUPPLY, INC.
2220 Carson, Street
Fort Worth, Texas 76117
817-222-9055
GAJESKE, INC.
2929 Antoine Drive
Houston, Texas 77092
713-688-2728
SECOR
2927 Westhollow Drive
Houston, Texas 77082
1-800-733-2455
EGW
1406 Hutton Drive
Carrollton, Texas 75006
972-446-1655
Release Date: February 16, 2009
3 of 10
APPENDIX C
Qualification Performance Table
Covered
Task
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
Span of Control 1:0
Required Qualification
APPROVED ASSESSMENT CENTERS
FOR CERTIFICATION
- CALL FOR VARIOUS LOCATIONS MID-TEX DIVISION
F-5
Joining of Polyethylene Pipe with Heat
Fusion (Socket)
192.281,
192.287,
192.311
NO
COOPER SUPPLY, INC.
2220 Carson, Street
Fort Worth, Texas 76117
817-222-9055
GAJESKE, INC.
2929 Antoine Drive
Houston, Texas 77092
713-688-2728
SECOR
2927 Westhollow Drive
Houston, Texas 77082
1-800-733-2455
EGW
1406 Hutton Drive
Carrollton, Texas 75006
972-446-1655
F-6
Joining of Polyethylene Pipe with
Mechanical Coupling (1/2” CTS
through 1” IPS)
192.281,
192.287,
192.311
F-7
Joining of Polyethylene Pipe with
Mechanical Coupling (1 ¼” and 2” IPS)
192.281,
192.287,
192.311
F-8
Joining of Polyethylene Pipe with
Mechanical Tapping Tee (1 ¼” and
above)
192.281,
192.287,
192.311
F-9
Joining of Polyethylene Pipe with
Mechanical Coupling (Bolt Style)
192.281,
192.287,
192.311
Release Date: February 16, 2009
4 of 10
Span of Control 1:0
NO
Required Qualification
Span of Control 1:0
NO
Required Qualification
Span of Control 1:0
NO
Required Qualification
Span of Control 1:0
NO
Required Qualification
APPENDIX C
Qualification Performance Table
Covered
Task
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
Span of Control 1:0
F-10
Joining of Polyethylene Pipe with
Compression Type Coupling
192.281,
192.287,
192.311
NO
Required Qualification
Span of Control 1:0
F-11
F-12
G-1
Repairing Non PE Plastic Pipe
Joining Dissimilar Pipe Sizes
Repairing Steel Pipe - Distribution
192.281,
192.287
NO
Required Qualification
APPROVED ASSESSMENT CENTERS
FOR CERTIFICATION
- CALL FOR VARIOUS LOCATIONS –
192.225,
192.309,
192.703,
192.711 –
192.717,
192.725
NO
192.225,
192.309,
192.703,
192.711 –
192.717,
192.725
YES
Span of Control 1:0
Required Qualification
Span of Control 1:3
Installation of Underground Casing
192.307,
192.319,
192.323,
192.325,
192.327
Yes
Span of Control 1:1
G-3
Installation / Excavation of Pipeline
192.317,
192.319,
192.325,
192.327,
192.614,
192.707,
192.725
Yes
Span of Control 1:1
H-1
Installing / Replacing Meters
192.357
Yes
Span of Control 1:3
H-2
Installing / Replacing Regulators
192.357
Yes
Span of Control 1:1
G-2
Release Date: February 16, 2009
5 of 10
APPENDIX C
Qualification Performance Table
Covered
Task
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
Yes
Span of Control 1:3
Yes
Span of Control 1:1
Yes
Span of Control 1:3
Yes
Span of Control 1:1
H-3
Installing / Replacing Service Lines
192.361,
192.365,
192.367
192.369,
192.379
H-4
Installing / Replacing Service Valves
192.365
I-1
Conducting Pipe to Soil Measurements
192.455,
192.457,
192.459,
192.463,
192.465,
192.467,
192.469,
192.471,
192.483,
192.485
192.487,
192.491
I-2
Monitoring Rectifiers
192.455,
192.457,
192.465,
192.491
I-3
Monitoring Interference Bonds
192.465,
192.473,
192.491
Yes
Span of Control 1.1
I-4
Installing / Repairing Impressed
Current Systems or Interference Bonds
192.455,
192.457,
192.465,
192.467,
192.471,
192.473,
192.485,
192.487,
Yes
Span of Control 1:1
I-5
Installing / Replacing CP Test Leads to
Pipe
192.469
192.471
Yes
Span of Control 1:1
Release Date: February 16, 2009
6 of 10
APPENDIX C
Qualification Performance Table
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
Installing Anodes and Insulating
Devices
192.455,
192.457,
192.463,
192.467,
192.491
Yes
Span of Control 1:1
I-7
Inspecting for External Corrosion and
Installing and Repairing Pipe Coating
192.455,
192.459,
192.461,
192.479,
192.491
Yes
Span of Control 1:3
I-8
Installing, Inspecting and Testing
Electrical isolation Devices
192.467,
192.491
Yes
Span of Control 1:1
I-9
Internal Corrosion Control
192.475,
192.477
Yes
Span of Control 1:3
I-10
Atmospheric Corrosion
192.479,
192.481,
192.491
Yes
Span of Control 1:3
L-1
Tapping Steel Pipelines under
Pressure
192.151,
192.627
Yes
Span of Control 1:1
L-2
Activating and Purging / Blowdown
Pipelines
192.605,
192.629
Yes
Span of Control 1:1
L-3
Perform Odorization Test
192.625
Yes
Span of Control 1:1
L-4
Tapping Pipelines under Pressure with
Self Tapping Tee
192.151,
192.627
Yes
Span of Control 1:1
Surveying Leaks
192.5,
192.703,
192.706,
192.709,
192.723
Yes
Span of Control 1:1
Covered
Task
I-6
M-1
Task Title
Release Date: February 16, 2009
7 of 10
APPENDIX C
Qualification Performance Table
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
M-2
Conducting Pipeline Patrolling Surveys
192.5,
192.317,
192.609,
192.611
192.705,
192.707,
192.709,
192.721
Yes
Span of Control 1:1
M-3
Locating and Marking Lines
192.614,
192.707
Yes
Span of Control 1:1
M-4
Testing Service Lines (New and
Reinstating)
192.511,
192.513,
192.517,
192.725
Yes
Span of Control 1:1
M-5
Testing Mains an Transmission Lines
192.503,
192.505,
192.507,
192.509,
192.513,
192.515,
192.517,
192.713
Yes
Span of Control 1:1
M-6
Inspecting and Testing Pressure
Limiting, Telemetering or
Recording Gauges and Relief Valves
192.739,
192.741,
192.743
Yes
Span of Control 1:1
M-7
Performing Valve Inspection and
Maintenance
192.745,
192.747
Yes
Span of Control 1:1
M-8
Preventing Accidental Ignition
192.751
Yes
Span of Control 1:1
M-9
Making Permanent Repairs on
Transmission Lines
192.711,
192.713,
192.715,
192.717
Yes
Span of Control 1:1
M-10
Inspect, Repair, Tap and Protect Cast
iron Pipe
192.489,
192.491,
192.753,
192.755
Yes
Span of Control 1:2
Covered
Task
Release Date: February 16, 2009
8 of 10
APPENDIX C
Qualification Performance Table
Covered
Task
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
M-11
Abandoning / Deactivating or Shutting
Down Gas Facility
192.605,
192.727
Yes
Span of Control 1:3
M-12
Monitor and Regulate the Flow and
Pressures of gas from remote
locations
192.741
Yes
Span of Control 1:1
M-13
Emergency Response
192.605,
192.615
Yes
Span of Control 1:1
M-14
Damage Prevention during Excavation
or Encroachment
192.614
Yes
Span of Control 1:1
M-15
Leak Classification
192.703,
192.723
Yes
Span of Control 1:1
M-16
Recognize and React to Generic
Abnormal Operating Conditions
192.615
NO
Installing / Maintaining Pipeline
Markers
192.707
Yes
Span of Control 1:3
M-18
Inspect Vault Conditions
192.185,
192.187,
192.189,
192.749
Yes
Span of Control 1:3
M-19
Inspect & Test Relief Devices at
Compressor Stations
192.731,
192.739,
192.743
Yes
Span of Control 1:1
M-20
Operating within established MAOP
192.619,
192.621,
192.623
Yes
Span of Control 1:1
M-17
Release Date: February 16, 2009
Span of Control 1:0
Required Qualification
9 of 10
APPENDIX C
Qualification Performance Table
Covered
Task
Task Title
49 CFR 192
Reference
Performed By
Non Qualified
Personnel?
Special Conditions
Yes
Span of Control 1:1
O-1
Conducting Indirect Inspection
192.455,
192.457,
192.459
192.463,
192.465,
192.467,
192.469
192.471,
192.483,
192.485,
192.487
O-2
External Pipe Inspection for Anomalies
192.921,
192.937,
192.939
Yes
Span of Control 1:1
Internal Corrosion Inspection (Nondestructive)
192.455,
192.457,
192.459
192.463,
192.465,
192.467,
192.469
192.471,
192.483,
192.485,
192.487
Yes
Span of Control 1:3
O-3
Release Date: February 16, 2009
10 of 10
APPENDIX D
Communication of Change
EFFECTIVE
DATE
February 16, 2009
PURPOSE OF CHANGE
DOCUMENTS AFFECTED BY CHANGE
Initial release of these provisions to contractors in
the Mid-Tex Division of Atmos Energy. This is the
first release to replace all prior programs.
Contractors are to be in full compliance with
program requirements by June 30, 2009.
Other Atmos Energy Divisions will be brought into
this plan in various stages.
Initial Release Date: February 16, 2009
-1-
These Provisions and supporting Appendices.
OPERATOR
QUALIFICATION PLAN
Table of Content
Revisions to Written Plan ................................................................ i
Introduction ..................................................................................... 1
Purpose ............................................................................................ 1
Procedure ......................................................................................... 1
Definitions ....................................................................................... 2
Covered Tasks ................................................................................. 4
Personnel Evaluation ....................................................................... 12
Use of Non-Qualified Individuals .................................................... 14
Personnel Evaluation Following an Incident.................................... 15
Evaluation of Qualified Personnel Performance .............................. 16
Plan Management ............................................................................ 17
Personnel Re-evaluation .................................................................. 20
Record Keeping ............................................................................... 21
Atmos Energy Corporation
Operator Qualification Plan
Revision
Date
Effective
Date
Document/Sections Updated
15-Sep.-00
OQ Written Plan Developed
22-May- 01
OQ Written Plan Updated
28-Sep-02
OQ Written Plan Definitions Updated
• New definition of work history pg. 2
• Revision made to state work history can not
be used after October28th, 2002
OQ Written Plan - Record Keeping Updated
• Changed Paper Flow pg.13
01-Apr-03
OQ Written Plan - Definitions Updated (page 2)
• Changed verbiage for Abnormal Operating
Conditions
• Added definition for New Construction
• Added definition for Maintenance
• Changed verbiage on Qualified to include
consideration of knowledge, skill and
physical ability
OQ Written Plan - Covered Tasks Updated (page 5
& 7)
• Added Task F11 Repairing Non PE Plastic
Pipe
• Changed Task M7 to include Inspection
• Added Task M13 Emergency Response
• Added Task M14 Excavation Damage
Prevention
• Added Task M15 Leak Classification
OQ Written Plan - Personal Evaluation Updated
(page 9)
• Changed Sec. A verbiage
• Changed Sec. B to include Knowledge and
Ability
• Changed Sec. D Rewritten
OQ Written Plan – Use of Non-Qualified
Individuals Updated (page 10)
• Changed Sec. E verbiage
i
Atmos Energy Corporation
Operator Qualification Plan
Revision
Date
01-Apr-03
11-Sep-03
17-Nov-03
16-Jun-04
Effective
Date
Document/Sections Updated
OQ Written Plan - Personal Evaluation Following
An Incident/Accident Updated (page 11)
• Changed Sec. B Rewritten
• Changed Sec. C Rewritten
• Changed Sec. D Rewritten
• Changed Sec. E Rewritten
OQ Written Plan - Evaluation Of Qualified
Personnel Performance Updated (page 12)
• Changed Sec. A verbiage
• Changed Sec. B verbiage
• Changed Sec. C Rewritten
OQ Written Plan - Changes Impacting Covered
Task Updated (page 13)
• Changed Title to: Plan Management
• Changed Sec. A verbiage
• Changed Sec. B Rewritten
• Changed Sec. C Rewritten
• Changed Sec. D Rewritten
• Changed Sec. E Rewritten
OQ Written Plan - Record Keeping (page 15)
• Changed Sec. C Rewritten
• Changed Sec. D Verbiage
• Changed Sec. E Verbiage
• Added Sec. F Contractor Record Keeping
OQ Written Plan – Covered Task (page 4)
• Added Re-qualification frequency
OQ Written Plan – Personnel Evaluation (page 9)
• Added Sec. C Training for New Employees
• Added Sec. D Testing for all Individuals
OQ Written Plan – Personnel Re-evaluation (page
14)
• Added Note Stating Reason for ReEvaluation frequency
Updates made per DOT Protocol Review
OQ Written Plan – Introduction page 1
Added wording for Contractors and sub-contractors,
included in the Plan they would be provided a copy
of the Plan and are required to comply with all
aspects therein
OQ Written Plan – Purpose page 1
Changed Individual should be re-Qualified to
…Qualified for New/Re-evaluated for current…
ii
Atmos Energy Corporation
Operator Qualification Plan
Revision
Date
16-Jun-04
Effective
Date
Document/Sections Updated
OQ Written Plan – Procedure page 1
Removed the word Accident from Personnel
Evaluation Following an Incident
OQ Written Plan – Definitions page 2
Redefined Abnormal Operating Conditions so that it
matches the definition in 192.803
OQ Written Plan – Definitions page 2
In Initial Qualification definition removed “on a
regular basis”
OQ Written Plan – Definition page 3
Added definition for Mutual Assistance
OQ Written Plan – Definition page 3
Added definition for Pipeline Facility
OQ Written Plan – Definition page 3
Added definition for Span of Control
OQ Written Plan – Definition page 3
In Transitional Qualification definition removed “on a
regular basis”
OQ Written Plan – Definition page 3
Removed definition for Work Performance History
Review and added statement that Atmos Energy
does not consider Work Performance History…
OQ Written Plan – Covered Tasks pages 4 thru 9
Added re-evaluation timeframes and span of control
ratios for each task
OQ Written Plan – Covered Tasks page 7
Changed task name for I7 to Inspecting for External
Corrosion and Repairing Pipe Coating
OQ Written Plan – Covered Tasks page 8
Changed task name for M4 to Testing Service Line
(New and Reinstating)
OQ Written Plan – Personnel Evaluation page 10
Section B – removed the word “physical” before
ability, removed “and to” before recognize and
changed “respond” to react
OQ Written Plan – Personnel Evaluation page 10
Section C – Removed “New employees, employed”
and added “new employees, who currently are not
qualified under Atmos Energy Plan” will be
trained…
Changed the word qualification to evaluation
iii
Atmos Energy Corporation
Operator Qualification Plan
Revision
Date
16-Jun-04
Effective
Date
Document/Sections Updated
OQ Written Plan – Personnel Evaluation page 10
Section F – Removed all words past Abnormal
Operating Conditions.
OQ Written Plan – Use of Non-Qualified
Individuals page 11
Header paragraph changed “directly supervised” to
“directed and observed”
OQ Written Plan – Use of Non-Qualified
Individuals page 11
Section A – added “by a qualified individual” and
changed “supervised” to directed and observed
OQ Written Plan – Use of Non-Qualified
Individuals page 11
Section C – removed “immediate supervision” and
replaced with “direction and observation”
OQ Written Plan – Use of Non-Qualified
Individuals page 11
Added verbiage for span of control
OQ Written Plan – Personnel Evaluation
Following an Incident/Accident page 12
Removed “Accident” from heading
OQ Written Plan – Personnel Evaluation
Following an Incident page 12
Removed “/accident” from all sections
Changed “supervision” to “direction and
observation”
OQ Written Plan – Evaluation of Qualified
Personnel Performance page 13
Section A - removed the word “valid” and removed
“such supervisor…with respect to that Covered
Task.”
Changed “qualified” to “evaluated”
OQ Written Plan – Evaluation of Qualified
Personnel Performance page 13
Section B– added examples for when an individual
may need to be re-qualified.
OQ Written Plan – Evaluation of Qualified
Personnel Performance page 13
Section D – changed “re-Qualified” to “reEvaluated” and “supervision” to “direction and
observation”
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Atmos Energy Corporation
Operator Qualification Plan
Revision
Date
16-Jun-04
26-Aug-04
10-Nov-04
Effective
Date
Document/Sections Updated
OQ Written Plan – Plan Management page 14
Section A – added “for approving plan changes” to
UOC’s responsibility
OQ Written Plan – Plan Management page 14
Section B – added “as required or” to the
Operations Committee shall meet
OQ Written Plan – Plan Management page 14
Section C – changed “Migrate” to “Transfer”
OQ Written Plan – Plan Management page 15
Added Section D – Roles and Responsibilities
OQ Written Plan – Plan Management page 15
Section F – changed to address “Maintaining Plan
Integrity”
OQ Written Plan – Plan Management page 16
Added Plan Changes/Management Flow Chart
OQ Written Plan – Personnel Re-Evaluation page
18
Section A – added “…at intervals not to exceed the
indicated Plan frequencies.”
OQ Written Plan – Record Keeping page 19
Section A – added “…and updating the appropriate
record keeping system” to evaluator’s
responsibilities.
OQ Written Plan – Record Keeping page 19
Section D – deleted “and entered into an approved
Atmos Energy Record Keeping System” from
supervisor’s responsibilities.
OQ Written Plan – Definitions page 2
Added to Abnormal Operating Condition; c) Require
an emergency response.
OQ Written Plan – Personnel Evaluation page 10
Section C; Removed requirement for new
employees and replaced with “Individuals”
OQ Written Plan – Personnel Re-Evaluation page
21
Removed “Note” below section C
OQ Written Plan – Definitions
Revised definition for New Construction
OQ Written Plan – Definitions Add a definition for
Evaluator
OQ Written Plan – Personnel Re-Evaluation
Section C; added “Note” that explains how reevaluation intervals were determined.
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Atmos Energy Corporation
Operator Qualification Plan
Revision
Date
Effective
Date
01-Feb-05
24-Feb-06
02-Jan-07
02-Jan-07
02-Jan-07
02-Jan-07
02-Jan-07
02-Jan-07
02-Jan-07
02-Jan-07
Document/Sections Updated
OQ Written Plan – Introduction section added
“additional documents that may support this plan
are located in Atmos Energy Inner Atmosphere,
docs, “Supervisor/Mgr. Toolbox.”
OQ Written Plan – Personnel Evaluation, page 10,
under section C, changed New Employees to
“Individuals”
OQ Written Plan – Personnel Evaluation, page 10,
added flow chart for evaluation processes to F.
Made the current section F to G
OQ Written Plan – Personnel Evaluation
Following an Incident, page 12, section C –
removed “and as a result of the subsequent
investigation”
OQ Written Plan – Covered Tasks, page 6,
Changed name of Task I-4 to “Installing or
Repairing Corrosion Control Devices”
OQ Written Plan – Covered Tasks, page 9, added
Task M16 – “Recognize and React to Generic
Abnormal Operating Conditions (AOC) with 36
month re-qualification timeline”
OQ Written Plan – Covered Tasks, page 9, added
Task M17 – “Installing/Maintaining Pipeline Markers
with 60 month requalification timeline”
OQ Written Plan – Record Keeping, page 18,
section A added “appropriate Atmos Energy record
keeping and is accessible at local Atmos Energy
Operations.”
OQ Written Plan – Covered Tasks, page 6,
Changed name of Task L-2 to “Activating and
Purging Pipelines”
OQ Written Plan – Covered Tasks, page 9,
Changed name of Task M-11 to
“Abandoning/Deactivating or Shutting Down Gas
Pipelines”
OQ Written Plan – Personnel Evaluation, page 10,
Paragraph D, ‘The time between knowledge
assessment and qualification/re-qualification by
observation or simulation shall not exceed 90
calendar days”
OQ Written Plan – Personnel Evaluation, page 10,
Paragraph F, “Changed waiting period from 10 to 5
working days, in figure”.
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Atmos Energy Corporation
Operator Qualification Plan
Revision
Date
24-Feb-06
Effective
Date
02-Jan-07
02-Jan-07
02-Jan-07
04-May-07
02-Jan-08
02-Jan-08
02-Jan-08
02-Jan-08
02-Jan-08
02-Jan-08
02-Jan-08
12-Nov-07
02-Jan-09
02-Jan-09
Document/Sections Updated
OQ Written Plan – Personnel Evaluation
Following an Incident, page 12, entire section was
revised.
OQ Written Plan – Evaluation of Qualified
Personnel Performance, page 13, Paragraph C,
added “If an Individual is determined non-Qualified,
a knowledge, skills and ability form will be
completed to reflect the date the Individual became
disqualified and the reason for such
disqualification.”
OQ Written Plan - Plan Management, page 15,
paragraph D, section Employees, added
“Employees may submit comments and feedback
on the plan through an appropriate Atmos Energy
e-form for proposed changes or improvements.”
E-form will be housed on the Atmosphere intranet.
OQ Written Plan - Plan Management, pages 14
and 15, Changed Operations Committee to the
Compliance Committee throughout section
OQ Written Plan – Personnel Evaluation
Following an Incident, page 12, Paragraph C add
or who are not part of Merger/acquisition
OQ Written Plan - Plan Management, page 14,
added Director of Regulatory and Compliance
OQ Written Plan - Plan Management, page 15,
Deleted word Manager after Compliance
OQ Written Plan – Introduction, page 1 Changed
paragraph to allow Contractor to have its own OQ
Plan
OQ Written Plan – Definitions, added the definition
of an Incident and Changed Definition of Individual
to clarify that it applies to only those who qualify
under Atmos Energy OQ plan
OQ Written Plan – Covered Tasks, pages 6
through 10, Added Tasks F12, G1, G2, G3, M18,
M19, M20, O1, O2, and O3, Changed task names
for tasks L1, M10, and M14
OQ Written Plan – Personnel Evaluation, page 10,
Paragraph F, “Changed waiting period from 5
working days to 7 days, in figure”.
OQ Written Plan – Definitions, added State
Specific to Incident
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Atmos Energy Corporation
Operator Qualification Plan
Revision
Date
05-Dec-08
Effective
Date
02-Jan-10
02-Jan-10
02-Jan-10
02-Jan-10
02-Jan-10
02-Jan-10
02-Jan-10
Document/Sections Updated
Changed Atmos to Atmos Energy throughout the
entire Plan
OQ Written Plan – Introduction, added that
contractors will be provided a copy of Written Plan
and Contractor Provisions
OQ Written Plan – Definitions, added definition of
Contractor Provisions, and updated definition of
Initial Qualification, and Subsequent Qualification
OQ Written Plan – Covered Tasks, corrected
several Task Titles to match KSA forms and
corrected Span of Control for several Tasks
OQ Written Plan – Personnel Evaluation
Following an Incident, page 15, section C – clarify
requirement for training following an Incident.
OQ Written Plan – Plan Management, page 17,
Section B – added “Develop, review and Maintain
Task training material” to Compliance Committee’s
responsibility
OQ Written Plan – Personnel Re-Evaluation page
20, Section B – added Clarification that training
would be required when significant changes are
made to Covered Tasks and documented on KSA
forms
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Atmos Energy Corporation
Operator Qualification Plan
INTRODUCTION
The Operator Qualification Program of Atmos Energy Corporation sets forth the policies and
procedures for compliance with the pipeline safety regulations defined in 49 CFR Part 192,
Subpart N and CFR Part 195, Subpart G. Specifically, this Program describes the requirements
for evaluating the qualifications of Individuals performing certain operating and maintenance
functions on Atmos Energy natural gas transmission and distribution pipeline system and
facilities. It is the responsibility of Atmos Energy Corporation (“Atmos Energy”) to ensure that
all Individuals working within a Covered Task are Qualified in accordance with this Program.
Records will be maintained indicating that Individuals performing Covered Tasks identified in
this Program have satisfied the requirements and are Qualified as such is described in the
foregoing federal regulations as such may be amended from time to time.
Contractor(s) and sub-contractor(s) (“Contractor”) or any other entities performing Covered
Tasks on behalf of Atmos Energy will be qualified according to this Plan or a plan approved by
Atmos Energy; or be directed and observed by a qualified individual. For Contractors that
qualify according to a plan approved by Atmos Energy, the Contractors will be provided a copy
of this Plan as well as a copy of the Contractor Provision and will be required to comply with all
aspects therein.
The final rule became effective on October 26, 1999. Records indicating compliance of
Individuals performing “Covered Tasks” identified in this Program will be available no later than
thirty-six (36) months from the effective date(s) of the federal regulations described above.
Additional documents that may support this plan are located in Atmos Energy Inner Atmosphere,
Docs, “Supervisor/Mgr Toolbox”. http://atmosphere.atmosenergy.com/docs/index.html?id=3
PURPOSE
The purpose of this program is to describe what procedures will be used to qualify an Individual,
the “Covered Tasks” in the Federal Regulations that meet the four part test, when an Individual
should be Qualified for New/Re-evaluated for current and what records are required.
PROCEDURE
Atmos Energy Corporation’s Operator Qualification Program is designed to achieve compliance
with State and Federal regulations as they pertain to operator qualifications. The Program
consists of the following required components:
Definitions (CFR 192.803)
Covered Tasks (CFR 192.805a)
Personnel Evaluation (CFR 192.805b)
Use of Non-Qualified Personnel (CFR 192.805c)
Personnel Evaluation Following an Incident (CFR 192.805d)
Evaluation of Qualified Personnel Performance (CFR 192.805e)
Plan Management (CFR 192.805f)
Personnel Re-Qualifications (CFR 192.805g)
Record Keeping (CFR 192.807a)
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Atmos Energy Corporation
Operator Qualification Plan
Definitions
Abnormal Operating Condition:
Means a condition identified by the operator that may indicate a malfunction of a component or
deviation from normal operations that may:
a) Indicates a condition exceeding design limits, or
b) Result in a hazard(s) to persons, property or the environment.
New Construction:
New construction is the act of building a pipeline facility, or expanding an existing pipeline
facility to provide new service to a customer(s) in order to meet load requirements. Note: Atmos
Energy requires all individuals to be qualified to perform Covered Task regardless if it is New
Construction or Maintenance.
Contractor Provisions – a document, which provides Contractor(s) with guidelines for
compliance with the Atmos Energy OQ Plan.
Covered Task:
Any activity identified by Atmos Energy that:
1)
Is performed on a pipeline facility;
2)
Is an operations or maintenance task;
3)
Is performed as a requirement of Department of Transportation regulation 192;
and
4)
Affects the operation or integrity of the Atmos Energy pipeline system.
Evaluation:
The process that assesses and documents the Individual’s ability to perform the “Covered Task.”
Evaluator:
A person who conducts and documents a task performance evaluation to determine if the
individual is qualified to perform a given task. Prior to a person being considered to be an
Atmos Energy evaluator they must be trained using the Atmos Energy Evaluator Training
Program.
Incident:
As define in 191.3 or State Specific as required
Individual(s):
Any person who is qualified to perform a Covered Task (s) under this Plan, regardless of
whether he or she is employed by Atmos Energy, a contractor, a sub-contractor. (Includes new
hires.)
Initial Qualification:
An evaluation of an individual not currently qualified to perform the Covered Task.
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Atmos Energy Corporation
Operator Qualification Plan
Definitions (cont).
Maintenance:
Any activity necessary to maintain or restore, replace, or repair existing pipeline facilities to
normal operating conditions. In the event, maintenance or repair work is performed on pieces of
equipment that are intended to be part of the pipeline facility, the Maintenance task(s) should be
performed by Qualified Individuals.
Mutual Assistance:
In the event of an incident that requires additional assistance, Atmos Energy may call upon
outside resource personnel. If this should occur, Atmos Energy will proceed in accordance with
this Plan for “Use of Non-Qualified Individuals”.
Operator:
Atmos Energy Corporation (“Atmos Energy”).
Pipeline Facility:
Means new and existing pipeline, rights-of-way, and any equipment, facility, or building used in
the transportation of gas or in the treatment of gas during the course of transportation.
Qualified Individual:
Any person who has been evaluated and is able to properly perform a Covered Task(s), and is
able to recognize and react to abnormal operating conditions that may be encountered during the
performance of the Covered Task(s). This includes consideration of the three elements needed to
perform the Covered Tasks. These elements are knowledge relative to the Covered Task, the
skill necessary to perform the Covered Task and the physical ability to perform the Covered Task.
Span of Control:
The number of non-qualified individuals if any, that a qualified individual can direct and observe
for a Covered Task. The first digit indicates the number of qualified individual(s) and the second
equals the number of non-qualified individuals. Example: 1:3 means that one qualified
individual can direct and observe three non-qualified individuals.
Subsequent Qualification:
An evaluation of an individual who is currently qualified and evaluation occurs prior to the date
of expiration for the Covered Task. Expiration intervals are determined by Atmos Energy. This
qualification also applies to re-evaluations.
Transitional Qualification:
Qualification evaluation completed on or before October 28, 2002, of Individuals who performed
a Covered Task prior to August 28, 1999. Note: This qualification is no longer applicable, but
will remain in this plan to reference compliance with CFR 192.809( c).
Work Performance History Review
Atmos Energy does not consider Work Performance History Review as an acceptable means to
evaluate individuals who perform Covered Tasks.
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Atmos Energy Corporation
Operator Qualification Plan
Covered Tasks
Task A1
Operating Propane Air System
Re-evaluation timeframe 12 months, Span of Control 1:1
Task E1
Welding in a Fixed Position using Manual Metal Arc Weld
Re-evaluation timeframe 12 months, Span of Control 1:0
Task E2
Welding Branch Connections using Manual Metal Arc Weld
Re-evaluation timeframe 12 months, Span of Control 1:0
Task E3
Welding Metal using Oxy-Acetylene in the Fixed Position
Re-evaluation timeframe 12 months, Span of Control 1:0
Task E4
Welding Metal using Oxy-Acetylene on Steel Branch Connections
Re-evaluation timeframe 12 months, Span of Control 1:0
Task E5
Perform Non-Destructive Tests on Steel Welds
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F1
Joining or Capping of Polyethylene Pipe with Electrofusion (Coupling fusion)
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F2
Joining of Polyethylene Pipe with Electrofusion (Saddle fusion)
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F3
Joining or Capping of Polyethylene Pipe with Heat fusion (Butt fusion)
Re-evaluation timeframe 12 months, Span of Control 1:0
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Atmos Energy Corporation
Operator Qualification Plan
Covered Tasks
Task F4
Joining of Polyethylene Pipe with Heat fusion (Sidewall fusion)
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F5
Joining or Capping of Polyethylene Pipe with Heat fusion (Socket)
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F6
Joining of Polyethylene Pipe with Mechanical Coupling
(1/2” CTS through 1” IPS)
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F7
Joining of Polyethylene Pipe with Mechanical Coupling
(1 ¼” and 2” IPS)
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F8
Joining of Polyethylene Pipe with Mechanical Tapping Tee
(1 ¼” and above)
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F9
Joining of Polyethylene Pipe with Mechanical Coupling (Bolt Style)
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F10
Joining or Capping of Polyethylene with Compression type coupling
Re-evaluation timeframe 12 months, Span of Control 1:0
Task F11
Repairing Non PE Plastic Pipe
Re-evaluation timeframe 12 months, Span of Control 1:0
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Atmos Energy Corporation
Operator Qualification Plan
Covered Tasks
Task F12
Joining Dissimilar Pipe Types
Re-evaluation timeframe 12 months, Span of Control 1:0
Task G1
Repairing Steel Pipe - Distribution
Re-evaluation timeframe 36 months, Span of Control 1:3
Task G2
Installing of Underground Casing
Re-evaluation timeframe 36 months, Span of Control 1:1
Task G3
Installation/Excavation of Pipeline
Re-evaluation timeframe 36 months, Span of Control 1:1
Task H1
Installing / Replacing Meters
Re-evaluation timeframe 60 months, Span of Control 1:3
Task H2
Installing / Replacing Regulators
Re-evaluation timeframe 60 months, Span of Control 1:1
Task H3
Installing / Replacing Service Lines
Re-evaluation timeframe 60 months, Span of Control 1:3
Task H4
Installing/Replacing Service valves
Re-evaluation timeframe 60 months, Span of Control 1:1
Task I1
Conducting Pipe to Soil Measurement
Re-evaluation timeframe 60 months, Span of Control 1:3
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Atmos Energy Corporation
Operator Qualification Plan
Covered Tasks
Task I2
Monitoring Rectifiers
Re-evaluation timeframe 60 months, Span of Control 1:1
Task I3
Monitoring Interference Bonds
Re-evaluation timeframe 60 months, Span of Control 1:1
Task I4
Installing/Repairing Impressed Current Systems or Interference Bonds
Re-evaluation timeframe 60 months, Span of Control 1:1
Task I5
Installing/Replacing CP Test leads to Pipe
Re-evaluation timeframe 60 months, Span of Control 1:1
Task I6
Installing Anodes and Insulating Devices
Re-evaluation timeframe 60 months, Span of Control 1:1
Task I7
Inspecting for External Corrosion and Inspecting, Installing and Repairing Pipe
Coating
Re-evaluation timeframe 60 months, Span of Control 1:3
Task I8
Installing, Inspecting and Testing Electrical Isolation Devices
Re-evaluation timeframe 60 months, Span of Control 1:1
Task I9
Internal Corrosion Control
Re-evaluation timeframe 60 months, Span of Control 1:3
Task I10
Atmospheric Corrosion
Re-evaluation timeframe 60 months, Span of Control 1:3
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Atmos Energy Corporation
Operator Qualification Plan
Covered Tasks
Task L1
Tapping Steel Pipelines Under Pressure
Re-evaluation timeframe 12 months, Span of Control 1:1
Task L2
Activating and Purging / Blowdown Pipelines
Re-evaluation timeframe 36 months, Span of Control 1:1
Task L3
Perform Odorization Test
Re-evaluation timeframe 36 months, Span of Control 1:1
Task L4
Tapping Pipelines under Pressure with Self-tapping Tee
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M1
Surveying Leaks
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M2
Conducting Pipeline Patrolling Surveys
Re-evaluation timeframe 60 months, Span of Control 1:1
Task M3
Locating and Marking Lines
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M4
Testing Service Lines (New and Reinstating)
Re-evaluation timeframe 60 months, Span of Control 1:1
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Atmos Energy Corporation
Operator Qualification Plan
Covered Tasks
Task M5
Testing Mains and Transmission Lines
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M6
Inspecting and testing pressure limiting, telemetering or recording gauges and
relief valves
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M7
Performing Valve Inspection and Maintenance
Re-evaluation timeframe 60 months, Span of Control 1:1
Task M8
Preventing Accidental Ignition
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M9
Making Permanent Repairs On Transmission Lines
Re-evaluation timeframe 12 months, Span of Control 1:1
Task M10
Inspect, Repair, Tap and Protect Cast Iron Pipe
Re-evaluation timeframe 12 months, Span of Control 1:2
Task M11
Abandoning/Deactivating or Shutting Down Gas Facilities
Re-evaluation timeframe 60 months, Span of Control 1:3
Task M12
Monitor and Regulate the flow and pressure of gas from remote locations
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M13
Emergency Response
Re-evaluation timeframe 12 months, Span of Control 1:1
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Atmos Energy Corporation
Operator Qualification Plan
Covered Task
Task M14
Damage Prevention during Excavation or Encroachment
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M15
Leak Classification
Re-evaluation timeframe 36 months, Span of Control 1:1
Task M16
Recognize and React to Generic Abnormal Operating Conditions (AOC)
Re-evaluation timeframe 36 months, Span of Control 1:0
Task M17
Installing/Maintaining Pipeline Markers
Re-evaluation timeframe 60 months, Span of Control 1:3
Task M18
Inspecting Vault Conditions
Re-evaluation timeframe 60 months, Span of Control 1:3
Task M19
Inspect & Test Relief Devices at Compressor Stations
Re-evaluation timeframe 12 months, Span of Control 1:1
Task M20
Operating Within Established MAOP
Re-evaluation timeframe 36 months, Span of Control 1:1
Task O01
Conducting Indirect Inspection
Re-evaluation timeframe 36 months, Span of Control 1:1
Task O02
External Pipe Inspection for Anomalies
Re-evaluation timeframe 36 months, Span of Control 1:1
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Atmos Energy Corporation
Operator Qualification Plan
Covered Task
Task O03
Internal Corrosion Inspection (Non-destructive)
Re-evaluation timeframe 36 months, Span of Control 1:3
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Atmos Energy Corporation
Operator Qualification Plan
PERSONNEL EVALUATION
A.
Supervisors/managers are responsible to ensure that every Individual reporting to such
supervisor/manager who performs a Covered Task is Qualified to perform such Covered
Task.
B.
The evaluation methods employed in the Qualification process will accurately verify that
the Individual(s) performing a Covered Task have the knowledge, skills and ability to
perform; recognize and react to Abnormal Operating Conditions.
C.
After January 1, 2004, Individuals, who currently are not qualified under Atmos Energy
Plan or who are not part of a merger/acquisition as detailed in Plan Management
paragraph C page 14, will be trained on the Covered Task(s) that they may be required to
perform prior to evaluation by observation or simulation.
D.
After January 1, 2004, existing Individuals shall have knowledge assessment testing prior
to qualification/re-qualification by observation or simulation. The time between
knowledge assessment and qualification/re-qualification by observation or simulation
shall not exceed 90 calendar days
E.
Methods used to determine Qualification(s) of Individual(s) may include but are not
limited to the following:
Written Exam
Oral Exam
Observation
Work Performance History Review (see definitions)
Simulation
F.
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Atmos Energy Corporation
Operator Qualification Plan
G.
Persons performing Qualification evaluations shall possess the required knowledge: 1) to
ascertain an Individual’s ability to perform Covered Tasks and 2) to substantiate an Individual’s
ability to recognize and react to Abnormal Operating Conditions.
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Atmos Energy Corporation
Operator Qualification Plan
USE OF NON-QUALIFIED INDIVIDUALS
All Covered Tasks should be performed by an Individual who is Qualified to perform such
Covered Task. However a non-Qualified Individual may perform a Covered Task but only if
such non-Qualified Individual is directed and observed by an Individual who is Qualified to
perform such Covered Task. In this regard:
A.
Local supervisors/managers are responsible to ensure that Covered Tasks are performed
by a qualified individual or directed and observed by an Individual who is Qualified.
B.
Local Supervisors/managers are responsible to communicate to all Individuals who report
to such supervisor a current list of Covered Tasks such Individuals are expected to
perform.
C.
Local supervisors/managers shall maintain a list of Individuals and the Covered Tasks
they are Qualified to perform. This ensures that a non-Qualified Individual is not
performing a Covered Task without direction and observation by an Individual who is
Qualified for that Covered Task.
D.
Persons employed by contractors and/or mutual assistance personnel who are not
Qualified to perform a Covered Task may perform that Covered Task provided a
Qualified Individual is within the immediate proximity while the task is being performed
and such Qualified Individual is able to take any required immediate remedial action.
E.
The Qualified Individual is responsible for the performance of the Covered Task when
non-Qualified Individual(s) are completing the task. The Qualified Individual is
responsible for ensuring that they are not directing and observing more individuals than
allowed for each task. This Span of Control should not exceed 1:3 ratio and/or as
identified for each task.
F.
Notwithstanding anything contained herein to the contrary any Covered Task involving
welding and fusion must be performed by Individuals Qualified/certified under paragraph
192.227 (welding) or 192.285 (plastic pipe fusion).
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Atmos Energy Corporation
Operator Qualification Plan
PERSONNEL EVALUATION FOLLOWING AN INCIDENT
A.
If the local supervisor/manager has reason to believe that performance of a Covered Task
could have contributed to an incident, then an investigation will be performed using
Atmos Energy Incident Review Process. During the investigation the Individual whose
performance of a Covered Task(s) may have contributed to the incident will only be
permitted to perform the Covered Task under the direction and observation of a Qualified
Individual in accordance with the span of control.
B.
If the result of the investigation is a determination that the Individual’s performance of
the Covered Task did not contribute to the incident, the Individual’s Covered Task
qualification will be reinstated.
C.
If the investigation results in a determination that the individual’s performance of the
Covered Task did contribute to the incident, the Individual will no longer be Qualified to
perform the Covered Task. A knowledge, skills and ability form will be completed to
reflect the date the Individual became disqualified and the reason for such
disqualification will be documented in the appropriate Atmos Energy recordkeeping
system. As a result of the incident and before any covered Task(s) qualification
reinstatement is allowed, this individual will be required to undergo training on the
Covered Task(s) prior to evaluation by observation or simulation.
D.
When an investigation results in a determination that an individual’s performance of a
Covered Task contributed to an incident, the OQ team will review the issues related to
the incident.
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Atmos Energy Corporation
Operator Qualification Plan
EVALUATION OF QUALIFIED PERSONNEL PERFORMANCE
A.
Should a local supervisor/manager have a reason to believe that an Individual is no longer
Qualified to perform a Covered Task, the supervisor/manager will immediately notify
such Individual that he/she is no longer considered to be Qualified to perform that
Covered Task and such Individual will be deemed to be non-Qualified until he/she has
been re- Evaluated as described herein.
B.
Should any person have reason to believe that another Individual is no longer Qualified to
perform a Covered Task, he/she has an obligation to report to local supervisor/manager
the reason(s) for such belief. Examples included but are not limited too: a positive drug
and/or alcohol test as a result of an incident, prolonged absence (180 days or more) away
from job duties, or other Human Resources related issues The supervisor/manager will
investigate and determine if re-Qualification needs to occur.
C.
If an Individual is determined non-Qualified, a knowledge, skills and ability form will be
completed to reflect the date the Individual became disqualified and the reason for such
disqualification. Until re- Evaluated, such Individual, if required to perform a Covered
Task must work under the direction and observation of a Qualified Individual in
accordance with the span of control.
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Atmos Energy Corporation
Operator Qualification Plan
PLAN MANAGEMENT
A.
The Utility Operating Council, working through the Compliance Committee, shall be
responsible for approving/modifying Plan changes, monitoring Plan effectiveness,
identifying and communicating information relating to the following:
Modifications to Atmos Energy policies or procedures
Changes in state or federal regulations
Utilization of new equipment and/or technology
New information from equipment or product manufacturers
B.
The Compliance Committee shall meet as required or at least annually to review current
Plan in place and determine recommendations for any Plan changes necessary to:
Remain in compliance
Monitor regulatory changes
Respond to regulatory or internal audits/inspections
Evaluate environmental changes
Integrate technical improvements
Review and/or update AOC’s
Develop, review and maintain Covered Task(s) training material with
assistance from Technical Training
C.
At such time, when a merger/acquisition occurs, the Compliance Committee will meet to
review Plan of acquired entity to:
Review plans in place
Develop a strategy to integrate plans
Recommend changes and/or updates to Plan
Integrate plans for consistency
Transfer individual qualification records and/or Qualify individuals as
needed
Maintain historical records
D.
Roles and Responsibilities:
Compliance Manager or Director of Regulatory and Compliance (Compliance)
Communicating and filing approved Plan changes with appropriate state regulatory
agencies
Monitoring Plan implementation within division
Ensuring integrity of Plan
Providing feedback to Compliance Committee
Oversight of evaluators
Ensuring compliance for employees and contractors
Updating division leadership
17
Atmos Energy Corporation
Operator Qualification Plan
Local Managers and Supervisors
Ensuring integrity of Plan
Communicating Plan changes to direct reports
Preparing and coaching employees
Ensuring individuals are qualified for tasks being performed
Evaluators
Staying abreast of Plan and process changes
Providing feedback to Compliance
Evaluating employee skill level in accordance with Plan
Maintaining accurate records
Employees
May submit comments and feedback on the plan through an appropriate Atmos Energy
e-form for proposed changes or improvements
E.
The Compliance Committee shall respond to all inquires/requests and if Plan changes are
necessary, the Compliance Committee chairman will present recommendations to the
Utility Operations Council for approval. Upon approval by the Utility Operations
Council, the chairman of the Compliance Committee will ensure the development of a
communication and implementation plan to determine the necessary steps. Should the
Utility Operations Council require changes to the proposals, they will instruct the
Compliance Committee for further review.
F.
Maintaining Plan Integrity
In order to comply with Protocol 9, the role of the Compliance will be as follows:
reviewing a supervisor’s plan adherence at a specific location,
randomly overseeing evaluators conducting a qualification activity, and
randomly observing an individual performing a Covered Task
When an internal field audit is conducted the Compliance will use the Operator
Qualification Field Audit Form.
Plan Changes/Management
Events:
Compliance update
Regulatory change
Environmental change
Technology change/upgrade
Equipment change/upgrade
AOC refinement
Employee question/grievance
Evaluator feedback
Industry best practice/updates
18
Atmos Energy Corporation
Operator Qualification Plan
Action:
Meet at least annually
Compliance
Committee
meets to
review and
update plan.
Plan
change?
No
Yes
Plan updated
No
No action
Approved
by the
UOC?
Yes
Communication Process
Communicate to: evaluators, managers/supervisors,
employees, commissions, contractors,
Plan updated and
document and
communicate
changes
By:
Updating: intranet documents, Managers/supervisors Toolkit,
Tests/evaluations, Qualification Packets
Publish: Articles in Atmos Monthly, EMPCOM
Prepare and distribute:
Meeting in a box materials to evaluators and
manager/supervisors
Conduct and document:
Tailgate meetings, net meetings, conference calls, classroom
instruction and record in appropriate Atmos Energy record
keeping system
19
Atmos Energy Corporation
Operator Qualification Plan
PERSONNEL RE-EVALUATION
A.
Local supervisors/managers shall be responsible for scheduling re-evaluation of
Individual(s) performance of Covered Task(s) at intervals not to exceed the indicated
Plan frequencies. Re-evaluation method requirements are identified in “Personnel
Evaluation” section of this Plan.
B.
All Individuals performing Covered Task(s) shall be re-evaluated in accordance with
D.O.T. Regulation, part 192.805. This regulation provides in part that Atmos Energy
must:
•
•
•
•
C.
Evaluate an Individual if the Operator has reason to believe that the Individual’s
performance of a Covered Task contributed to an incident as defined in Part 191;
Evaluate an Individual if the Operator has reason to believe that the Individual is no
longer Qualified to perform a Covered Task; and
Communicate changes that affect Covered Tasks to Individuals performing those
Covered Tasks.
When a significant change affecting Covered Task(s) or individual performing
Covered Task(s) is made in: Atmos Energy Policies or procedures; state or federal
regulations; utilization of new equipment and/or technology; and new information
from equipment or product manufacturers, re-qualification, which includes training
and evaluation, will be required. Changes will be documented on the knowledge,
skills and ability form.
Subsequent qualification of an Individual who performs a Covered Task will occur at
least every 5 years or as may be required by Part 192.
Note: Atmos Energy determined intervals from one to five years (not to exceed five years)
based on a Safety, Complexity and Frequency analysis for each task.
Each was assigned a value to each of the three categories of 1, 3, or 5.
•
Safety refers to how serious the consequences would be if the task was done
improperly (1 = minor 5 = catastrophic)
•
Complex task have a score of 5 and a simple tasks have a score of 1
•
Frequently performed tasks have a score of 1, while infrequently performed have a
score of 5.
If the Total Score (X) per tasks is:
X < 6 = 60 months re-evaluation frequency
6< X <10 = 36 months re-evaluation frequency
10< X 16 = 12 months re-evaluation frequency
20
Atmos Energy Corporation
Operator Qualification Plan
RECORD KEEPING
A.
Evaluators shall be responsible for providing updated records on an Individual’s
qualification to local supervision and updating appropriate Atmos Energy record keeping
system and is accessible at local Atmos Energy operations.
B.
Qualification records shall include:
§
§
§
§
C.
Identification of Qualified Individual(s) (Name and Individual’s id
number)
Identification of Covered Tasks the Individual is Qualified to perform
Date(s) of current qualification(s)
Qualification method(s) used
If an Individual is deemed no longer Qualified for a specific Covered Task, the
Qualification record needs to be updated with:
§
§
The date that Qualification becomes invalid
Stated reason for non-Qualification
D.
All Qualification information shall be completed and maintained by the supervisor on
approved forms.
E.
Supervisors are responsible for maintaining records on Individuals performing Covered
Tasks. All operator Qualification records shall be maintained as long as an Individual is
actively performing Covered Task(s) and for a period of five (5) years after the Individual
has ceased to perform the Covered Task(s).
21
Utility Operations Handbook
Section:
Construction Procedures
Subject:
Introduction
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Construction
Procedures
Reference and Guide for Construction Processes
Atmos Energy Corporation
UOC Document Management Committee
P. O. Box 650205 – Dallas, TX 75265-0205
Phone 972.934.9227 – Fax 972.855.3080
1Original Approved
1
Utility Operating
Utility Operations Handbook
Section:
Construction Procedures
Subject:
Introduction
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
THE INFORMATION CONTAINED IN THIS MANUAL IS
CONFIDENTIAL AND IS INTENDED SOLELY FOR REVIEW OR USE
BY THE EMPLOYEES OF ATMOS ENERGY CORPORATION IN
CONNECTION
WITH
COMPANY
OPERATIONS
AND
MAINTENANCE
PROCESSESS
AND
MEASUREMENT
PROCEDURES. ANY OTHER DISTRIBUTION OR COPYING OF THIS
MANUAL OR ANY OF THE MATERIALS HEREIN, OTHER THAN
FOR PERMITTED PURPOSES, IS STRICTLY PROHIBITED.
2Original Approved
2
Utility Operating
Utility Operations Handbook
Section:
Construction Procedures
Subject:
Table of Contents
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
CHAPTER 1: OVERVIEW......................................................................................................................... 1
CHAPTER 2: GENERAL REQUIREMENTS.......................................................................................... 2
CHAPTER 3: PLASTIC PIPE.................................................................................................................... 4
ELECTRO-FUSION ....................................................................................................................................... 5
BUTT FUSION.............................................................................................................................................. 6
SIDEWALL/SADDLE FUSION........................................................................................................................ 8
MECHANICAL COUPLING ............................................................................................................................ 9
SLIP-FIT TYPE COUPLINGS ....................................................................................................................... 11
POLYAMIDE PIPE BUTT FUSION ................................................................................................................ 12
ELECTRO-FUSION (EF) COUPLINGS AND SADDLES FOR POLYAMIDE PIPE ................................................ 14
CHAPTER 4: PIPE INSTALLATION - MAIN TRANSMISSION/HIGH PRESSURE
DISTRIBUTION ........................................................................................................................................ 16
DISTRIBUTION .......................................................................................................................................... 19
TIE-IN LINE PRESSURE CONTROL TRANSMISSION/HIGH PRESSURE DISTRIBUTION .................................. 23
CHAPTER 5: PIPE INSTALLATION – SERVICE TRANSMISSION/HIGH PRESSURE
DISTRIBUTION ........................................................................................................................................ 29
SERVICE INSTALLATION DISTRIBUTION.................................................................................................... 31
TIE-IN/LINE PRESSURE CONTROL – TRANSMISSION/HIGH PRESSURE DISTRIBUTION ............................... 35
DISTRIBUTION - POLYETHYLENE MAIN .................................................................................................... 39
EXCESS FLOW VALVE INSTALLATION ...................................................................................................... 41
CHAPTER 6: TESTING MAINS AND SERVICES – GENERAL PROCEDURES........................... 46
CHAPTER 7: FULL ENCIRCLEMENT SLEEVE INSTALLATION................................................. 48
ENCAPSULATION ...................................................................................................................................... 49
CASING PIPE INSTALLATION ..................................................................................................................... 51
PERMANENT CLAMP INSTALLATION ......................................................................................................... 52
CHAPTER 8: DAMAGE PREVENTION – LINE LOCATING ........................................................... 53
DIRECTIONAL BORING .............................................................................................................................. 54
CHAPTER 9: APPENDIX......................................................................................................................... 55
POLYETHYLENE QUALIFICATION .............................................................................................................. 56
DESTRUCTIVE TESTING – GENERAL GUIDELINES ..................................................................................... 56
DITCH WIDTH MINIMUM TABLE .............................................................................................................. 60
PIPELINE PROTECTIVE COVERING ............................................................................................................ 61
STATIC ELECTRICITY ................................................................................................................................ 63
HOT SPOT ANODE INSTALLATION ............................................................................................................ 64
INTERNAL REFERENCE MATERIAL............................................................................................................ 65
TERMS, DEFINITIONS AND ACRONYMS ..................................................................................................... 67
i
Utility Operations Handbook
Section:
Chapter 1
Subject:
Overview
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Chapter 1: Overview
The Construction Procedures team, a sub-committee of the UOC Procedures Manual
Team, has compiled this guide for the purpose of providing affected employees of Atmos
Energy Corporation (“Atmos Energy” or the “Company”), who are assigned the
responsibilities of dealing with construction and maintenance procedures and processes
with instructions, guidelines and reference points. Continuing with the Atmos Energy
philosophy of utilizing “common practices” whenever possible, this manual was designed
and prepared to standardize construction procedures and processes.
During the development of this manual, consideration was given to using existing
practices, manufacturer’s recommendations and material specifications as well as
practical applications of processes.
As changes in Atmos Energy’s policies and operations normally occur due to regulatory
requirements, new technology, material standardization and further development of
common utility practices, this manual will undergo changes to reflect revisions, deletions
and additions as they are adopted by the UOC.
1
Utility Operations Handbook
Section:
Chapter 2
Subject:
General Requirements
Reference:
Issue Date:
09-04-07
Effective
Date:
01-01-08
Revision Date:
01-01-08
Chapter 2: General Requirements
Technical Services review or design is required when installing and/or replacing pipe,
fittings, full encirclement sleeves and permanent clamps on a Transmission system. This
includes High Pressure Distribution lines operated above 20% SMYS.
Technical Services review or design may be required when installing and/or replacing
pipe, fittings, full encirclement sleeves and permanent clamps on a Distribution system.
All pipe and materials must meet company standards and any deviations from established
standards must be approved by Technical Services and documented. When installing
pipe and materials, special consideration should be given to the MAOP of each system
and pipe and material pressure rating. All pipe and material will be inspected for
damages and defects before or during installation. Refer to Pipeline Integrity protocol if
defects in steel pipe are found. Proper testing of joints, pipe, and material must be
completed prior to being put into service. Before backfilling, ensure pipe and fittings are
supported to minimize stress on fitting and pipe. Backfilling should ensure the pipeline is
not damaged by bedding in granular material and using at least 6 inches of granular
material or other approved method above the pipe.
When steel natural gas pipelines are exposed by field personnel, they will take and record
pit depths (where applicable) on appropriate work order. They will also note the
presence of corrosion activity and will respond to the presence of heavy corrosion
activity. Field personnel should consult with local or designated corrosion personnel to
determine inspection requirements for steel pipe. Only approved coating materials will
be used when protecting steel pipe, joints, and fittings. Manufacturer application
instructions will be used and the area being coated will be clean and free of foreign
material as required by manufacturer’s specifications.
Welder must meet current company welding qualification standards. Pipe joiner must
meet current company fusion, mechanical fitting and other applicable qualification
standards.
2
Utility Operations Handbook
Section:
Chapter 2
Subject:
General Requirements
Reference:
Issue Date:
09-04-07
Effective
Date:
01-01-08
Revision Date:
01-01-08
All appropriate personal protective equipment will be used and safety guidelines will be
followed. Special consideration will be given to the control of static electricity. Refer to
appendix – Static Electricity – for general guidelines. Refer to respiratory protection
guidelines if excavation site is potentially hazardous. All waste material will be disposed
of properly.
3
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyethylene Pipe – Electro-Fusion
Reference:
OQ Task – F1, F2, M14: DOT 192.281, 192.283, 192.285, 192.287
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Chapter 3: Plastic Pipe
The preferred method for joining polyethylene pipe will be by either electro-fusion or
butt fusion. The preferred method for installing polyethylene taps will be electro-fusion
or saddle fusion. For leaks identified on mechanical fittings used to join polyethylene
pipe, the fitting must be removed and replaced with polyethylene pipe. The repair
method will be either electro-fusion or butt fusion. Electro-fusion is the preferred method
for making a permanent repair of damaged pipe.
Repairs/replacements on PVC and other non-polyethylene plastic pipe may be made with
approved mechanical fittings, glued fittings, or encapsulation. Refer to appendix –
Dissimilar Polyethylene Materials Table - for examples of dissimilar pipes.
Polyamide pipe is only to be joined by electro-fusion, butt fusion, or saddle fusion.
Pipe Coil Considerations:
When working with 4-inch and larger plastic pipe coils, consider cutting off the ends of
the coil and adding a straight piece of 10 to 40 feet long pipe between coils and at tie-ins.
Temperature and larger pipe sizes are factors to consider when working with coiled pipe
to ensure rounding.
4
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyethylene Pipe – Electro-Fusion
Reference:
OQ Task – F1, F2, M14: DOT 192.281, 192.283, 192.285, 192.287
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Electro-Fusion
General Procedures
In conjunction with manufacturer instructions Electro-fusions should be made as follows:
Ensure the electrical power source has sufficient amperage capacity to
accommodate the fusion control box. (Equipment can be damaged and fusion
process compromised by power source of insufficient amperage.)
Prepare the pipe ends so that they fit evenly and squarely into inside the fitting.
Remove any burrs or shavings from the pipe ends.
Clean pipe ends inside and out using a clean dry or wet cloth. Alcohol can be used
to remove oily residue. Do not use a soap solution.
Measure and mark the pipe ends at the proper stab depth. This is determined by
measuring from the spacer inside the fitting to the outside edge of the fitting.
Remove all oxidized surface material from the pipe fusion area by utilizing the
appropriate scraping tool and process.
The proper depth for scraping can be determined by the complete removal of the
print line on the pipe surface. Do not remove more than 10% of the pipe wall.
Clean the residue from the fusion area after scraping with a clean dry cloth. Do
not touch the prepared area with your hands as this can cause contamination.
If after the first scrape the coupling does not slide onto the pipe easily, scrape up
to two additional times to achieve proper fit. Do not drive or hammer the coupling
onto the pipe as this may damage the wire coil inside the coupling.
Slide the fitting onto the pipe ends to the previously marked stab depths. Do not
twist the fitting onto pipe ends as this can damage the built in coil wire in fitting.
Place the assembled joint in the appropriate clamping tool to secure the pipe from
movement during the fusion process.
After giving the assembled joint a final check to make sure it is ready to be fused,
connect output leads from the fusion control box to fitting terminals and activate
the fusion control box in the prescribed manner to begin the fusion process.
Disconnect output leads from the fitting after fusion cycle is complete and leave
joint secure for the required cooling time. (Refer to the manufacture’s fusion
procedures for correct cooling times.)
5
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyethylene Pipe – Heat Fusion - Butt
Reference:
OQ Task F3, M14: DOT 192.281, 192.283, 192.285, 192.287: Plastic Pipe
Institute PPI BF Procedures TR-33/2003
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Butt Fusion
Atmos has adopted the Plastics Pipe Institute’s guidelines related to heat fusion. Access
to website is available in the Operations and Maintenance Manual under section 24.3.
Plastics Pipe Institute (PPI)
Generic Butt Fusion Joining Procedure for Polyethylene Gas Pipe - TR-33/2003
General Procedures
In conjunction with PPI instructions Butt fusions should be made as follows:
Check and clean heating surface of iron. Pre-heat iron and verify that the
temperature is correct. (Refer to manufacture’s fusion procedures for correct
heating temperatures.)
Clean the inside and outside of the pipe to be joined with a clean cloth to
remove all contaminates.
Place the ends of the PE pipe to be joined in the joining jig or clamps leaving
adequate room for the heating tool.
Use the facing tool to plane smooth, flat surfaces on both ends of the pipe to
be joined.
Bring pipe ends together to check for proper alignment. It may be necessary to
adjust and reface to ensure proper fit up.
Remove any burrs or shavings from the pipe ends caused by the facing of the
pipe ends. Do not touch the prepared surface with your hands as this can cause
contamination.
After assuring proper alignment, insert heating tool and bring both ends to
bear on heating surface. Apply sufficient force to maintain full heating surface
contact with both pipe ends for the full heating time. Heating time cycle starts
when the bead of molten material is first visible around the entire
circumference of both pipe ends. (Refer to the manufacture’s fusion
procedures for correct heating times.)
Snap the jig open and remove heating tool.
Bring the heated surfaces together quickly, but do not slam together as this
may cause excessive displacement of the molten material. Apply sufficient
force on the jig handle to cause a double roll back fusion bead.
6
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyethylene Pipe – Heat Fusion - Butt
Reference:
OQ Task F3, M14: DOT 192.281, 192.283, 192.285, 192.287: Plastic Pipe
Institute PPI BF Procedures TR-33/2003
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Maintain fusion pressure while joint cools. (Refer to the manufacture’s fusion
procedures for correct cooling times.)
Visually inspect the joint for proper fusion when removed from jig or clamps.
Inspect and clean heater faces before next fusion is made.
7
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyethylene Pipe – Heat Fusion – Sidewall/Saddle
Reference:
OQ Task M14: DOT 192.281, 192.283, 192.285, 192.287: Plastic Pipe
Institute PPI BF Procedures TR-33/2003
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Sidewall/Saddle Fusion
Atmos has adopted the Plastics Pipe Institute’s guidelines related to heat fusion. Access
to website is available in the Operations and Maintenance Manual under section 24.3.
Plastics Pipe Institute (PPI)
Generic Saddle Fusion Joining Procedure for Polyethylene Gas Pipe – TR-41/2002
General Procedures
In conjunction with PPI instructions Sidewall/Saddle fusions should be made as follows:
Preheat the heating iron equipped with the proper heating surfaces.
Sand the saddle flange fusion surface and the pipe surface to remove glaze from
the fusion area.
Remove any burrs, shavings and other residue from the fusion area with a clean
dry cotton cloth. Do not touch the prepared fusion surface with your hands as this
can cause contamination.
Brace the pipe in the fusion area so that it cannot bend or bow during the fusion
process.
A bolster plate must be used in conjunction with the saddle jig on 6” and smaller
pipe.
Use saddle fusion jigs equipped with a pressure gauge on high volume tapping
tees and service saddles to help maintain their shape and insure uniform pressure
on the flange during the heating process.
Place the heating tool on the pipe at the point where the fitting is to be mounted.
Place the fitting against the heater face and apply pressure.
If the melt patterns are satisfactory, press the fitting onto the pipe (within 3
seconds) with firm pressure until a melt bead of the correct size appears.
Adjust the fusion jig to maintain pressure of the fitting on the pipe.
Allow the fusion to cool and visually inspect fitting and fusion joint; if the joint
appears unsatisfactory remove cutter from tee and cut off top of fitting to avoid
misuse later.
Inspect and clean heater faces before next fusion is made.
8
Utility Operations Handbook
Section:
Chapter 3
Subject:
Mechanical Coupling for Polyethylene Pipe
Reference:
OQ Task F6 – F10, M 10, M14: DOT 192.281, 192.283, 192.287, 192.317,
192.614, 192.753, 192.755
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Mechanical Coupling
Approved mechanical fittings may be used as a temporary (provisional – see O&M
section 9.4.2) repairs.
When it is not practical to fuse a fitting on distribution lines mechanical fittings may be
used as a permanent solution with Technical Services approval. Install fitting according
to manufacturer’s instructions.
For mechanical fitting found on polyethylene pipe exposed during O&M activities:
No action is needed if the fitting is not damaged or leaking and contains seal and
restraint and have no evidence of leaking or being damaged. Some examples are
Con-Stab, Lycofit, Metfit, or Perfection Permasert.
If the fitting is damaged, leaking, or is not one of the above fittings, then the
fitting will be replaced with polyethylene pipe utilizing either electro-fusion or
butt fusion.
Mechanical fittings used on above ground facilities are also excluded.
9
Utility Operations Handbook
Section:
Chapter 3
Subject:
Mechanical Coupling for Polyethylene Pipe
Reference:
OQ Task F6 – F10, M 10, M14: DOT 192.281, 192.283, 192.287, 192.317,
192.614, 192.753, 192.755
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
General Procedures
In conjunction with manufacturer mechanical couplings should be installed as follows:
Clean pipe ends, removing oil, dirt, loose scale, cutter burrs and rust. Gasket
should seat on bare metal when installing on steel.
Make sure that the polyethylene pipe ends have been cut square and lightly
chamfered according to manufacture recommendation. If there are any scratches,
gouges, or damaged areas, remove that section of pipe and start over
When centering coupling, mark each pipe an equal distance from pipe end. This
should be a minimum of one half the middle body ring length plus 2 inches.
Wipe clean rubber gaskets, pipe end separator (if applicable) and insulating sleeve
(if applicable).
When installing insulator coupling, place insulating gasket over pipe to be
insulated. Note that insulator couplings may be identified with paint and larger
bore hole on insulating side.
When installing coupling on polyethylene or non-polyethylene plastic pipe insert
appropriate support stiffener sleeve into pipe ends. Ensure pipe ends are straight
to ensure proper seating.
Center the middle body ring between marks. Maximum pipe end gap should be 1
½ inches for 5 inch middle body ring and 2 inches for 7 inch middle body ring.
Gap should be spaced equally for each pipe end.
Lubricate gaskets and body flares with soapy water.
Move follower rings and gaskets so they are in contact with middle body ring and
line up bolt holes.
Insert bolt holes and tighten uniformly following manufacturer torque
recommendations.
When pipe movement out of the coupling is possible, properly anchor the pipe and
coupling to support connection.
10
Utility Operations Handbook
Section:
Chapter 3
Subject:
Mechanical Coupling for Polyethylene Pipe
Reference:
OQ Task F6 – F10, M 10, M14: DOT 192.281, 192.283, 192.287, 192.317,
192.614, 192.753, 192.755
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Slip-Fit Type Couplings
In conjunction with manufacturer slip-fit type couplings should be installed as follows:
Prepare the polyethylene ends of the two lengths of pipe being joined by cleaning
them thoroughly. Make sure that the polyethylene pipe ends have been cut square
and lightly chamfered according to manufacture recommendation. If there are any
scratches, gouges, or damaged areas, remove that section of pipe and start over.
Line up the pipe ends.
There should be no misalignment or kinks in either pipe length.
Measure the proper engagement length and mark it on each pipe end.
Install the coupling using the manufacturer’s recommended procedure which is
packaged with the coupling.
Be sure that proper engagement has been achieved. A bubble-tight seal is formed
when the coupling is properly assembled.
11
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyamide Pipe – Heat Fusion - Butt
Reference:
OQ Task F3: DOT 192.281, 192.283, 192.285, 192.287: Generic Butt Fusion
Procedures for Polyamide Pipe
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Polyamide Pipe Butt Fusion
Atmos has adopted the Manufacturers’ Generic Butt fusion procedure for joining
Polyamide pipe. A copy of their generic procedures can be found in the Appendix.
Polyamide and Polyethylene pipe are not compatible and therefore are not
interchangeable and cannot be cross-fused.
This procedure is for Polyamide 11 and Polyamide 12. Polyamide 11 and Polyamide 12
shall not be cross-fused.
General Procedures
Follow manufacturer’s instruction while giving consideration to the following:
Check and clean heating surface of iron. Pre-heat iron and verify that the
temperature is correct. (Refer to manufacturer’s fusion procedures for correct
heating temperatures.)
Clean the inside and outside of the pipe to be joined with a clean cloth to
remove all contaminates.
Place the ends of the Polyamide pipe to be joined in the joining jig or clamps
leaving adequate room for the heating tool.
Use the facing tool to plane smooth, flat surfaces on both ends of the pipe to
be joined.
Bring pipe ends together to check for proper alignment. It may be necessary to
adjust and reface to ensure proper fit up.
Remove any burrs or shavings from the pipe ends caused by the facing of the
pipe ends. Do not touch the prepared surface with your hands as this can cause
contamination.
After assuring proper alignment, insert heating tool and bring both ends to
bear on heating surface. Apply sufficient force to maintain full heating surface
contact with both pipe ends for the time required to obtain correct bead size
for the size of the pipe being fused. Heating time cycle starts when the bead of
molten material is first visible around the entire circumference of both pipe
ends. (Refer to the manufacturer’s fusion procedures for correct heating
times.)
12
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyamide Pipe – Heat Fusion - Butt
Reference:
OQ Task F3: DOT 192.281, 192.283, 192.285, 192.287: Generic Butt Fusion
Procedures for Polyamide Pipe
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Snap the jig open and remove heating tool.
Bring the heated surfaces together quickly, but do not slam together as this
may cause excessive displacement of the molten material. Apply sufficient
force on the jig handle to cause a double roll back fusion bead.
Maintain fusion pressure while joint cools. (Refer to the manufacturer’s fusion
procedures for correct cooling times.)
Visually inspect the joint for proper fusion when removed from jig or clamps.
Inspect and clean heater faces before next fusion is made.
13
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyamide Pipe – Electro-Fusion (EF) Couplings and Saddles
Reference:
OQ Task F1 – F2, I7, L1, L4, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Electro-Fusion (EF) Couplings and Saddles for Polyamide Pipe
General Procedures
In conjunction with manufacturers’ instructions Electro-fusions should be made as
follows:
Ensure the electrical power source has sufficient amperage capacity to
accommodate the fusion control box. (Equipment can be damaged and fusion
process compromised by power source of insufficient amperage.)
Prepare the pipe ends and pipe surfaces so that there is an even and square fit into
the fitting.
Remove any burrs or shavings from the pipe ends and pipe surface.
Clean pipe ends inside and out using a clean dry or wet cloth. Alcohol can be used
to remove oily residue. Do not use a soap solution.
For EF couplings measure and mark the pipe ends at the proper stab depth. This is
determined by measuring from the spacer inside the fitting to the outside edge of
the fitting.
For EF saddles measure and mark the pipe surface for proper installation.
Remove all oxidized surface material from the pipe fusion area by utilizing the
appropriate scraping tool and process.
The proper depth for scraping can be determined by the complete removal of the
print line on the pipe surface. Do not remove more than 10% of the pipe wall.
Clean the residue from the fusion area after scraping with a clean dry cloth. Do
not touch the prepared area with your hands as this can cause contamination.
If after the first scrape the coupling does not slide onto the pipe easily, scrape up
to two additional times to achieve proper fit. Do not drive or hammer the coupling
onto the pipe as this may damage the wire coil inside the coupling.
For EF couplings slide the fitting onto the pipe ends to the previously marked stab
depths. Do not twist the fitting onto pipe ends as this can damage the built in coil
wire in fitting.
Place the assembled joint in the appropriate clamping tool to secure the pipe from
movement during the fusion process.
14
Utility Operations Handbook
Section:
Chapter 3
Subject:
Joining Polyamide Pipe – Electro-Fusion (EF) Couplings and Saddles
Reference:
OQ Task F1 – F2, I7, L1, L4, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
After giving the assembled joint a final check to make sure it is ready to be fused,
connect output leads from the fusion control box to fitting terminals and activate
the fusion control box in the manufacturer’s prescribed manner to begin the fusion
process.
Disconnect output leads from the fitting after fusion cycle is complete and leave
joint secure for the required cooling time. (Refer to the manufacturer’s fusion
procedures for correct cooling times.)
15
Utility Operations Handbook
Section:
Chapter 4
Subject:
Main Installation – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, M5, M8, M14, M17: DOT 192.315, 192.317, 192.319,
192.325, 192.327, 192.627, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Chapter 4: Pipe Installation - Main
Transmission/High Pressure Distribution
General Procedures
Corrosion Protection
All new buried steel pipe and components must be protected against external
corrosion by an external protective coating and be cathodically protected.
For pipe 2 inches and larger inspect pipe coating with a holiday detector prior to
installation. Repair all coating defects. Test all coating repairs with a holiday
detector.
Pipe less than 2 inches in diameter must be visually inspected for coating damage
prior to installation in a ditch.
Install electrical test leads. Test leads on foreign pipeline shall be installed by the
owner or operator of the foreign pipeline.
Use an approved coating on valves, fittings, and pipe. Use heat shrink sleeves or
an approved coating on all butt welds on new construction and replacement of
mains.
Refer to Pipeline Integrity Management protocol if defects in steel pipe are found.
Wrinkle bends and miter joints will not be used.
Cleaning Pipe
After pipe is joined and before it is pressure tested, pipe will be cleaned as follows:
For pipe that is smaller than 2 inches in diameter, release air into one end while
other end is open.
For pipe that is 2 inches or larger, pass a squeegee or foam pig through pipe.
Repeat cleaning as necessary to ensure all foreign material has been removed.
Remove all water if pipeline has been hydrostatically tested.
16
Utility Operations Handbook
Section:
Chapter 4
Subject:
Main Installation – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, M5, M8, M14, M17: DOT 192.315, 192.317, 192.319,
192.325, 192.327, 192.627, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Defects in Pipe
Steel Pipe with defects (including gouges, grooves, notches, dents, etc.,) that do not meet
the specification allowance will be corrected by repair or removal prior to installation.
Defects will be removed by grinding if the resulting wall thickness is not less than
90% of the nominal wall thickness required; otherwise, the defect will be
removed by cutting out a cylindrical section of pipe.
Dents which exceed a maximum depth of ¼-inch in pipe 12-3/4-inch O.D. or less,
or more than two percent nominal pipe diameter over 12-3/4-inch O.D., will be
removed by cutting out the damaged portion as a cylinder. Insert patching and the
pounding out of dents is prohibited.
Protection from external forces and other damage
When adequate protection of the pipe is not provided by the minimum cover, increase the
amount of cover or provide additional protection when minimum cover is impractical
(due to underground structures, rock, etc) by:
Increasing the load-bearing capability of the cover material through the use of
consolidated rock or partially cemented backfill with Technical Services approval
Installing the pipe in casing with Technical Services approval.
Installing steel plating material or a 5 inches layer of concrete over the pipe
(appendix) with Technical Services approval.
Referring to appendix “Minimum Ditch Width in Rock”
Using approved material such as Rock Shield, etc.
A minimum clearance of 12 inches is required between any main and any electrical
conduit or direct buried electrical cable. If 12 inches cannot be attained, contact
Technical Services for possible options.
Maintain a clearance of 12 inches between any main and other underground structures.
Provide additional protection when minimum clearance cannot be maintained by:
Encasing pipeline with Technical Services approval.
Installation of insulating sheet with Technical Services approval.
If pipeline is left unattended, cap ends of pipe to ensure no foreign materials enter the
pipeline.
17
Utility Operations Handbook
Section:
Chapter 4
Subject:
Main Installation – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, M5, M8, M14, M17: DOT 192.315, 192.317, 192.319,
192.325, 192.327, 192.627, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Pipeline markers should be installed on all high pressure pipe installation and
replacements. Refer to Operations and Maintenance Manual Section 7.1 for minimum
guidelines for placement of pipeline markers.
Backfill
Minimum cover is 36 inches unless specified otherwise by Technical Services.
Steel pipe must be in contact with the bottom of the ditch for substantially the entire
length of the pipe so that external force is not required to hold it in place prior to
backfilling.
An approved warning tape must be installed with pipe during open trench excavations.
The tape should be installed approximately 12 inches above the pipe during the backfill
process. Warning tape is not required with directional bores.
Backfilling should ensure the pipeline is not damaged by bedding in granular material
and using at least 6 inches of granular material or other approved method above the pipe.
All waste material will be disposed of properly outside the right of way.
18
Utility Operations Handbook
Section:
Chapter 4
Subject:
Main Installation – Distribution
Reference:
OQ Task E1 – E4, F1 – F10, I7, M5, M8, M14, M17: DOT 192.315, 192.317,
192.319, 192.325, 192.327, 192.627, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Distribution
General Procedures
Corrosion Protection
All new buried steel pipe and components must be protected against external
corrosion by an external protective coating and be cathodically protected.
For pipe 2 inches and larger inspect pipe coating with a holiday detector prior to
installation. Repair all coating defects. Test all coating repairs with a holiday
detector.
Pipe less than 2 inches in diameter must be visually inspected for coating damage
prior to installation in a ditch.
Install electrical test leads. Test leads on foreign pipeline shall be installed by the
owner or operator of the foreign pipeline.
Use an approved coating on valves, fittings, and pipe. Use heat shrink sleeves or
an approved coating on all butt welds on new construction and replacement of
mains.
Refer to Pipeline Integrity protocol if defects in steel pipe are found. Field personnel
should consult with local or designated corrosion personnel to determine inspection
requirements for steel pipe.
Cleaning Pipe
After pipe is joined and before it is pressure tested, pipe will be cleaned as follows:
For pipe that is smaller than 2 inches in diameter, release air into one end while
other end is open.
For pipe that is 2 inches or larger, pass a squeegee or foam pig through pipe.
Repeat cleaning as necessary to ensure all foreign material has been removed.
Defects in Pipe
Polyethylene pipe with defects (including gouges, grooves and notches greater than 10%
of the pipe wall thickness) will be removed, replaced or, if applicable, repaired with a
patching saddle.
Steel Pipe with defects (including gouges, grooves, notches, dents, etc.,) that do not meet
the specification allowance will be corrected by repair or removal prior to installation.
19
Utility Operations Handbook
Section:
Chapter 4
Subject:
Main Installation – Distribution
Reference:
OQ Task E1 – E4, F1 – F10, I7, M5, M8, M14, M17: DOT 192.315, 192.317,
192.319, 192.325, 192.327, 192.627, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Defects will be removed by grinding if the resulting wall thickness is not less than
90% of the nominal wall thickness required; otherwise, the defect will be
removed by cutting out a cylindrical section of pipe.
Dents which exceed a maximum depth of ¼-inch in pipe 12-3/4-inch O.D. or less,
or more than two percent nominal pipe diameter over 12-3/4-inch O.D., will be
removed by cutting out the damaged portion as a cylinder. Insert patching and the
pounding out of dents is prohibited.
Protection from external forces and other damage
An approved warning tape must be installed with the main during open trench
excavations. The tape should be installed approximately 12 inches above the pipe during
the backfill process.
Locator wire will be installed the entire length and adjacent to the polyethylene pipeline.
Place wire approximately 4 inches from pipe where possible. Use approved
method for splices, junctions, anode connections etc.
Locator wire will not be wrapped or tied around pipe.
Wire will be extended to ground level at each polyethylene service riser, valve
box or junction box.
Locator wire should be brought to surface at approximately 500 foot intervals
and installed in test lead boxes during installation of polyethylene pipe for new
construction and replacement of mains during open trench excavation. The
locator lead box should be identified with an approved marking device.
An approved 5 lb. anode will be installed at approximately 1,000 foot locator
wire intervals during polyethylene installations.
When locator wire terminates at a steel main, it may be thermit welded to the main
depending on the pipeline’s cathodic protected. Field personnel should consult with local
or designated corrosion personnel before attaching locator wire to steel pipelines.
After backfilling check the continuity of the locator wire system. Any locator wire
lacking continuity must be repaired.
20
Utility Operations Handbook
Section:
Chapter 4
Subject:
Main Installation – Distribution
Reference:
OQ Task E1 – E4, F1 – F10, I7, M5, M8, M14, M17: DOT 192.315, 192.317,
192.319, 192.325, 192.327, 192.627, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Approved locating devices that transmit the specified gas frequency may be installed with
all locator lead boxes. Such devices may also be installed at all polyethylene valves and
dead end locations. Locating devices will be secured to ensure it does not move during
backfill process.
A minimum clearance of 12 inches is required between any main and any electrical
conduit or direct buried electrical cable. If 12 inches cannot be attained, contact
Technical Services for possible options.
Maintain a clearance of 6 inches between any main and other underground structures.
Provide additional protection when minimum clearance cannot be maintained by:
Encasing pipeline with Technical Services approval.
Installation of insulating sheet with Technical Services approval.
If pipeline is left unattended, cap ends of pipe to ensure no foreign materials enter the
pipeline.
Pipeline markers should be installed on all pipe installation and replacements. Refer to
Operations and Maintenance Manual Section 7.1 for minimum guidelines for placement
of pipeline markers.
Backfill
Minimum cover is 24 inches unless specified otherwise by Technical Services.
Polyethylene pipe will be installed on undisturbed or well compacted soil. Its full length
shall be supported on the ditch bottom. Pipe will be allowed to lie loosely along the ditch
bottom. Steel pipe must be in contact with the bottom of the ditch for substantially the
entire length of the pipe so that external force is not required to hold it in place prior to
backfilling.
When pulling polyethylene pipe 2 inches or larger through conventional or directional
bore holes use an approved manufactured “weak link” or one constructed of the same
pipe type and one size smaller than the pipe being pulled. It should be at least 1 foot in
length and installed on the lead end of the pipe. Locator wire will be installed along with
pipe.
21
Utility Operations Handbook
Section:
Chapter 4
Subject:
Main Installation – Distribution
Reference:
OQ Task E1 – E4, F1 – F10, I7, M5, M8, M14, M17: DOT 192.315, 192.317,
192.319, 192.325, 192.327, 192.627, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Backfilling should ensure the pipeline is not damaged by bedding in granular material
and using at least 6 inches of granular material or other approved method above the pipe.
All waste material will be disposed of properly outside the right of way.
When adequate protection of the pipe is not provided by the minimum cover, increase the
amount of cover or provide additional protection when minimum cover is impractical
(due to underground structures, rock etc) by:
Increasing the load-bearing capability of the cover material through the use of
consolidated rock or partially cemented backfill with Technical Services approval
Installing the pipe in casing with Technical Services approval
Installing steel plating material or a 5 inches layer of concrete over the pipe
(appendix) with Technical Services approval
Referring to appendix “Minimum Ditch Width in Rock”
Using approved material such as Rock Shield etc.
22
Utility Operations Handbook
Section:
Chapter 4
Subject:
Tie In/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Tie-in Line Pressure Control Transmission/High Pressure Distribution
General Procedures
Pressure Control
Pressure gauges will be installed on both sides (both up and downstream) of any pressure
control device during all manual pressure control activities. Pressure control devices
include those named in this procedure, as well as any valve used to control pressure while
making a tie-in. These gauges must be watched as the pressure control device is
activated and the flow of gas is stopped.
Mueller Line Stopper Equipment
Mueller Line Stopper equipment may be used for pressure control on
pipelines up to eight inches in diameter of various pipe types being
operated at various pressures, and to make welded tie-ins. See the
manufacturer’s specifications for pressure limitations.
T.D. Williamson Shortstopp Equipment
Intermediate pressure T.D. Williamson Shortstopp equipment may be used
on pipelines 1-1/4 inch through 12-inch in diameter being operated at
pressures not exceeding 60 psig, and to make welded tie-ins.
High pressure T.D. Williamson Shortstopp equipment may be used on
pipelines up to 40-inch in size, and at various pressures according to size
to make welded tie-ins. See manufacturer’s specifications for pressure
limitations.
Squeeze Method
Pressure control on polyethylene pipe may be achieved by squeezing the
pipe walls together to seal off or substantially decrease flow, to make
fusion tie-ins. The squeeze and release of the pipe shall be slow and
controlled so that the pipe is not damaged. The squeeze point shall be 3
times the pipe diameter or 12 inches whichever is greater, away from any
fitting, fusion, or previous squeeze location.
Squeeze tools must have mechanical stops to prevent over squeezing.
An approved double bar or flat bar squeeze tool must be used when
squeezing 8 inch and larger polyethylene pipe.
23
Utility Operations Handbook
Section:
Chapter 4
Subject:
Tie In/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Squeeze points on polyethylene pipe will be identified by two wraps of an
approved pipeline tape wrapped around the pipe, leaving a two-inch gap
between the wraps. Use an electro-fusion coupling to reinforce pipe that
has been over squeezed.
Size on Size Tie-in
Size on size tie-ins can be made by installing an in-line poly tee. On a two-way feed
system, the main must be squeezed at two locations near the tie in. On a one-way feed, a
bypass may be needed if several customers will be out of service. Pressure should be
monitored while squeezing to make sure the by-pass is working.
Steel Tie-ins
Steel pipe is an electrical conductor. When pipe ends are separated or brought together
they may cause an electrical spark. Bonding cables will be used during steel tie-ins to
prevent electrical spark by providing continuous electrical contact between the pipe ends.
Fitting Installation
Follow the manufacturer’s recommended procedure for installation and use of the tie-in
fitting.
Clean the pipe or fitting thoroughly around the complete circumference making
certain all oil, dirt, rust, scale, and debris are removed assuring proper fit of the
fitting.
When installing a fitting to accommodate a main stopple/plugging machine, a minimum
distance of one foot is to be maintained between the stopple fitting and the end of the new
tie-in point.
If bypassing is necessary ensure pressure gauges are functioning properly and
mounted so they are readily viewable throughout the tie-in process.
Follow the manufacturer’s recommended procedure for installation and use of the
stopple fitting.
Follow the manufacturer’s recommended procedures and instructions when
tapping, plugging, inserting completion plugs and control valves.
Minimum cover is 36 inches unless specified otherwise by Technical Services.
24
Utility Operations Handbook
Section:
Chapter 4
Subject:
Tie In/Line Pressure Control – Distribution
Reference:
OQ Task E1 – E4, F1 – F11, I7, L1, L4, M5, M8, M14: DOT 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Distribution
General Procedures
Polyethylene Main
All polyethylene to polyethylene laterals and tap tees will be made by electro-fusion, butt
fusion, or saddle fusion (electro-fusion is the preferred fusion method)
Mechanical tap-tees may be used “when approved” by Technical Services for joining to
dissimilar plastic pipe (Refer to Mechanical Couplings section of Chapter 3). Follow
manufacturer’s recommended procedures for installation of mechanical tap tees.
All one-half inch through 1-1/4-inch hot taps on polyethylene pipe shall be made by
polyethylene fusers, certified in using Gas Distribution fusion procedures, using tapping
tees. The tapping tees must be installed using a side wall fusion jig. The tap must be
completed with a tool that will assure a complete cut out and removal of the tapped
material in order to assure uninterrupted flow of gas through the tap.
When it is not practical to fuse a tap-tee on distribution lines mechanical fittings may be
used as a permanent solution with Technical Services approval. Install fitting according
to manufacturer’s instructions.
Steel Main
The preferred method for joining steel pipe, installing taps, or transition fitting will be by
welding. In areas that are remote and do not readily have access to a welder mechanical
fittings may be used in joining provided that the fittings meet the company’s standards
and specifications with Technical Services approval.
For leaks identified on mechanical fittings used to join steel pipe, repairs will be made by
replacing the fitting with either welded pipe, installing a weld-over sleeve or welding in
transitions and installing plastic pipe.
Approved mechanical fittings may be used as a temporary (provisional – see O&M
section 9.4.2) repairs.
25
Utility Operations Handbook
Section:
Chapter 4
Subject:
Tie In/Line Pressure Control – Distribution
Reference:
OQ Task E1 – E4, F1 – F11, I7, L1, L4, M5, M8, M14: DOT 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Mechanical fittings used to join steel pipe that are exposed during operations and
maintenance activities should be replaced, when practical, by either welding a piece of
steel pipe, installing a weld-over sleeve, or welding in transitions and installing plastic
pipe. This does not apply to approved fittings that contain seal and restraint and have no
evidence of leaking or being damaged.
Mechanical fittings used on above ground facilities are also excluded.
In Texas, replace any fitting used to mechanically join steel pipe that is exposed during
operations and maintenance activities unless the operator can determine the fitting was
installed after 1980.
A welded tap connection (WTC), on steel pipe shall be installed by a welder, certified,
using approved welding procedures.
An approved self-tapping welded tee, or an approved, pressure rated weld-o-let, steel
nipple, and steel valve will be used when installing service lines on a system with a
Maximum Allowable Operating Pressure (MAOP) greater than 60 PSIG.
Either an approved self-tapping welded tee or an approved service saddle kit (WTC,
CTC, or TTC), may be used when installing steel service lines on systems with an MAOP
of 60 PSIG or less.
26
Utility Operations Handbook
Section:
Chapter 4
Subject:
Tie In/Line Pressure Control – Distribution
Reference:
OQ Task E1 – E4, F1 – F11, I7, L1, L4, M5, M8, M14: DOT 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Cast Iron Main
Connect polyethylene service to cast iron mains by drilling and threading the main and
installing an approved brass service ell. A stainless steel reinforcing sleeve must be used
for tap holes larger than 25% of the nominal diameter of the main, except that a four-inch
main may be tapped 1-1/4 inch without reinforcement. Existing taps that exceed 25% of
the nominal main diameter may be reused if there are no cracks and the threads are in
good condition.
Poly Service Line Taps off Steel and Cast Iron Mains
Install a plastic protective sleeve over the poly transition point of the service line tap and
secure with approved pipeline wrapping tape to prevent movement during back-fill
operations.
Gas Bag or Balloon Method
Bagging will only be used on Utilization pressure systems.
In conjunction with manufacturer’s instructions complete taps and bagging as follows:
Drill and tap the main approximately 12" from the intended cut-off point.
Install pressure gauges both upstream and downstream from the repair site. These
gauges must be monitored at all times.
Locate the tap so that it will not be covered by installation of a mechanical fitting.
Tap holes for cast iron must not exceed 25% of the main diameter.
Install a proper size bag in the tap hole, upstream from the gas flow. Use a cotton
cloth to slow gas flow at the tap hole, until the bag is inflated.
Connect a pump and inflate the bag. Exercise caution not to exceed the maximum
pressure as established by manufacturer. Leave the pump connected so more air
can be added, if needed.
Diaphragm stoppers may also be used for gas control, Follow the manufacturer’s
recommendations for installation and use.
27
Utility Operations Handbook
Section:
Chapter 4
Subject:
Tie In/Line Pressure Control – Distribution
Reference:
OQ Task E1 – E4, F1 – F11, I7, L1, L4, M5, M8, M14: DOT 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Table 1 – Tap Hole
Pipe Size
2"
3"
4"
6"
8"
10"
Revision Date:
03-31-11
Table 2 – Maximum Inflation Pressure
Tap Hole
1"
1"
1-1/4"
1-1/2"
2"
2"
Pipe Size
Inflation (psig)
2"
3"
4"
6"
8"
10"
12
12
12
12
10
9
Bolt style mechanical fittings will be used for tie-ins.
Welding against a bag or balloon is prohibited.
28
Utility Operations Handbook
Section:
Chapter 5
Subject:
Service Installation – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, H3, I7, M5, M8, M14, M17: DOT 192.315, 192.317,
192.319, 192.325, 192.327, 192.725, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
11-14-08
Chapter 5: Pipe Installation – Service
Transmission/High Pressure Distribution
General Procedures
Service lines should be installed upright directly off of the main unless specified
otherwise by Technical Services. When applicable, select a protected location when
installing a service line.
Install riser so that inlet stop is approximately 15 inches above ground level.
Cleaning Pipe
After pipe is joined and before it is pressure tested, pipe will be cleaned as follows:
For pipe that is smaller than 2 inches in diameter, release air into one end while other end
is open.
For pipe that is 2 inches or larger, pass a squeegee or foam pig through pipe.
Repeat cleaning as necessary to ensure all foreign material has been removed.
Corrosion Protection
Employees will use approved coating materials when protecting weld joints, weld fittings
or bare spots. They will ensure the area being coated is clean and free of foreign
material.
All new buried steel pipe and components must be protected against external corrosion
by an external protective coating and be cathodically protected.
For pipe 2 inches and larger inspect pipe coating with a holiday detector prior to
installation. Repair all coating defects. Test all coating repairs with a holiday detector.
Pipe less than 2 inches in diameter must be visually inspected for coating damage prior to
installation in a ditch.
Install electrical test leads. Test leads on foreign pipeline shall be installed by the owner
or operator of the foreign pipeline.
Use heat shrink sleeves or an approved coating on all butt welds on new construction and
replacement of services.
29
Utility Operations Handbook
Section:
Chapter 5
Subject:
Service Installation – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, H3, I7, M5, M8, M14, M17: DOT 192.315, 192.317,
192.319, 192.325, 192.327, 192.725, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
11-14-08
Backfill
Backfilling should ensure the pipeline is not damaged by bedding in granular material
and using at least 6 inches of granular material or other approved method above the pipe.
All waste material will be disposed of properly away from the right of way.
Protection from external forces and other damage
When adequate protection of the pipe is not provided by the minimum cover, increase the
amount of cover or provide additional protection when minimum cover is impractical
(due to underground structures, rock etc) by:
Installing the pipe in casing with Technical Services approval
Referring to appendix “Minimum Ditch Width in Rock”
Using approved material such as Rock Shield, etc.
A minimum clearance of 12 inches is required between any service and any electrical
conduit or direct buried electrical cable. If 12 inches cannot be attained, contact
Technical Services for possible options.
Maintain a clearance of 6 inches between any service and other underground structures.
Provide additional protection when minimum clearance cannot be maintained by:
Encasing pipeline with Technical Services approval.
Installation of insulating sheet with Technical Services approval.
If service is left unattended, cap ends of pipe to ensure no foreign materials enter the
pipeline.
Pipeline markers may need to be installed on some service line installations and
replacements. Refer to Operations and Maintenance Manual Section 7.1 for minimum
guidelines for placement of pipeline markers.
30
Utility Operations Handbook
Section:
Chapter 5
Subject:
Service Installation – Distribution
Reference:
OQ Task E1 – E4, F1 – F11, H3, I7, M5, M8, M14, M17: DOT 192.315,
192.317, 192.319, 192.321, 192.325, 192.327, 192.725, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Service Installation Distribution
General Procedures
Tap tees should be installed on top of the pipe (at the 12 o’clock position) with the outlet
parallel to the ground unless specified otherwise by Technical Services.
Install approved polyethylene riser per manufacturer’s instructions. Install steel riser so
that inlet stop is approximately 15 inches above ground level.
Refer to appendix – Polyethylene Pipe Bend Radius - for bends in polyethylene pipe
specifications. Steel pipe weld elbows will be used when change of directions are
required. Wrinkle bends and miter joints will not be used.
Cleaning Pipe
After pipe is joined and before it is pressure tested, pipe will be cleaned as follows:
For pipe that is smaller than 2 inches in diameter, release air into one end while
other end is open.
For pipe that is 2 inches or larger, pass a squeegee or foam pig through pipe.
Repeat cleaning as necessary to ensure all foreign material has been removed.
Corrosion Protection
Employees will use approved coating materials when protecting weld joints, weld fittings
or bare spots. They will ensure the area being coated is clean and free of foreign
material.
All new buried steel pipe and components must be protected against external
corrosion by an external protective coating and be cathodically protected.
For pipe 2 inches and larger inspect pipe coating with a holiday detector prior to
installation. Repair all coating defects. Test all coating repairs with a holiday
detector.
Pipe less than 2 inches in diameter must be visually inspected for coating damage
prior to installation in a ditch.
Install electrical test leads. Test leads on foreign pipeline shall be installed by the
owner or operator of the foreign pipeline.
Use heat shrink sleeves or an approved coating on all butt welds on new
construction and replacement of services.
Service risers shall be non-corrodible.
31
Utility Operations Handbook
Section:
Chapter 5
Subject:
Service Installation – Distribution
Reference:
OQ Task E1 – E4, F1 – F11, H3, I7, M5, M8, M14, M17: DOT 192.315,
192.317, 192.319, 192.321, 192.325, 192.327, 192.725, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Defects in Pipe
Polyethylene pipe with defects including gouges, grooves and notches greater than 10%
of the pipe wall thickness will be removed, replaced or, if applicable, repaired with a
patching saddle.
Steel Pipe with defects (including gouges, grooves, notches, dents, etc.,) that do not meet
the specification allowance will be corrected by repair or removal prior to installation.
Protection from external forces and other damage
Select a protected meter location.
Install a support post or similar device with the service line riser as needed to provide
additional support. Extra consideration for additional support should be given during the
installation of manifolds.
An approved warning tape must be installed with service stubs during open trench
excavations. The tape should be installed approximately 12 inches above the pipe during
the back fill process.
Locator wire will be installed the entire length and adjacent to the polyethylene pipeline.
Place wire approximately 4 inches from pipe where possible. Use approved
method for splices, junctions, anode connections etc.
Locator wire will not be wrapped or tied around pipe.
When locator wire terminates at a steel main, it may be thermit welded to the
main depending on if the pipeline is cathodically protected. Field personnel
should consult with local or designated corrosion personnel before attaching
locator wire to steel pipelines
Extend locator wire to ground level at each meter riser and wrap wire around
riser.
After backfilling check the continuity of the locator wire system. Any locator wire
lacking continuity must be repaired.
Where polyethylene service stub lines terminate below ground an approved locator
device may be used to facilitate the location of the service stub at a later date. Locating
devices will be secured to ensure it does not move during backfill process.
32
Utility Operations Handbook
Section:
Chapter 5
Subject:
Service Installation – Distribution
Reference:
OQ Task E1 – E4, F1 – F11, H3, I7, M5, M8, M14, M17: DOT 192.315,
192.317, 192.319, 192.321, 192.325, 192.327, 192.725, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
A minimum clearance of 12 inches is required between any main and any electrical
conduit or direct buried electrical cable. If 12 inches cannot be attained, contact
Technical Services for possible options.
Maintain a clearance of 6 inches between any main and other underground structures.
Provide additional protection when minimum clearance cannot be maintained by:
Encasing pipeline with Technical Services approval.
Installation of insulating sheet with Technical Services approval.
If service is left unattended, cap ends of pipe to ensure no foreign materials enter the
pipeline.
Pipeline markers may need to be installed on some service line installations and
replacements. Refer to Operations and Maintenance Manual Section 7.1 for minimum
guidelines for placement of pipeline markers.
Backfill
Minimum cover is 18 inches on public Right of Way and 12 inches on private property
unless specified otherwise by Technical Services.
Polyethylene pipe will be installed on undisturbed or well compacted soil. Its full length
shall be supported on the ditch bottom. Pipe will be allowed to lie loosely along the ditch
bottom. Steel pipe must be in contact with the bottom of the ditch for substantially the
entire length of the pipe so that external force is not required to hold it in place prior to
backfilling.
When pulling polyethylene pipe 2 inches or larger through conventional or directional
bore holes use an approved manufactured “weak link” or one constructed of the same
pipe type and one size smaller than the pipe being pulled. It should be at least 1 foot in
length and installed on the lead end of the pipe. Locator wire will be installed along with
pipe.
Backfilling should ensure the pipeline is not damaged by bedding in granular material
and using at least 6 inches of granular material or other approved method above the pipe.
33
Utility Operations Handbook
Section:
Chapter 5
Subject:
Service Installation – Distribution
Reference:
OQ Task E1 – E4, F1 – F11, H3, I7, M5, M8, M14, M17: DOT 192.315,
192.317, 192.319, 192.321, 192.325, 192.327, 192.725, 192.707
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
When adequate protection of the pipe is not provided by the minimum cover, increase the
amount of cover or provide additional protection when minimum cover is impractical
(due to underground structures, rock, etc) by:
Increasing the load-bearing capability of the cover material through the use of
consolidated rock or partially cemented backfill with Technical Services approval
Installing the pipe in casing with Technical Services approval
Installing steel plating material or a 5 inches layer of concrete over the pipe
(appendix) with Technical Services approval
Referring to appendix “Minimum Ditch Width in Rock”
Using approved material such as Rock Shield, etc.
34
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
11-14-08
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
General Procedures
Qualification
Note: High Pressure (H.P.) for the purpose of this procedure is defined as having a
MAOP of greater than 100 PSIG.
All hot taps shall be installed by crews qualified to make hot taps, using a certified
welder and the Company’s approved welding procedures.
Conditions
A. The joint of pipe to be tapped shall be free of bends. The outside diameter of the
hot tap nipple will be a minimum of two inches from the longitudinal seam of the
mainline pipe and any weld.
1. Contact the Technical Services for branch connection design and selection
when installing a two inch or larger hot tap on a steel main when the MAOP
is greater than 100 PSIG and the nominal diameter of the pipe is 6 inches or
greater.
2. Hot taps with a ratio of branch to mainline greater than 40% shall be designed
by Technical Services.
3. The mainline pipeline shall operate at a temperature below 200ºF.
B. Prior to the start of any welding operation, the mainline pressure shall be reduced
to the lowest pressure practical. The reduced pressure shall be maintained until
all hot tapping operations are completed.
C. Prior to welding the hot tap nipple in place visually inspect the main to determine
if the pipe is in good condition.
D. The wall thickness of the main should be determined by use of an ultrasonic
thickness gauge if the operating pressure is over 100 PSIG. If there is a question
about the integrity of the pipe on systems with operating pressures below 100
PSIG Technical Services should be contacted. If there is evidence of corrosion or
wall thickness reduction on the main pipe, a safety evaluation will be made. The
mainline pipe is to have a wall thickness equal to or greater than 0.154 inches.
35
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
11-14-08
Branch Connections
A. A full encirclement sleeve/nipple shall be used (except where approved by
Technical Services) for the branch connection if:
1. The nominal diameter of the branch is 6” or larger or,
2. The nominal diameter of the branch is equal to or greater than one-half the
diameter of the H.P. main or,
3. The branch connection will be subjected to greater than normal bending,
torque, or cyclic loads.
If none of the conditions are applicable, then a reinforcing weld saddle/nipple or in case
of a two inch hot tap, a two inch hot tap nipple per the appropriate Standard Drawing may
be used. A weld-o-let or thread-o-let may be used if the nominal diameter of the hot tap
is less than two inch.
B. The full-encirclement sleeve or reinforcing weld saddle shall:
1. Have a thickness not greater than two times the original wall thickness of
the main pipe when the MAOP is greater than 100 PSIG.
2. Be of a grade that is compatible with the main pipe when the MAOP is
greater than 100 PSIG.
3. Have a weld saddle as an integral part of the fitting. DO NOT use teetype, sleeve type, or saddle and sleeve type branch connection fittings.
C. The hot tap nipple shall:
1. Be pre-tested to one and one-half times the design pressure of the H.P.
main.
2. Be of a minimum length, but not shorter than the nominal diameter.
3. Be beveled at the proper angle to allow for full penetration of the stringer
bead.
4. Not be notched or modified in any way to fit over the longitudinal seam of
the H.P. main pipe.
36
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
11-14-08
Installation of Branch Connections
A. All fit-up, alignment, and welding performed during the hot tapping operation
shall be accomplished in accordance with approved Company welding
procedures.
B. Remove all kraft paper, coal tar, primer, or other pipe coating material from the
H.P. main pipe in the area of and immediately adjacent to the branch connection.
C. Prior to the start of any welding operation on the mainline, the amount of gas
flowing in the H.P. main shall be minimized.
D. Install the hot tap nipple as follows:
1. Pre-heat the H.P. main pipe and the nipple to 150-200ºF immediately prior
to welding.
2. Weld the hot tap nipple to the H.P. main, making sure that a 90 degree
angle is maintained between the centerline of the nipple and the centerline
of the H.P. main pipe.
3. Welding shall be such that full penetration of the stringer bead in the root
gap is obtained.
4. If the H.P. main and the nipple are allowed to cool below 300ºF prior to
completion of the final pass, reheat the H.P. main and the nipple to 300400ºF immediately prior to making the final pass.
E. Fit-up and align the full encirclement sleeve or reinforcing weld saddle over the
nipple. Make sure that the saddle or sleeve is tight and snug against the H.P. main
pipe.
F. If a full-encirclement sleeve is installed, weld in the following sequence:
1. Tack weld the flat bar(s) provided with the sleeve over the gap(s) where
the two halves of the saddle meet. DO NOT weld the two halves of the
sleeve together.
2. Run a continuous fillet weld on both sides of the flat bar(s), between the
bar and the sleeve.
3. Run a continuous fillet weld between the sleeve and the hot tap nipple.
37
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
11-14-08
4. An optional one-eighth inch fillet seal weld may be run circumferentially
between the full-encirclement sleeve and the H.P. main pipe. If a seal
weld is run, drill a one-eight inch diameter hole in the saddle area of the
sleeve.
G. If a reinforcing weld saddle is installed, weld in the following sequence.
1. Prior to welding, the weep hole in the saddle shall be clear and open.
2. Run a continuous fillet weld between the skirt of the saddle and the
mainline. (See Items D-1 and D-4 for preheating requirements).
3. Run a continuous fillet weld between the saddle and the hot tap nipple.
H. Install a flange and a hot tap valve on the nipple after allowing sufficient time for
all welds to cool.
1. Leak test the branch connection in accordance with Operations and
Maintenance manual procedure 3-12.
Cathodic Protection
A. After a hot tap is complete, the following steps shall be taken to prevent
corrosion:
1. Take a pipe to soil reading. If the reading is not – 0.85 volts or more
negative, contact Survey and Corrosion Supervisor.
2. Fill the hole in the full-encirclement sleeve of reinforcing weld saddle
with mastic.
3. Coat all pipe, fittings, and flanges with an approved coating system.
Coating shall overlap the existing mainline coating system two pipe
diameters or 12 inches, whichever is greater.
4. If the hot tap valve was not tar-set coated by the valve supplier, coat the
valve with an approved coating.
Support of the Hot Tap Connection
All tap installations will be supported by placing backfill material under the main and
branch connection. Compact it to as near original density as possible. Six-inch and
larger side mounted taps should be supported by a concrete pad.
38
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Distribution - Polyethylene Main
General Procedures
Polyethylene Main
All polyethylene to polyethylene laterals and tap tees will be made by electro-fusion, butt
fusion, or saddle fusion (electro-fusion is the preferred fusion method)
Mechanical tap-tees may be used for joining dissimilar plastic pipe (Refer to Mechanical
Couplings section of Chapter 3). Follow manufacturer’s recommended procedures for
installation of mechanical tap tees.
All one-half inch through 1-1/4-inch hot taps on polyethylene pipe shall be made by
polyethylene fusers, certified using Gas Distribution fusion procedures, using tapping
tees. The tapping tees must be installed using a side wall fusion jig. The tap must be
completed with a tool that will assure a complete cut out and removal of the tapped
material in order to assure uninterrupted flow of gas through the tap.
Steel Main
The preferred method for joining steel pipe, installing taps, or transition fitting will be by
welding. In areas that are remote and do not readily have access to a welder mechanical
fittings may be used in joining provided that the fittings meet the company’s standards
and specifications with Technical Services approval.
For leaks identified on mechanical fittings used to join steel pipe, repairs will be made by
replacing the fitting with either welded pipe, installing a weld-over sleeve or welding in
transitions and installing plastic pipe.
Approved mechanical fittings may be used as a temporary (provisional – see O&M
section 9.4.2) repairs.
Mechanical fittings used to join steel pipe that are exposed during operations and
maintenance activities should be replaced, when practical, by either welding a piece of
steel pipe, installing a weld-over sleeve, or welding in transitions and installing plastic
pipe. This does not apply to approved fittings that contain seal and restraint and have no
evidence of leaking or being damaged. Mechanical fittings used on above ground
facilities are also excluded.
39
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
In Texas, replace or repair any fitting used to mechanically join steel pipe that is exposed
during operations and maintenance activities unless the operator can determine the fitting
was installed after 1980.
A welded tap connection (WTC), on steel pipe shall be installed by a welder, certified,
using approved welding procedures. An approved self-tapping welded tee, or an
approved, pressure rated weld-o-let, steel nipple, and steel valve will be used when
installing service lines on a system with a Maximum Allowable Operating Pressure
(MAOP) greater than 100 PSIG. Either an approved self-tapping welded tee or an
approved service saddle kit (WTC, CTC, or TTC), may be used when installing steel
service lines on systems with an MAOP of 60 PSIG or less.
Cast Iron Main
Connect polyethylene service to cast iron mains by drilling and threading the main and
installing an approved brass service ell. A stainless steel reinforcing sleeve must be used
for tap holes larger than 25% of the nominal diameter of the main, except that a four-inch
main may be tapped 1-1/4 inch without reinforcement. Existing taps that exceed 25% of
the nominal main diameter may be reused if there are no cracks and the threads are in
good condition.
Poly Service Line Taps off Steel and Cast Iron Mains
Install a plastic protective sleeve over the poly transition point of the service line tap and
secure with approved pipeline wrapping tape to prevent movement during back-fill
operations.
40
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Excess Flow Valve Installation
General Procedures
Appropriately sized, bleed-by type (self-resetting) excess flow valves (EFV) will be
installed in all new and replacement residential service lines that serve single residential
customers or that serve no more than two residential customers through a branch
(split or companion) services. EFVs need not be installed in service lines when:
The service line is located on a gas system that operates at pressures of less than 5
psig for all or part of the year, or
There is a documented history of solid or liquid contaminates in the gas stream, or
The service line is located on a “utilization” pressure (4 oz) gas system.
Contact the Divisional Technical Services Group for a list of towns or areas that will
not require the installation of EFVs on new or replaced residential service lines.
If connected load is over 1600 CFH, Technical Services should be consulted for
appropriate EFV selection.
EFV Installation Procedures
1. Install tapping saddle with the EFV in the outlet branch on the main or install poly
pipe stick with the EFV in the service line as close to the main tie-in as possible.
Components containing EFVs shall be installed in accordance with
manufacturer’s instructions packaged with each unit. When installing EFVs,
make sure that flow arrow points in the direction of gas flow.
2. If the service line will be installed at a later date, steps should be taken to close
the end of the service line stub so that dirt and debris cannot enter the service line
stub and cause the EFV to become inoperable.
41
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Pressure Testing New Service Lines with EFVs
1. Test as specified in Atmos Testing of Mains and Services Procedure.
2. Soap test the tapping tee, couplings and the LW valve while maintaining the test
pressure.
3. Disconnect the pressure source and monitor the test pressure for a minimum of 5
minutes.
4. Bleed out the test pressure from the assembly by opening the LW valve and then
close the valve.
5. Loosen the cap on the tap tee slowly to allow any trapped pressure to escape from
the tap tee.
Tapping Mains
1. Follow tapping tee manufacture’s instructions to properly tap the main line.
2. Back the punch out slowly allowing gas to flow into the service line at a slow
controlled rate to prevent the EFV from closing.
3. Re-soap test the cap on the tapping tee after tightening and prior to backfilling.
42
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Purging New Service Lines with EFVs
1. Before purging the service line or testing the EFV, assure that the pressure at the
riser has stabilized to system pressure. This indicates that the EFV is in the open
position.
2. Install appropriate diameter test nipple and cap, with a 3/32” bleed hole drilled in
the cap if desired.
3. Open the LW valve and allow gas flow through the bleed hole to remove the test
media (air or nitrogen) and assure that the EFV does not close during normal
operating conditions. Gas may also be throttled through the LW valve to prevent
tripping of the EFV while purging if a cap is not installed.
4. Close the LW valve and remove the test cap if present.
5. Re-open the LW valve slowly until the internal EFV closes and verify that a small
“bypass” flow exist through the EFV.
6. Close the LW valve and allow the service line to re-pressurize.
(Approximately 6 minutes for service lines 50 feet in length and 60 psig main
pressure. A longer time may be required for longer services.)
7. Close and lock the LW valve after verifying that the EFV is operating properly
and all test media (air or nitrogen) has been purged from the service line.
8. Before leaving the location, install a permanent EFV identification marker (ring
or embossed ID tag) on the inlet meter riser and a cap of appropriate diameter in
the outlet of the LW valve. The EFV identification marker will alert service
personnel that an EFV is installed in the service line and special purging
procedures are required.
43
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Special Purging Instructions for Existing Services Lines with EFV’s
When a service line is installed with an EFV, an EFV identification marker (ring or
embossed ID tag) will be installed on the nipple in the outlet of the Lock Wing (LW)
valve. The presence of an EFV identification marker will alert the service personnel that
an EFV is installed and these special procedures must be used.
Purging Existing Service Lines with EFVs
1. Whenever an EFV identification marker is seen on the riser, applicable portions
of these instructions must be followed, keeping in mind that the EFV has been
tested and the service line purged by the construction personnel during
installation.
2. Check the pressure at the riser to assure that it has stabilized at system pressure.
This indicates that the EFV is in the open position.
3. If purging of the service line is necessary before installing the regulator and
meter, a test cap with a 3/32” bleed hole on the nipple may be installed in the
outlet of the LW valve, before purging.
4. The Lock Wing (LW) valve can either be used to throttle gas while purging or, if
a test cap is installed, can be fully opened allowing flow through the bleed hole
without tripping the EFV. Purging or bleeding can only be accomplished at
this reduced flow rate, when an EFV is present.
5. If purging is necessary after installation of the service regulator or regulator /
meter combination, no special precautions are necessary. The normal flow
through a service regulator and meter setup will not cause an EFV’s to close.
6. Before leaving the location, verify that an EFV identification marker is installed.
44
Utility Operations Handbook
Section:
Chapter 5
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Testing the Operation of Installed EFVs - Optional
1. If testing of an installed EFV is desired, follow these instructions.
2. Remove the meter and regulator, if installed, and install a test cap, with a 3/32”
bleed hole drilled in the cap on the nipple above the LW valve.
3. Open the LW valve and allow flow through the bleed hole to assure that the EFV
does not close during normal operating conditions.
4. Close the LW valve and remove the test cap.
5. Reopen the LW valve slowly until the internal EFV closes and verify that a very
small bypass flow exist through the EFV.
6. Close the LW valve and allow the service line to re-pressurize.
(Approximately 6 minutes for service lines 50 feet in length and 60 psig
pressure.
A longer time may be required for longer services.)
7. When assured that the EFV is operating properly, close the LW valve and proceed
with installing the meter and regulator.
8. Before leaving the location, verify that an EFV identification marker is installed.
The EFV identification marker will alert service personnel that an EFV is
installed in the service line.
Resetting a Closed EFV
1. Atmos’ installs “bleed-by type” EFV’s that have a self-resetting feature. This
feature allows the EFV to automatically reset when the pressure equalizes on both
sides of the EFV.
2. If an EFV appears to be closed, assure that there are no leaks on the service
between the EFV and the LW valve on the riser, and allow the service line to repressurize. (Approximately 6 minutes for service lines 50 feet in length and 60
psig main pressure. A longer time may be required for longer services.)
3. Retest the EFV in accordance with the above section, if necessary.
4. When assured that the EFV is operating properly, close the LW valve and proceed
with installing the meter and regulator.
Before leaving the location, verify that an EFV identification marker has been installed.
The EFV identification marker will alert service personnel that an EFV is installed in the
service line.
45
Utility Operations Handbook
Section:
Chapter 6
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Chapter 6: Testing Mains and Services – General Procedures
Pipe Size
Length of Main
Minimum Duration
of Test
3” and less
3” and less
3” and less
3” and less
3” and less
4"
4"
4"
4"
6" and larger
6" and larger
0 feet to 250 feet
250 feet to 500 feet
500 feet to 1000 feet
1000 feet to 5000 feet
Over 5000 feet
0 feet to 250 feet
250 feet to 500 feet
500 feet to 5000 feet
Over 5000 feet
Less than 2000 feet
2000 feet or greater
15 minutes
30 minutes
1 hour
4 hours
8 hours
1 hour
2 hours
4 hours
8 hours
4 hours
8 hours
Pipe Size
Length of Service
Minimum Duration
of Test
2” or less
0 to 250 feet
5 minutes
For sizes and lengths of service not included in the chart above, use the test duration
listed for mains of that size or length.
Acceptable test mediums are Natural Gas, Air, Inert Gas.
Steel lines will be tested to a minimum of 120 psig or 150% of the MAOP, whichever is
greater. Steel lines with an MAOP of 150 PSIG or greater will require Technical
Services to specify pressure testing parameter. The minimum test time for steel mains
and transmission lines with MAOP equal to or greater than 100 PSIG and less than 150
PSIG is ONE HOUR.
Medium Density pipe (Yellow) should be tested to a minimum of 120 PSIG. High
Density pipe (Black) should be tested to a minimum of 150 PSIG.
46
Utility Operations Handbook
Section:
Chapter 6
Subject:
Tie-in/Line Pressure Control – Transmission/High Pressure Distribution
Reference:
OQ Task E1 – E4, I7, L1, M5, M8, M14: DOT 192.151, 192.627
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Any leaks or failures found during the test must be repaired and the line must be re-tested.
Tie-in joints and/or service tees not pressure tested should be soap-tested and inspected
for leaks at operating pressure.
Documentation of the pressure test shall be kept as a permanent record for the life of the
pipeline.
47
Utility Operations Handbook
Section:
Chapter 7
Subject:
Full Encirclement Sleeve Installation
Reference:
OQ Task E1 - E4, G1, I7, M5, M8, M9, M14: DOT 192.225, 192.309, 192.245,
192.703, 192.713, 192.715, 192.711 - 717, 192.719, 192.725
Issue Date:
09-04-07
Effective Date:
01-01-08
Revision Date:
01-01-08
Chapter 7: Full Encirclement Sleeve Installation
The split sleeve must be designed for the maximum allowable operating pressure of the
pipeline. Lower existing pressure on pipeline if possible until the defect is corrected on
Transmission and High Pressure Distribution systems. Follow the manufacturer’s
recommended procedure for lubrication and installation of a permanent clamp should it
be necessary to install prior to welded sleeve.
General Procedures
In conjunction with manufacturer instructions full encirclement sleeves should be
installed as follows:
Clean the pipe area where the split sleeve will be installed around its entire
circumference to remove all oil, dirt, rust, scale or other debris to ensure a proper
fit of the sleeve fitting.
Assemble encirclement sleeve and hold into place (use chain binder or similarly
approved device if necessary) then tack weld.
Weld sleeve completely in accordance with manufacturer’s recommendations and
in compliance with applicable company welding standards.
Once fitting has properly cooled, pressure test if applicable by welding a thread-olet over one vent hole and attach testing apparatus. Introduce test medium to
desired pressure and verify. Weld both vent holes if verifying by leak detection
solution only.
48
Utility Operations Handbook
Section:
Chapter 7
Subject:
Encapsulation
Reference:
OQ Task M10: DOT 192.485, 192.487, 192.753, 192.755
Issue Date:
09-04-07
Effective Date:
01-01-08
Revision Date:
03-31-11
Encapsulation
General Procedures
Encapsulation may be used for permanent repair on both steel and cast iron pipe and
components.
Permanent repair on cast iron pipe shall be accomplished be one of the following
methods:
Bell Joint Leaks
a. Encapsulation using an approved process. Anaerobic injection is a repair option.
b. Seal the joint using an approved sealing process such as Permabond Gaseal. Do
not use caulking.
c. Eliminate the bell joint by replacement or insertion with polyethylene pipe.
NOTE: Mechanical bell joint clamps or tightening of existing clamp bolts is a temporary
repair. Schedule for permanent repair as soon as practical.
Cracks
a. Install a full encirclement clamp such that the entire length of the crack is under
the clamp.
b. Encapsulate the entire length of the crack.
c. Eliminate the crack by replacement or insertion with polyethylene pipe.
Graphitization
1. Eliminate the entire segment of pipe containing graphitization by replacement or
insertion with polyethylene pipe.
Note: DO NOT install leak clamps, full encirclement clamps, or encapsulate pipe
containing graphitization.
49
Utility Operations Handbook
Section:
Chapter 7
Subject:
Encapsulation
Reference:
OQ Task M10: DOT 192.485, 192.487, 192.753, 192.755
Issue Date:
09-04-07
Effective Date:
01-01-08
Revision Date:
03-31-11
Abandoned Service Tap / holes
Either a band or a full circle clamp may be used to repair an abandoned service tap with
bad threads or a hole in the main. Be sure the sealing gasket covers the area.
1. Each cast iron caulked bell and spigot joint that is exposed for any reason must
be:
a. Encapsulated using an approved process.
b. Sealed using an approved sealing process such as Permabond Gaseal
(Do not use caulking); or
c. Eliminated by polyethylene pipe replacement or insertion.
Composite products (such as Clock Spring, Trident Seal, etc.) may be used for permanent
repair of steel pipe and components. Due to the large number of products on the market
and variety of applications and installation conditions, only approved products may be
used. All products should be applied per the manufacturer’s instructions for the
particular circumstances surrounding installation.
50
Utility Operations Handbook
Section:
Chapter 7
Subject:
Casing Pipe Installation
Reference:
OQ Task G2: DOT 192.321, 192.323, 192.467
Issue Date:
09-04-07
Effective Date:
01-01-08
Revision Date:
01-01-08
Casing Pipe Installation
An approved Technical Services design with specifications relating to casing pipe
diameter, type of pipe, carrier pipe, casing filler, vent design, cathodic protection
requirements and ability to withstand superimposed loads of the highway or railroad is
required.
When installing steel carrier pipe into steel casing pipe, Technical Services will provide
design specifications with insulator type and spacing of insulators. Before backfilling,
check for effective electrical isolation between carrier and casing pipe.
General Procedures
When installing steel pipe in steel casing steps to be taken during installation if
applicable:
When installing steel carrier pipe in steel casing, provide electrical isolation
between the carrier pipe and the casing pipe.
After the carrier pipe has been placed in the casing, check for effective
electrical isolation, this must always be accomplished before backfilling.
Seal the ends of the casing in a manner that will prevent water from entering the casing.
If vents are installed on the casing, the vents must be protected from the
weather to prevent water from entering the casing.
Pipeline markers should be installed by vents.
When installing polyethylene pipe in steel casing steps to be taken during installation if
applicable:
Remove any sharp edges or burrs.
Remove water and debris from the casing before installing the carrier pipe.
Push the pipe and tracer wire into the casing. Pull the pipe only if a weak link is installed
to reduce stress to the pipe. Examine the pipe for damage as it exits the casing.
Prevent shear stress at the casing ends after the pipe in installed.
51
Utility Operations Handbook
Section:
Chapter 7
Subject:
Invasion Tubing, Boiler Pipe – Thin Wall Pipe Repair
Reference:
OQ Task E1 – E4, F1 – F10, G1: DOT 192.225, 192.309, 192.703, 192.711 –
717, 192.725
Issue Date:
09-04-07
Effective Date:
01-01-08
Revision Date:
01-01-08
Permanent Clamp Installation
General Procedures
Lower existing pressure on pipeline if possible when installing clamp on Transmission or
High Pressure Distribution pipelines.
In conjunction with manufacturer’s instructions, install the clamp as follows:
Remove protective coating from pipe as required. Clean an area large enough to
accommodate the clamp. Taper the edge of remaining wrap at the leak location.
This eliminates voids and provides better adherence when reapplying wrap after
the repair. Clean the repair area with soapy water and a wire brush. Wipe dry
with a cotton cloth.
Apply soap solution inside of the repair clamp to ease installation.
Install the clamp and snug the center nut. Rotate the repair clamp in the proper
direction to properly seat the clamp liner.
Tighten the center nut of the clamp snugly. Alternate tightening each nut,
working away from the center, until all nuts are torque to approximately 50-ft. lbs.
on clamps up to 4” and 70 ft. lbs. on clamps larger than 4”. Bolts should be
tightened uniformly.
Test the repair clamp with leak detection fluid.
Bond the clamp to the main using 12 gauge wire. Wrap the wire tightly around the
center bolt on the clamp. Double-nut the bolt. Thermit weld the other end of the
wire to the main. Coat the wire and nuts on the bolt with mastic. This step may
be omitted when using stainless steel clamps with stainless steel bolts.
Repair the coating as needed.
Invasion Tubing
Technical Services will be notified for further direction when invasion tubing, boiler pipe
and other non-standard pipe is exposed.
52
Utility Operations Handbook
Section:
Chapter 8
Subject:
Damage Prevention – Pipeline Locating and Marking
Reference:
OQ Task M3, M14: DOT 192.614
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Chapter 8: Damage Prevention – Line Locating
General Procedures
Refer to manufacturer’s recommendations and operating instructions for maintenance of
equipment related to pipeline marking and locating.
Refer to company maps detailing pipeline locations and indicators of the presence of a
pipeline including pipeline markers, gas meters, regulating stations, rectifier boxes etc.
Pipeline locators should be used on every pipeline location with the exception of plastic
mains which were installed without locator wire or devices.
If a non-locatable plastic pipeline is exposed, an approved locating device should be
installed.
Approved marking paint, flags or a combination will be used when locating Atmos gas
pipelines.
If using “Smart” locators, depths will not be provided to excavators.
If an Atmos Energy gas pipeline is not in the proposed excavation site, an approved flag
noting “Atmos Energy Gas Pipeline Not Present” should be used. In situations where it
is not practical to use an approved flag, consult with the excavator or provide an
indication (paint) that an Atmos Energy pipeline is not present.
Transmission lines require on-site excavation inspection by Atmos employees at cross
points or if the pipeline is being paralleled to ensure the integrity of the pipeline is not
compromised.
Atmos may also require its natural gas pipelines to be exposed prior to excavation to
ensure damage does not occur. In either event, local supervision will decide which action
is appropriate to ensure pipelines are not damaged by excavators.
53
Utility Operations Handbook
Section:
Chapter 8
Subject:
Directional Boring
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
12-17-08
Directional Boring
General Procedures
All areas except for Georgia, Illinois, Missouri & Virginia
Construction Procedure
When practical, utility lines such as phone cables, water mains, television cables and
electric cables should be exposed at cross points before directional boring process begins.
Special consideration is to be given to storm sewers, sewer mains and laterals due to the
inability to locate these types of lines. If possible, expose sewer mains and laterals and
observe the drill stem as it crosses to ensure clearance between pipeline and sewer line.
Directional bores must be recorded on the appropriate field work order noting changes in
directions and when pipe depth is less than 24 inches or greater than 60 inches. Any
deviations from normal depth of 24 inches to 60 inches will be recorded at 10 foot
intervals.
The design for pipe directional bores that exceed 6 feet in depth shall be approved by
Technical Services.
Investigation Procedure
When contacted to investigate a sewer problem, local supervision will determine what
type of assistance is needed to resolve the issue.
All appropriate personal protective equipment will be used and safety guidelines will be
followed during the boring process.
Georgia Only
Georgia Public Service Commission has adopted the 'Horizontal Directional Drilling
Good Practice Guidelines,' dated May, 2001.
Illinois Only
The State of Illinois legislature enacted the “Illinois Underground Utilities Facilities
Damage Prevention Act”. This act provides state specific excavation guidelines.
54
Utility Operations Handbook
Section:
Chapter 9
Subject:
Appendix
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
Chapter 9: Appendix
POLYETHYLENE QUALIFICATION – GENERAL GUIDELINES
Destructive Testing
Polyethylene Pipe Bend Radius
Ditch Width Minimum Table
Pipeline Protective Covering
Dissimilar Polyethylene Materials Table
Static Electricity
Hot Spot – Anode Installation______________________________
Internal Resources_______________________________________
Terms, Definitions and Acronyms
55
01-01-08
Utility Operations Handbook
Section:
Appendix
Subject:
Polyethylene and Polyamide Qualification
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
Polyethylene Qualification
Pipe sizes for qualification testing on plastic pipelines should be determined locally
depending on what is predominately used in the area.
Destructive Testing – General Guidelines
Butt Fusion
For butt fusion, compare to the Plastics Pipe Institute (PPI) acceptable fusion
recommendation for bead visibility and size.
For butt fusion, saw three test straps approximately 3/4" wide and 14" long at 120°
intervals around the pipe.
Examine for voids and gaps at the joint. Grip samples 3" from each side of the fusion
and bend 180º both ways. Inspect for separations, cracks or voids. If fusion remains
intact, it passes the test.
Saddle Fusion
For saddle fusion, compare to the Plastics Pipe Institute (PPI) acceptable fusion
recommendation for bead visibility and size.
Saw the fused saddle into 2 - 14" long test straps. Both sides of the saddle bead should
be on edge of the straps. Inspect for voids, cracks, or separation.
Grip test strap 3" on each side of the cut portion of the saddle. Bend 180º with the saddle
on the outside portion. If there are no visible cracks, separation or voids, the sample
passes the test.
56
Utility Operations Handbook
Section:
Appendix
Subject:
Polyethylene and Polyamide Qualification
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
03-31-11
ELECTRO-FUSION
For Electro-Fusion, saw three test straps approximately 3/4" wide and 14" long at 120°
intervals around the pipe.
Examine for voids and gaps at the joint. Grip samples 3" from each side of the fusion
and bend 180º fitting on the outside portion. Inspect for separations, cracks or voids. If
fusion remains intact, it passes the test.
General Qualification Requirements
Any fusion joint or mechanical fitting installation found unacceptable by supervisor or
designee during the qualification process requires the testing person to review applicable
guidelines and instructions before re-taking qualification test.
A person must be re-qualified:
Annually or,
If during any 12 month period that person does not make any joints under the qualified
procedure or,
If that person has 3 joints or 3% whichever is greater, of the joints made found to be
unacceptable by pressure testing.
57
Utility Operations Handbook
Section:
Appendix
Subject:
Ditch Width Minimum Table - Rock
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
POLYETHYLENE PIPE BEND RADIUS
Bend polyethylene pipe in accordance with figure below.
Minimum Radius with no fusion joint in bend:
= 25 x outside diameter of pipe
Minimum Radius with fusion joint in bend:
= 125 x outside diameter of pipe
If minimum radius cannot be maintained, elbow fittings must be installed.
58
01-01-08
Utility Operations Handbook
Section:
Appendix
Subject:
Ditch Width Minimum Table - Rock
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
Refer to radius table for the minimum radius requirements:
Size
1/2"
3/4"
1 1/4"
2"
3"
4"
6"
8"
10"
12"
Minimum Radius
No Fusion
1' 9"
2' 2"
3' 6"
5'
7' 4"
9' 6"
13' 10"
18'
22' 5"
26' 7"
Minimum Radius
With Fusion
8' 9"
10' 8"
17' 4"
24' 9"
36' 6"
46' 11"
69'
89' 10"
112'
133'
Note: Service saddles and high-volume tap tees will not be installed in a bend.
59
01-01-08
Utility Operations Handbook
Section:
Appendix
Subject:
Ditch Width Minimum Table - Rock
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Ditch Width Minimum Table
Minimum Ditch Width
Pipe Size
Ditch Width
1 1/4" or less
6"
2"
8"
3"
12"
4"
12"
6"
14"
8"
18"
Note: Maintain 6 inches of clearance on each side of pipe larger than 8 inches in
diameter.
Backfilling should ensure the pipeline is not damaged by bedding in granular material
and using at least 6 inches of granular material or other approved method above the pipe.
60
Utility Operations Handbook
Section:
Appendix
Subject:
Pipeline Protective Covering
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Pipeline Protective Covering
Additional protection for a pipeline can be achieved with steel plating or a layer of
reinforced concrete above the pipeline.
Backfilling should ensure the pipeline is not damaged by bedding in granular material
and using at least 6 inches of granular material or other approved method above the pipe.
Technical Services approval required before installing protective covering.
Street
surface
Protective Layer –
Steel plate or 5” of
reinforced concrete
6” Minimum
Main with 6” of
bedding material
61
Utility Operations Handbook
Section:
Appendix
Subject:
Dissimilar Polyethylene Materials Table – Approved Joining Methods
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
Dissimilar Polyethylene Table
Pipe Types to be Joined
PE 2406 / 2708
Dupont Aldyl A
03-31-11
Method
Electro-fusion
PE 2306
Dupont Aldyl A
Electro-fusion
Dupont Aldly A
Dupont Aldyl A
Electro-fusion
Dupont Aldly A
PE 3406
Electro-fusion
Dupont Aldly A
PE 3408 / 4710
Electro-fusion
Driscopipe 7000 or 8000
PE 3406
Electro-fusion
Driscopipe 7000 or 8000
PE 3408 / 4710
Electro-fusion
Driscopipe 7000 or 8000
Dupont Aldly A
Electro-fusion
Driscopipe 7000 or 8000
PE 2306
Electro-fusion
Driscopipe 7000 or 8000
PE 2406 /2708
Electro-fusion
Driscopipe 7000 or 8000
Driscopipe 7000 or 8000
Electro-fusion
Notes:
1. Dupont Aldyl A is a PE 2306 pipe
2. Driscopipe 7000 is a PE 3406 pipe
3. Driscopipe 8000 is a PE 3408 Pipe
62
Utility Operations Handbook
Section:
Appendix
Subject:
Static Electricity
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Static Electricity
When confronted with a gas leak from damaged plastic piping, stopping the flow of gas
by squeeze-off in remote bell holes is the initial consideration. These two bell holes
should be adjacent to, but far enough away from the gaseous atmosphere, to prevent
ignition (should a static discharge occur).
Arc-preventing safety precautions are necessary if conditions exist that flammable gas-inair mixture may be encountered and static charges may be present, such as when:
Repairing a leak
Squeezing-off an open pipe
Purging
Making a connection, etc.
General Procedures
If natural gas is present, the pipe should be sprayed with anti-static solution prior
to entering excavation. Wet the pipeline starting from ground end towards
damaged section.
Start wrapping from the ground end and work towards damaged section. The
anti-static wrapping should be wound around or laid in contact with the entire
section of the exposed piping. The anti-static wrapping should left in place during
the repair process.
The anti-static wrapping should be kept wet by occasional applications of antistatic solution. The anti-static wrapping should be grounded properly.
Ground all tools including squeeze off device, saw or cutting device, clamps,
fusion equipment etc.
A manned fire extinguisher should be present when an employee is working in a
flammable atmosphere.
Do not vent gas using an ungrounded plastic pipe or tubing. Even with grounded metal
piping, venting gas with high scale or dust content could generate a charge in the gas
itself and could result in an arc from the dusty gas cloud back to the pipe and ignition.
63
Utility Operations Handbook
Section:
Appendix
Subject:
Hot Spot – Anode Installation
Reference:
DOT 192.461, 192.483
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Hot Spot Anode Installation
The “hot spot” method may be used on such lines when cathodic protection is not
practical.
Each segment of metallic pipe that replaces pipe removed from a buried or
submerged pipeline because of external corrosion must have a properly prepared
surface and must be provided with an external protective coating.
Each segment of metallic pipe that replaces pipe removed from a buried or
submerged pipeline because of external corrosion must be cathodically protected.
Except for cast iron or ductile iron pipe, each segment of buried or submerged
pipe that is required to be repaired because of external corrosion must be
cathodically protected.
General Procedures
On well-coated lines, a minimum separation of 18" should be maintained between
the pipe and the anode.
On bare or poorly coated pipe, this distance should be extended to a minimum of
three feet.
It is important that water be poured on the anode to initiate the generation of
electric current.
DO NOT cut or tear the cloth bag containing the anode as this destroys the
effectiveness of the prepared low resistance backfill.
Anodes may be installed horizontally where soil conditions prevent vertical
installation.
Anodes should be installed at a level below the bottom of the pipe that they are to
protect.
Good installation of anodes requires that the backfill be well tamped.
If needed, an anode may have a connecting wire extended to the surface to
provide a means of checking current flow.
The appropriate Corrosion Control Representative shall be consulted to determine
the need.
64
Utility Operations Handbook
Section:
Appendix
Subject:
Internal Reference Material
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Internal Reference Material
Internal Resources:
Safety Manual
Section 2 – Bloodborne Pathogens
Section 3 – Confined Space Entry
Section 4 – Lockout/Tagout Procedures
Section 7 – Ladder Safety
Section 8 – First Aid
Section 11 - Personal Protective Equipment
Section 13 – Trenching, Shoring and Excavation
Section 14 – Tools and Equipment
Section 15 – Traffic Safety
Section 16 – Respiratory Protection
Section 19 – Emergency Action and Fire Prevention
Section 20 – Natural Gas Safety
http://atmosphere.atmosenergy.com/docs
Operations & Maintenance Manual
Section 2 – Pipeline Integrity
Section 3 – Damage Prevention Program
Section 5 – Maximum Allowable Operating Pressures
Section 6 – Abandoning / Reinstating Facilities
Section 7 – Pipeline Markers
Section 8 – Valve Maintenance
Section 9 – Gas Leak Surveys
Section 10 – Pipeline Patrolling
Section 11 – Pressure Control Stations
Section 12 – Odorization
Section 13 – Corrosion Control
Section 14 – Purging
Section 15 – Protecting Cast Iron Pipelines
Section 16 – Tapping Pipelines Under Pressure
Section 18 – Transmission
Section 19 – Uprating
Section 22 – Pipe Joining
Section 23 – Meters, Regulators and Service Lines
Section 24 – Test Requirements
Section 26 – Material Failure
http://atmosphere.atmosenergy.com/docs
65
Utility Operations Handbook
Section:
Appendix
Subject:
Internal Reference Material
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Service Procedure Manual
http://atmosphere.atmosenergy.com/docs
Measurement Procedures Manual
Chapter 4 – Meter By-Pass
Chapter 5 – Regulator By-Pass
http://atmosphere.atmosenergy.com/docs
Pipeline Integrity Management Plan
http://atmosphere.atmosenergy.com/docs
Procurement Material Failure Website Reporting
http://atmosphere.atmosenergy.com/apps
Welding Procedures Manual
http://atmosphere.atmosenergy.com/docs
66
Utility Operations Handbook
Section:
Appendix
Subject:
Terms, Definitions and Acronyms
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
Terms, Definitions and Acronyms
System Pressures
MAOP
High Pressure Distribution system
Intermediate Pressure system
Transmission system
Utilization Pressure system
Maximum Allowable Operating Pressure
MAOP >IP pressure and < 20% SMYS unless
otherwise noted
MAOP can vary from 1 through 100 PSIG
MAOP > 20% SMYS
MAOP < 1 PSIG
NOTE: Some intermediate pressure systems are less than 60 LBS due to pressure rating
and testing pressures which established the MAOP of each system when it was installed.
These vary due to different types of pipe that were installed prior to the standardization of
the 60 and 100 PSIG systems. Refer to Testing Section of the Construction Procedure
manual for guidance when installing pipe on system MAOP of less than 60 PSIG for
guidance. Technical Services approval is required if testing pressures do not meet the
minimum requirements in the Construction Procedure manual.
General Acronyms
AGA
AOC
BCF
BTU
CCF
CFR
CGI
City Gate
CNG
CO
CPR
CSST
DIM
DOE
DOT
eAM
EFV
– American Gas Association
– Abnormal Operating Condition
– Billion Cubic Feet
– British Thermal Unit
– Hundred Cubic Feet
– Code of Federal Regulations
– Combustible Gas Indicator
– Delivery point for pipeline or transport company to LDC
– Compressed Natural Gas
– Carbon Monoxide
– City Plant Regulator Station
– Corrugated Stainless-Steel Tubing
– Distribution Integrity Management
– Department of Energy
– Department of Transportation
– Enterprise Asset Management
– Excess Flow Valve
67
Utility Operations Handbook
Section:
Appendix
Subject:
Terms, Definitions and Acronyms
Reference:
Issue Date:
09-04-07
Effective Date: 01-01-08
Revision Date:
01-01-08
EPA
– Environmental Protection Agency
FERC
– Federal Energy Regulatory Commission
FI Unit/ Flame Pak – Flame Ionization Unit
HCA
– High Consequence Area
H.E.L.P.
– Identify Hazard, Evaluate the Risk, Protect Life, Protect Property
HP Dist
– High Pressure Distribution system
H2 S
– Hydrogen Sulfide Gas
IP
– Intermediate Pressure system
IMP
– Integrity Management Program
LDC
– Local Distribution Company
LEL
– Lower Explosive Limit generally accepted as 4.5% gas concentration
LNG
– Liquefied Natural Gas
L&U
– Lost and Unaccounted for Gas
MAOP
– Maximum Allowable Operating Pressure
MCF
– Thousand Cubic Feet
NGV
– Natural Gas Vehicle
O&M
– Operations and Maintenance Manual
OMD
– Optical Methane Detector
OQ
– Operator Qualification
OPS
– Office of Pipeline Safety
OSHA
– Occupational Safety & Health Administration
PIG
– Intelligent PIG’s are used for internal inspections of pipelines
PPI
– Plastics Pipe Institute
PSIA
– Pounds per Square Inch Atmospheric
PSIG
– Pounds per Square Inch Gauge
PIM
– Pipeline Integrity Management
PPE
– Personal Protective Equipment
RAD
– Riser Alignment Device
SCADA
– Supervisory Control and Data Acquisition
SGA
TBS
SMYS
UEL
UOC
UP
UPM
– Southern Gas Association
– Town Border Station
– Specified Minimum Yield Strength
– Upper Explosive Limit generally accepted as 14.5% gas concentration
– Utility Operations Council
– Utilization Pressure system
– Utilization Pressure Manifold
WNA
– Weather Normalization Adjustment
68
Utility Operations Handbook
Section:

Subject:


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
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
 
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











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








Utility Operations Handbook
Section:

Subject:

Reference:
 
Issue Date:


Effective Date:

Revision Date:



Original Approved by:



Utility Operations Handbook
Section:

Subject:

Reference:
 
Issue Date:


Effective Date:

Revision Date:




















 










Original Approved by:



Utility Operations Handbook
Section:

Subject:

Reference:

Issue Date:


Effective Date:

Revision Date:





             
                 



















Original Approved by:



Utility Operations Handbook
Section:

Subject:

Reference:

Issue Date:

Effective Date:

Revision Date:















Original Approved by:



Utility Operations Handbook
Section:
Operations & Maintenance
Subject:
Test Requirements – For Pipelines Operating Below 100 psig (24.5)
Reference:
192.509, KAR 82-11-4(s)
Issue Date:
03/07
24.5
Effective Date:
01/08
Revision Date:
02/09
Test requirements for pipelines to operate below 100 psig
Except for service lines and plastic pipelines, each segment of pipeline to be operated below
100 psig shall be leak tested in accordance with the following:
(a) The test procedure used shall ensure discovery of all potentially hazardous leaks in the
segment being tested.
(b) Each segment of main shall be tested as outlined by Construction Procedure manual
Chapter 6.
Kansas Specific KAR 82-11-4(s)
Each steel main that is to be operated at less than 1 p.s.i.g. shall be tested to at least 10 p.s.i.g.
and each main to be operated at or above 1 p.s.i.g. shall be tested to at least 100 p.s.i.g.
Original Approved by:
Utility Operating Council
Page 1 of 1
Utility Operations Handbook
Section:

Subject:

Reference:

Issue Date:


Effective Date:

Revision Date:





  
               
   
Original Approved by:



Utility Operations Handbook
Section:

Subject:

Reference:

Issue Date:


Effective Date:

Revision Date:










Original Approved by:



Utility Operations Handbook
Section:

Subject:

Reference:

Issue Date:


Effective Date:

Revision Date:





              
              

                 

Original Approved by:



Utility Operations Handbook
Section:
Operations & Maintenance
Subject:
Test Requirements - Records (24.9)
Reference:
192.517, KAR 82-11-4 (t)& (u)
Issue Date:
03/07
24.9
Effective Date:
01/08
Revision Date:
02/09
Records
Each operator shall make, and retain for the useful life of the pipeline, a record of each test
performed under subsections (3) and (4) of this section. The record shall contain at least the
following information:
(a) Operator's name, name of operator's employee responsible for making the test, and
name of any test company used.
(b) Test medium used.
(c) Test pressure.
(d) Test duration.
(e) Pressure recording charts, or other record of pressure readings.
(f) Elevation variations, whenever significant for the particular test.
(g) Leaks and failures noted and their disposition.
(h) Test date.
(i) Description of facilities being tested.
(j) For any pipeline installed after May 1, 1989, each operator shall make, and retain for the
useful life of the pipeline, a record of each test performed under §§ 192.509, 192.511 and
192.513.
Original Approved by:
Utility Operating Council
Page 1 of 1
Utility Operations Handbook
Section:

Subject:

Reference:

Issue Date:

Effective Date:

Revision Date:

 

 
 
 

  

 
 



 




Original Approved by:



Utility Operations Handbook
Section:
Operations & Maintenance
Subject:
Prevention of Accidental Ignition (21.1)
Reference:
192.605(b)(9), 192.751
Issue Date:
03/07
Effective Date:
0/0
Revision Date:
0/0
21.1 Prevention of Accidental Ignition
Each operator shall take steps to minimize the danger of accidental ignition of gas in any
structure or area where the presence of gas constitutes a hazard of fire or explosion, including
the following:
1. When a hazardous amount of gas is being vented into open air, each potential source
of ignition will be removed from the area and a fire extinguisher will be provided.
See Atmos Energy Corporation’s Safety Manual
Section 16 “Respiratory Protection” for guidance on the Definition of a
“Hazardous Atmosphere - 4.5”
“Requirements for Working in a Potentially Hazardous Atmosphere
(Engineering/Administrative Controls) - 5.1 through 5.45”
2. Gas or electric welding or cutting will not be performed on pipe or on pipe components
that contain a combustible mixture of gas and air in the area of work. In removing
combustible mixture of gas an air mover/purger may be utilized.
3. Post warning signs, where appropriate.
4. Adequate precautions will be taken in excavation trenches to protect personnel from
the hazards of unsafe accumulations of vapor or gas. Emergency rescue equipment,
including a breathing apparatus and a rescue harness with line, will be made available
when needed at the excavation.
See Atmos Energy Corporation’s Safety Manual
Section 16 “Respiratory Protection” for guidance on “Training - 3.1 through 3.7”
“Definitions - 4.1 through 4.9”
“Requirements for Working in a Potentially Hazardous Atmosphere
(Engineering/Administrative Controls) - 5.1 through 5.4”
“Requirements to sample Atmosphere - 7.1 - 7.2”
5. Fire extinguishers will be in the area of work, during tie-ins, squeeze offs, tapping or
purging operations, or if a hazardous amount of gas may be introduced into the area,
and should be available upwind and adjacent to the work area. The fire extinguisher
should be checked to ensure it is ready for service.
Original Approved by:
Utility Operating
Council
Page 1 of 1
Utility Operations Handbook
Section:
Welding Procedures Welder Qualification and Inspection (WPWQI)
Subject:
Cover Introduction
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
ATMOS ENERGY
ENTERPRISE DIVISIONS
WELDING PROCEDURES
WELDER QUALIFICATION
AND INSPECTION
MANUAL
(WPWQI)
MAY 25, 2010
Original Approved by:
Utility Operating Council
Page 1 of 2
Utility Operations Handbook
Section:
Welding Procedures Welder Qualification and Inspection (WPWQI)
Subject:
Cover Introduction
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Atmos Energy Corporation
UOC Procedures Manual Team
P. O. Box 650205 – Dallas, TX 75265-0205
Phone 972.934.9227 – Fax 972.855.3080
THE INFORMATION CONTAINED IN THIS MANUAL IS CONFIDENTIAL
AND IS INTENDED SOLELY FOR REVIEW OR USE BY THE EMPLOYEES
OF ATMOS ENERGY CORPORATION IN CONNECTION WITH COMPANY
OPERATIONS AND MAINTENANCE PROCESSESS AND MEASUREMENT
PROCEDURES. ANY OTHER DISTRIBUTION OR COPYING OF THIS
MANUAL OR ANY OF THE MATERIALS HEREIN, OTHER THAN FOR
PERMITTED PURPOSES, IS STRICTLY PROHIBITED.
Original Approved by:
Utility Operating Council
Page 2 of 2
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welding Procedures Welder Qualification and Inspection Program
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006
Specification No.:
Revision Date: May 25, 2010
WPWQI
Table of Contents
TITLE
WPWQI Program
Qualifying and Approving Welding Procedures
Qualifying Welders by Representation
Welder Qualification
Qualifying Visual Welding Inspectors by Representation
Visual Welding Inspector Qualification
Welding Procedure Specification Outline
Welding Procedure Specification Selection Guide
Inspection and Testing of Production Welds
Repair and Removal of Defects
Visual Welding Inspection Report Form WIR
Welder Qualification Record Form WQR
Welder and VWI Qualification RightFax Form
Welder Qualification Specification API-1104 Multiple
Welder Qualification Specification API-1104 Multiple-Low Hydrogen
Welder Qualification Specification CFR-192 Appendix C
Welder Qualification Specification API-1104 Single
Welder Qualification Specification CFR-192 Appendix C Oxyacetylene
Welder Qualification Specification API-1104 GMAW Multiple Fixed
Welder Qualification Specification API-1104 GMAW Multiple Rolled
Welder 6-Month Re-qualification Specification API-1104 Multiple
Welder 6-Month Re-qualification Specification API-1104 Multiple-Low Hydrogen
Welder 6-Month Re-qualification Specification API-1104 GMAW Multiple Fixed
Welder 6-Month Re-qualification Specification API-1104 GMAW Multiple Rolled
Welder Qualification Specification API-1104 Gas Tungsten Metal-arc (GTAW)
Original Approved by:
CHAPTER
1
2
3
4
5
6
7
8
9
10
Form WIR
Form WQR
Form RFAX
WQS-1M
WQS-1ML
WQS-1C
WQS-1S
WQS-1OXY
WQS-1MIGX
WQS-MIGR
WQS-6CW
WQS-6CWL
WQS-6MIGX
WQS-6MIGR
WQS-1TS
Utility Operating Council
Page 1 of 1
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 1
1.1
SCOPE
The Welding Procedure, Welder Qualification and Inspection Program (WPWQI) has been
developed for the qualification and approving of new welding procedures for the use on new
construction and maintenance in-service welding. These procedures have been adopted for
use by Atmos Energy. The WPWQI program includes new welding specifications, welder
qualification and welding inspection practices.
New welding procedures have been qualified under the API Standard 1104, Nineteenth
Edition, September 1999; Welding of Pipelines and Related Facilities. The WPWQI Program
references this Standard as the qualifying Standard.
Welder qualification has been defined under this program to ensure compliance with the
qualifying Standard. All welder qualifications for use on Atmos Energy Facilities shall be in
compliance with Title 49, CFR Part 192.227(a) and Title 49, CFR Part 192.227(b) where
applicable. A welder may be required to re-qualify if a question arises about his competence.
The welder qualification program provides for four (4) different types of qualifications to
comply with API-1104, Section 6 and Appendix “C” of Part 192.
A. API-1104 Single Qualification
B. API-1104 Multiple Qualification
C. API-1104 Multiple Qualification Low Hydrogen
D. CFR Part 192, Appendix “C” Qualification Of Welders For Low Stress Level Pipe
(Less than 20 SMYS)
Welding inspection performed under this program shall be in compliance with the qualifying
Standard. All welding inspection performed on Atmos Energy Facilities shall be in compliance
with API-1104, Section 9.
The WPWQI Program provides additional details and processes for welding pipe and
materials in accordance with Atmos Energy Welding Procedure Specifications and the
requirements of the qualifying Standard.
The WPWQI Program shall be maintained by Technical Services and shall be followed,
except where a change is specifically authorized by Technical Services as provided by the
qualifying Standard.
Original Approved by:
Utility Operating Council
Page 1 of 1
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Qualifying and Approving Welding Procedures
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006
Revision Date:
Chapter: 2
2.1
GENERAL
All welding procedures shall be qualified in accordance with API Standard 1104,
Nineteenth Edition, September 1999; Welding of Pipelines and Related Facilities. This
Standard covers arc and oxyacetylene welding of butt and fillet welds in carbon and lowalloy steel pipe and components used in the compression, pumping, transmission and
distribution systems.
2.2
PROCEDURE QUALIFICATION
Before production welding can be performed, a detailed procedure specification shall be
established, qualified and approved to demonstrate that welds with suitable mechanical
properties such as strength, ductility, hardness and soundness can be made by the
specification. The quality of the welds shall be determined by destructive testing. These
procedure specifications shall be adhered to except where a change is specifically
authorized by Technical Services as provided for in the API Standard 1104, Nineteenth
Edition, September 1999; Welding of Pipelines and Related Facilities. A welding
procedure must be re-established as a new procedure specification and must be
completely re-qualified if any of the essential variables as specified in the above
qualifying Standard are changed.
2.3
RECORD DETAILS
The details of each qualified welding procedure shall be recorded on the Procedure
Qualification Record (Form PQR). The PQR shall show complete results of the
procedure qualification test. The PQR shall be maintained as long as the procedure is in
use.
2.4
RECORD KEEPING
All original PQR’s shall be maintained by Technical Services. These PQR’s shall be
maintained to be provided for review as requested. All requests for information shall be
directed to the appropriate Technical Services Representative.
Original Approved by:
Utility Operating Council
Page 1 of 1
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Representation
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Effective Date: June 13, 2006 Revision Date:
Chapter: 3
3.1
REPRESENTATION OF WELDERS
Welders that are to be tested under this program are required to have representation. The
representative will be an Atmos Energy or Contractor Designee.
Designee’s are responsible for insuring that all welders in their area of responsibility are
qualified under this program and the welder maintains a current welding permit. The
designee is responsible for coordinating all welder qualification and renewal tests. The
designee will be responsible for any and all cost associated with the qualification of
welders. This cost may include the test nipples, welding electrodes, oxygen/acetylene
and/or other expenses incurred by the Welding Inspector.
Original Approved by:
Utility Operating Council
Page 1 of 1
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4.1
4
NEW WELDER QUALIFICATION
All welding to be performed on Atmos Energy Facilities, whether Company or Contractor
including in-house pre-fabrication and all off-site welding that will become a part of an Atmos
Energy Facility shall be performed by welders who have been qualified to the applicable
procedure specification under the Atmos Energy Welding Program. Welding associated with
manufactured fittings and assemblies that is provided as a material product such as factory
welds shall be acceptable to Atmos Energy. Welding will not be allowed by any welder who has
not qualified under an Atmos Energy approved program.
The purpose of the welder qualification test is to determine the ability of welders to make sound
butt or fillet welds using previously qualified procedures. Before any production welding is
performed, welders shall be qualified according to the applicable requirements of the qualifying
standard.
A welder shall be qualified by completing a test weld in accordance with an applicable
procedure specification and subjecting the test weld to the visual and destructive testing
requirements.
The welder shall be allowed reasonable time to setup and adjust his welding equipment to be
used. The welder shall use the same welding technique and proceed with the same speed he
will use if he passes the test and is permitted to do production welding. The qualification of
welders shall be conducted in the presence of an Atmos Energy Welding Inspector or other
testing firm certified and authorized to perform welder qualifications.
All testing firm
certifications shall be verified and acceptable by Atmos Energy.
A welder shall qualify for welding by performing a test on pipe nipples as specified. Pipe nipples
shall be supported so that typical flat, vertical and overhead welds are produced.
All welders qualifying for the first time shall be the responsibility of the Company or Contractor
Designee. The Designee shall request to have a welder tested by contacting the appropriate
Atmos Energy Welder Inspector. The request shall be submitted in a manner to allow proper
time to perform the process before the welder is required to report for duty. Normally 24 to 72
hours is required for the test and to receive the testing results. These times may vary and are
dependant upon the Welding Inspector. The Welding Inspector shall fill in and complete the
Welder Qualification Record (Form WQR) for each new welder qualification test. The WQR
shall be sufficiently detailed to demonstrate that the qualification test(s) met the requirements of
the qualifying standard for each test given. The WQR shall be submitted along with the
destructive test results to Technical Services for processing. A list of qualified welders and the
procedures for which they are qualified shall be maintained by Technical Services. A welder
may be required to re-qualify if a question arises about his competence.
Original Approved by:
Utility Operating Council
Page 1 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
Company Welders
The Company welder’s Supervisor acting as the Designee shall contact the appropriate Atmos
Energy Welding Inspector. Once the request has been received, the Designee will be
contacted to set up a date, time and place to perform the welding test. The Atmos Energy
Welding Inspector has the necessary testing equipment to come to your site to administer the
welding test or may determine the site. Where there is more than one (1) welding test to be
administered at one time, the Welding Inspector may determine the site for testing. For
welding tests to be administered to welders from different geographical locations a centrally
located testing site will be selected at the discretion of the Atmos Energy Welding Inspector.
Contract Welders
The Contractor Designee shall contact the appropriate Atmos Energy Welding Inspector.
Once the request has been received, the Designee will be contacted to set up a date, time
and place to perform the welding test or directed to a testing firm that has been authorized to
administer welder qualifications by Atmos Energy.
Independent Rig Welders
Independent Rig Welders shall contact an authorized Contractors Office for representation.
The Representative acting as Designee shall contact the appropriate Atmos Energy Welding
Inspector. Once the request has been received, the Designee will be contacted to set up a
date, time and place to perform the welding test or directed to a testing firm that has been
authorized to administer welder qualifications by Atmos Energy.
All Company, Contractor and Independent Rig Welders qualifying for the first time shall
demonstrate their abilities by performing a welding test issued by either Atmos Energy or other
approved testing firm using the Atmos Energy approved welding procedure specifications and
having the test welds destructively tested. Radiographic testing of test welds for new welder
qualification shall not be accepted by Atmos Energy. Once the welder has demonstrated his
ability by passing the test, he will be issued a six (6) month welding permit allowing the welder to
make welds on Atmos Energy Facilities. The permit will be mailed to the requesting Designee for
documentation and issuance to the welder. A welder may be required to re-qualify if a question
arises about his competence.
Any welder not passing the welding test on his first try may re-take the test at a later date as
specified by the Atmos Energy Welding Inspector. This date shall not be less than one (1)
working day from the initial test date. A welder not passing the welding test on his second try
shall have Designee approval to re-take the test and shall show proof of any welding training
and/or courses taken. A welder not passing the test on his third consecutive try shall be
disqualified from further testing.
Contractors and Independent Rig Welders qualified to perform welding on Atmos Energy Facilities
shall show proof of contractors insurance coverage’s in the amount that is acceptable to Atmos
Energy before any welding is allowed. Atmos Energy may request at any time to review the
Contractors or Independent Rig Welders proof of insurance coverage.
Original Approved by:
Utility Operating Council
Page 2 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4.2
4
WELDER QUALIFICATION RENEWAL
API-1104 Welders re-qualifying under the Atmos Energy Welding Program shall show proof of
welding using the same process as those qualified by Atmos Energy within the preceding 6
calendar months to be eligible for a renewal. The proof of welding may be determined from the
welder’s previous employer or from the Atmos Visual Welding Inspection Form. The welder
shall be required to submit a six (6) inch test weld to Atmos Energy for radiographic or
destructive testing. See Figure A1 and Table 1 for specifications on destructive test coupons. A
six (6) inch or larger production weld that has been radiographic tested and found to be
satisfactory may also be used as the renewal method. Radiographic testing of production
welds for the use of welder renewal shall be double exposed to provide documentation for both
the project and welder renewal files.
API-1104 welders failing the re-qualification test may be given a second opportunity to re-qualify
as described by the Welding Inspector. The second opportunity re-qualification test shall be
performed on the date as specified by the Welding Inspector. An API-1104 welder failing the
second opportunity re-qualification test shall be disqualified from performing any further welding
on Atmos Energy Facilities and shall be required to take the complete New Welder Qualification
Test for qualifying to weld on Atmos Energy Facilities. A welder may be required to re-qualify if
a question arises about his competence.
Company Welders - The Designee should contact the appropriate Welding Inspector for a
welder renewal within thirty (30) calendar days of the current card expiration date. Renewal
requests for any welder received after the current expiration date shall be discarded and the
welder will be required to qualify as a new welder. Once the request has been made, the
Designee will be contacted to set up a date, time and place to perform the welding test or other
instructions for the request. The Welding Inspector shall fill in and complete the Welder
Qualification Record (Form WQR) for the welder re-qualifying and submit the document along
with the radiographic report (if non-destructive testing was used as the testing means) to the
appropriate department for processing. Once the welder has demonstrated his ability by
passing the test, he will be issued a renewal six (6) month welding permit allowing the welder to
make welds on Atmos Energy Facilities.
Company Welders qualifying under Appendix C of Part 192 must re-qualify annually in order to
remain qualified.
Original Approved by:
Utility Operating Council
Page 3 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
Contractor Welders - The Designee shall contact the appropriate Atmos Energy Welding
Inspector or an approved testing firm that has been authorized to administer welder
qualifications and renewals by Atmos Energy within thirty (30) calendar days of the welder’s
current card expiration date. Renewal requests for any welder received after the current
expiration date shall be discarded and the welder will be required to qualify as a new welder.
The Atmos Energy Welding Inspector or testing firm authorized to administer welder renewals
shall complete the Welder Qualification Record (Form WQR), radiographic report (if nondestructive testing was used as the testing means) and the 6-month renewal card (if the welder
passes the test) and submit these to the Designee. A completed copy of the Welder
Qualification Record (Form WQR) and radiographic report shall also be furnished to the
appropriate Atmos Energy Records Group.
Independent Rig Welders - Independent Rig Welders shall contact their Contractor Designee
for renewals. The Designee shall contact the appropriate Atmos Energy Welding Inspector or
an approved testing firm that has been authorized to administer welder qualifications and
renewals by Atmos Energy within thirty (30) calendar days of the welder’s current card
expiration date. Renewal requests for any welder received after the current expiration date
shall be discarded and the welder will be required to qualify as a new welder. The Atmos
Energy Welding Inspector or testing firm authorized to administer welder renewals shall
complete the Welder Qualification Record (Form WQR), radiographic report (if non-destructive
testing was used as the testing means) and the 6-month renewal card (if the welder passes the
test) and submit these to the Designee. A completed copy of the Welder Qualification Record
(Form WQR) and radiographic report shall also be furnished to the appropriate Atmos Energy
Records Group.
4.3
WELDER QUALIFICATION RECORD KEEPING
All original Company WQR’s shall be maintained by the appropriate Atmos Energy Records
Group. These WQR’s shall be maintained to be provided for review as requested. All requests
for information shall be directed to the Atmos Energy Designee. Each Welder shall be
responsible for keeping their welding qualification current. There shall be no notices of welding
permit expirations mailed out.
All original Contractor and Independent Rig Welder WQR’s can be maintained by an external
database. Access to these records shall be available to Atmos Energy.
Original Approved by:
Utility Operating Council
Page 4 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4.4
4
API-1104 MULTIPLE QUALIFICATION
For multiple qualification, a welder shall successfully complete two (2) tests using qualified
procedure specifications. The Welding Inspector shall determine the specifications the welder
shall use according to the type of qualification.
For the first test, the welder shall make a butt weld in the fixed position with the axis of the pipe
in the horizontal plane. This butt weld shall be made on pipe whose diameter is at least 12-3/4
inches and whose wall thickness is a least 1/4 inch without a backing strip. The finished weld
shall exhibit a neat, workmanlike appearance. Test specimens shall be removed from the test
weld at various locations as shown in Figure A1. The number and type of specimens to be
removed from the test weld is shown in Table 1.
For the second test, the welder shall lay out, cut, fit and weld a full size branch-on-pipe
connection. This test shall be made with pipe whose diameter is at least 12-3/4 inches and
whose wall thickness is at least 1/4 inch. A full size hole shall be cut in the run. The weld shall
be made with the run pipe axis extending vertically downward from the run. The finished weld
shall exhibit a neat, workmanlike appearance. Test specimens shall be removed from the test
weld at various locations as shown in Figure B1. The number and type of specimens to be
removed from the test weld is shown in Table 2.
A welder who successfully completes these two (2) tests shall be qualified to weld in all
positions, on all wall thicknesses, joint designs, fittings and all pipe diameters.
4.5
API-1104 MULTIPLE QUALIFICATION VARIABLES
A welder who has successfully completed the multiple qualification tests shall be qualified within
the limits of the following essential variables. If any of the following essential variables are
changed, the welder shall be re-qualified:
a. A change from one welding process to another welding process or combination of
processes.
b. A change in the direction of welding from vertical uphill to vertical downhill or vice versa.
c. A change of filler-metal classification from Group 1 or 2 to Group 3 or from Group 3 to Group
1 or 2.
Original Approved by:
Utility Operating Council
Page 5 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
4.6
API-1104 SINGLE QUALIFICATION – PROJECT SPECIFIC
For single qualification, a welder shall make a test weld, using qualified procedure specifications
to join pipe nipples to meet the requirements of the specification. The diameter and wall
thickness of the pipe nipples shall be equal to that of the largest to be welded on the project.
The Welding Inspector shall determine the specification the welder shall use according to the
type of qualification. The welder shall make a butt weld in the fixed position with the axis of the
pipe inclined forty five (45) degrees from the horizontal plane. The finished weld shall exhibit a
neat, workmanlike appearance. This test shall qualify the welder to do butt welds in all positions
on pipe within the outside diameter and wall thickness groups of that tested. Test specimens
shall be removed from the test weld at various locations as shown in Figure A1 for pipe
diameters four and one half (4-1/2) inches thru twelve and three quarter (12-3/4) inches. The
number and type of specimens to be removed from the test weld is shown in Table 1. Contact
Atmos Energy Technical Services for test specimen requirements for other pipe sizes.
4.7
API-1104 SINGLE QUALIFICATION VARIABLES
A welder who has successfully completed the single qualification test shall be qualified within
the limits of the following essential variables. If any of the following essential variables are
changed, the welder shall be re-qualified:
a. A change from one welding process to another welding process or combination of
processes.
b. A change in the direction of welding from vertical uphill to vertical downhill or vice versa.
c. A change of filler-metal classification from Group 1 or 2 to Group 3 or from Group 3 to
Group 1 or 2.
d. A change from one outside diameter group to another. These groups are defined as
follows:
1. Outside diameter less than 2-3/8 inches.
2. Outside diameter from 2-3/8 inches through 12-3/4 inches.
3. Outside diameter greater than 12-3/4 inches.
e. A change from one wall thickness group to another. These groups are defined as follows:
1. Nominal pipe wall thickness less than 3/16 inch.
2. Nominal pipe wall thickness from 3/16 inch through 3/4 inch.
3. Nominal pipe wall thickness greater than 3/4 inch.
f.
g.
A change in position from fixed to rolled or a change from a 45 degree incline to horizontal
or vertical or vice versa.
A change in joint design from a V bevel to a U bevel or the use of a backing strip.
Original Approved by:
Utility Operating Council
Page 6 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4.8
4
API-1104 DESTRUCTIVE TESTING REQUIREMENTS
BUTT WELD
Upon completion of the Butt Weld Test, the welder as directed by the Welding Inspector shall
layout, cut and remove six (6) test specimens from the test weld at the locations as shown in
Figure A1. Two (2) Tensile Strength, two (2) Nick-Break and two (2) Root-Bend test specimens
shall be removed as shown in Table 1. These specimens shall be approximately one (1) inch
wide and nine (9) inches long as shown in Figures T1, N1 and R1.
The cover bead and root bead on the Tensile Strength specimens shall remain and the edges
shall be smooth and parallel as shown in Figure T1. The cover bead and root bead on the NickBreak specimens shall remain and the edges shall be smooth and parallel. Notches shall be cut
into the sides of the Nick-Break specimens at the center of the weld approximately 1/16” deep
as shown in Figure N1.
The cover bead and root bead on the Root-Bend specimens shall be ground smooth and flush
with the pipe wall without removing any pipe wall material. The Root-Bend specimen shall not
be flattened prior to testing and the edges shall be smooth and parallel as shown in Figure R1.
If any of the six (6) specimens fail to meet the minimum requirements of testing as specified by
the qualifying standard, the welding test shall be unsatisfactory and the welder shall be required
to re-test.
BRANCH FILLET WELD
Upon completion of the Branch Fillet Weld Test, the welder as directed by the Welding Inspector
shall layout, cut and remove four (4) specimens from the test weld at the locations as shown in
Figure B1. Four (4) Nick-Break specimens shall be removed as shown in Table 2.
Each specimen shall be approximately two (2) inches wide. The sides of the test specimens at
the weld shall be flame cut to allow approximately one (1) inch of weld to remain for testing as
shown in Figure B2. Each specimen shall be notched approximately 1/16” deep across the top
of the cover bead and on each side as shown in Figure B2. The edges shall be smooth and
parallel.
If any of the four (4) specimens fail to meet the minimum requirements of testing as specified by
the qualifying standard, the welding test shall be unsatisfactory and the welder shall be required
to re-test.
Original Approved by:
Utility Operating Council
Page 7 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
Type and Number of Butt-Weld Test Specimens per Welder
for Welder Qualification and Renewal Tests for Destructive Testing
Number of Specimens
Type of Test
Pipe
O.D.
Wall
Thickness
Tensile
Strength
Nick
Break
Root
Bend
Total
API-1104
Multiple
Qualification Weld
12-3/4”
1/4"
2
2
2
6
API-1104
6-Month
Renewal Weld
6” or
Larger
3/16”
or
1/4"
2
2
2
6
TABLE 1
Source: API Standard 1104, Nineteenth Edition, September 1999
Original Approved by:
Utility Operating Council
Page 8 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
Source: API Standard 1104, Nineteenth Edition, September 1999
Original Approved by:
Utility Operating Council
Page 9 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
Type and Number of Nick-Break Test Specimens for Fillet
Welds per Welder for Welder Qualification Test
Pipe
O.D.
12-3/4”
Wall
Thickness
Number of Specimens
Nick-Break
Total
4
4
1/4"
TABLE 2
Source: API Standard 1104, Nineteenth Edition, September 1999
Original Approved by:
Utility Operating Council
Page 10 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
Source: API Standard 1104, Nineteenth Edition, September 1999
Original Approved by:
Utility Operating Council
Page 11 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4.9
4
CFR PART 192, APPENDIX C – QUALIFICATION OF WELDERS FOR LOW STRESS LEVEL
PIPE LESS THAN 20% SMYS
For Appendix C, a welder shall successfully complete the following four (4) tests using the
appropriate approved Welding Procedure Specifications for which the qualification applies.
Mainline Butt Weld Test
A welder required to make butt welds on various pipe diameters 2 inches through twelve 12
inches shall make a butt weld in the fixed position with the axis of the pipe in the horizontal
plane. The test specimen shall be positioned so that the test weld includes at least one
section of overhead position welding. This butt weld shall be made on pipe nipples whose
nominal diameter is at least six (6) inches.
Service Line Connection to Main Test
A welder required to weld service taps or hot tap fittings with a diameter of less than 2 inches
onto mains shall make a fillet weld in the fixed position with the run pipe in the horizontal plane
and whose nominal diameter is at least six (6) inches. The service line connection fitting shall
be placed centered onto the run pipe with the axis in the vertical plane. The service line
connection fitting shall be a one and one quarter (1-1/4) inch or less in diameter by six (6) inch
long pipe nipple segment scarfed and ground to fit the run pipe.
Small Diameter Service Line Test
A welder required to weld on small service lines less than 2 inches in diameter shall make two
(2) butt welds in the fixed position with the axis of the pipe in the horizontal plane. The test
welds shall be approximately nine (9) inches long with the weld centered. The test specimens
shall be positioned so that the butt welds include at least one section of overhead position
welding. These butt welds shall be made on pipe whose nominal diameter is at least one and
one quarter (1-1/4) inches or less.
Large Diameter Fillet Weld Connections to Mains Test
A welder required to make fillet welds on various pipe diameters 2 inches through twelve 12
inches shall make a fillet weld in the fixed position with the run pipe in the horizontal plane and
whose nominal diameter is at least six (6) inches by twelve (12) inches long. The branch
connection fitting shall have a nominal diameter of at least six (6) inches by six (6) inches long
and placed centered onto the run pipe with the axis in the vertical up plane. The branch
connection fitting shall be scarfed and ground to fit the run pipe.
Original Approved by:
Utility Operating Council
Page 12 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
A welder who successfully completes the Mainline Butt Weld Test, Service Line Connection to
Main Test, Small Diameter Butt Weld Test and Large Diameter Fillet Connections to Mains Test
shall be qualified to make butt welds and fillet welds on pipe and fittings having a nominal
diameter through twelve (12) inches that is to be operated at a MAOP that produces a hoop
stress of less than 20 percent SMYS. Intermediate and high pressure pipelines operating at a
MAOP that produces a hoop stress of less than 20 percent SMYS must be evaluated for
conditions that may be beyond the capacity of the Appendix C welder’s length of qualification
experience.
An Appendix C welder shall have performed welding on an Atmos Energy Facility within the
preceding 6 calendar months to maintain his qualification. The welding may be determined from
the Atmos Visual Welding Inspection Form. A welder may be required to re-qualify if a question
arises about his competence.
4.10 APPENDIX C DESTRUCTIVE TESTING REQUIREMENTS
Mainline Butt Weld Test
Upon completion of the Mainline Butt Weld Test, the welder as directed by the Atmos Energy
Welding Inspector shall layout, cut and remove from the test weld four (4) specimens
approximately 1 inch wide and 9 inches long as shown in Figure C1. Each coupon shall be cut
from between the quarter sections of the pipe or between the (12 and 3), (3 and 6), (6 and 9)
and (9 and 12) o’clock positions as shown in Figure C2. The cover bead and the root bead
shall be ground smooth to the pipe wall without removing any pipe wall material. The edges of
the specimen shall be smooth with a maximum of 1/8” radius on all corners. These coupons
shall be subjected to the root bend test. If, as a result of this test, two (2) or more of the four (4)
coupons develop a crack in the weld material or between the weld material and base material
that is more than 1/8 inch long in any direction, the weld is unacceptable. Cracks that occur on
the corner of the coupon during testing are not considered.
Service Line Connection to Main Test
Upon completion of the Service Line Connections to Main Test, the welder as directed by the
Atmos Energy Welding Inspector shall test the weld by attempting to break the fitting off the run
pipe. This can be done by supporting the run pipe and hitting the fitting with an appropriate tool
such as a sledge hammer. The weld is unacceptable if it breaks and shows incomplete fusion,
overlap or poor penetration at the junction of the fitting and run pipe.
Small Diameter Service Line Test
Upon completion of the Small Diameter Service Line Test, the welder as directed by the Atmos
Energy Welding Inspector shall layout, cut and remove from each test weld one (1) specimen
approximately one (1) inch wide by nine (9) inches long as shown in Figure C1, at the locations
as shown in Figure C3 and destructively tested as follows:
Original Approved by:
Utility Operating Council
Page 13 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
1. One (1) test weld coupon shall have both the face and root ground flush with the pipe wall
and with a maximum of one eighth (1/8) inch radius on all corners. The test weld coupon
shall be centered in a guided bend testing machine and bent to the contour of the die for a
distance of two (2) inches on each side of the weld. Weld test sample made on pipe less
than 1-1/4 inch diameter shall have the entire test sample bent tested. If the test weld
shows any breaks or cracks after removal from the bending machine, it is unacceptable.
2. The second test weld coupon shall have a maximum of one eighth (1/8) inch radius on all
corners. The test weld coupon shall be subjected to a tensile strength test. Weld test
samples made on pipe less than 1-1/4 inch diameter shall have the entire test sample
tensile tested. If failure occurs adjacent to or in the weld metal, the weld is unacceptable. If
no tensile machine is available the second test weld shall be bent tested as specified in
paragraph 1 above.
Large Diameter Fillet Weld Connections to Mains Test
Upon completion of the Large Diameter Fillet Weld Connections to Mains Test, the welder as
directed by the Atmos Energy Welding Inspector shall layout, cut and remove from the test weld
four (4) specimens approximately 2 inches wide and 4 inches long as shown in Figure C4.
Each coupon shall be cut from the valleys and long point sections of the pipe as shown in
Figure C5. The coupons shall be cleaned of slag and all sharp edges removed. The specimens
shall be subjected to the nick break test. Each specimen shall show complete penetration and
fusion. Gas pockets shall not exceed 1/16 inch in diameter. Slag inclusions shall not be more
than 1/32 inch in depth and shall not be more than 1/8 inch in length.
Original Approved by:
Utility Operating Council
Page 14 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
Appendix C Test Specimens
Original Approved by:
Utility Operating Council
Page 15 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4.11
4
VISUAL EXAMINATION
A welder qualification test weld failing to meet the Welding Inspectors as designated by the
Atmos Energy visual examination requirements shall be adequate cause to eliminate
radiography or destructive testing. For a welder qualification test weld to meet the requirements
for visual examination, the weld shall meet the following criteria:
A. At no point shall the crown surface or cover bead be below the outside surface of the pipe.
B. The crown surface or cover bead should not be raised above the parent metal by more
than 1/16 inch.
C. The face of the completed weld shall be approximately 1/8 inch wider than the width of the
original groove.
D. Two beads shall not be started at the same location.
E. Free from cracks of any size or location in the weld that is not a shallow crater or star
crack.
F. Shallow crater cracks or star cracks length shall not exceed 5/32 inch.
G. There shall be no arc burns on the pipe wall surface.
H. Inadequate penetration without high-low (IP) is defined as incomplete filling of the weld
root. This condition is shown in Figure V1. IP shall be unacceptable when any of the
following conditions exists:
a. The length of an individual indication of IP exceeds 1 inch.
b. The aggregate length of indications of IP in any continuous 12-inch length of weld
exceeds 1 inch.
c. The aggregate length of indications of IP exceeds 8 percent of the weld length in any
weld less than 12 inches in length.
I.
Inadequate penetration due to high-low (IPD) is defined as a condition that exists when
one edge of the root is exposed (or unbonded) because adjacent pipe or fitting joints are
misaligned. This condition is shown in Figure V2. IPD shall be unacceptable when any of
the following conditions exists:
a. The length of an individual indication of IPD exceeds 2 inches.
b. The aggregate length of indications of IPD in any continuous 12-inch length of weld
exceeds 3 inches.
Original Approved by:
Utility Operating Council
Page 16 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
J. Burn-through (BT) is defined as a portion of the root bead where excessive penetration
has caused the weld puddle to be blown into the pipe. For pipe with an outside diameter
less than 2-3/8 inches, a BT shall be unacceptable when any of the following conditions
exists:
a. The maximum dimension exceeds 1/4 inch and the density of the BT’s image exceeds
that of the thinnest adjacent base metal.
b. The maximum dimension exceeds the thinner of the nominal wall thickness joined, and
the density of the BT’s image exceeds that of the thinnest adjacent base metal.
c. More than one BT of any size is present and the density of more than one of the
images exceeds that of the thinnest adjacent base metal.
K. For pipe with an outside diameter greater than or equal to 2-3/8 inches, a BT shall be
unacceptable when any of the following conditions exists:
a. The maximum dimension exceeds 1/4 inch and the density of the BT’s image exceeds
that of the thinnest adjacent base metal.
b. The maximum dimension exceeds the thinner of the nominal wall thickness joined, and
the density of the BT’s image exceeds that of the thinnest adjacent base metal.
c. The sum of the maximum dimensions of separate BT’s whose image density exceeds
that of the thinnest adjacent base metal exceeds 1/2 inch in any continuous 12-inch
length of weld or the total weld length, whichever is less.
L. Internal concavity (IC) is defined as a bead that is properly fused to and completely
penetrates the pipe wall thickness along both sides of the bevel, but whose center is
somewhat below the inside surface of the pipe wall. The magnitude of concavity is the
perpendicular distance between an axial extension of the pipe wall surface and lowest
point on the weld bead surface. This condition is shown in Figure V3. Internal concavity
shall be unacceptable when any of the following conditions exist:
a. The maximum dimension exceeds 1/4 inch and the density of the IC’s image exceeds
that of the thinnest adjacent base metal.
b. The maximum dimension exceeds the thinner of the nominal wall thickness joined, and
the density of the IC’s image exceeds that of the thinnest adjacent base metal.
c. The sum of the maximum dimensions of separate IC’s whose image density exceeds
that of the thinnest adjacent base metal exceeds 1/2 inch in any continuous 12-inch
length of weld or the total weld length, whichever is less.
Original Approved by:
Utility Operating Council
Page 17 of 18
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter:
4
M. Undercutting is defined as a groove melted into the base metal adjacent to the toe or root
of the weld and left unfilled by weld metal. Undercutting adjacent to the cover pass (EU)
or root pass (IU) shall be unacceptable when any of the following conditions exists:
a. Undercutting adjacent to the final bead on the outside of the pipe shall not be more
than 1/32 inch deep or 12.5 percent of the pipe wall thickness, whichever is smaller
and there shall not be more than 2 inches of undercutting in any continuous 12-inch
length of weld.
b. The aggregate length of indications of EU and IU, in any combination, in any
continuous 12-inch length of weld exceeds 2 inches.
c. The aggregate length of indications of EU and IU, in any combination, exceeds onesixth of the weld length.
N. The weld must present a neat workmanlike appearance.
Source: API Standard 1104, Nineteenth Edition, September 1999
Original Approved by:
Utility Operating Council
Page 18 of 18
41378
Welder & VWI Certification Form
Employee Information
ID
Name
Appendix C Certification Information
/
Appendix C Issue Date
/
API 1104 Certification Information
/
API 1104 Issue Date
/
API 1104 L-H Certification Information
API 1104 L-H Issue Date
/
/
API 1104 Single Certification Information
API 1104 Single Issue Date
/
/
Visual Welding Inspection Information
Visual Welding Inspection Date
/
Fax this form to 1-800-861-4268 when completed.
/
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Record (Form WQR)
Reference:
API–1104, CFR 192 Subpart E
Issue Date:
June 13, 2006
Effective Date:
June 13, 2006
Revision Date:
May 25, 2010
Welder Name: __________________________________________
Welder ID / OQ No.:
____________________________________________
WPS No.:
Project / Charge No.:
____________________________________________
_____________________________________________
Employed By:
Atmos Energy Employee
Contractor
Independant Rig Welder
(S.S. No. Required)
Address:
____________________________________
Company / Name:
_______________________________________________
City/St./Zip:
____________________________________
Address:
_______________________________________________
Telephone:
____________________________________
Telephone:
_______________________________________________
Supervisor:
____________________________________
Contact / S.S. No.:
_______________________________________________
Single (Requires Engineering Approval)
Multiple
Type of Welder Qualification Test:
Appendix C (Atmos Employees Only
and Specific Contractors)
API-1104 Multiple Qualification Butt Weld (WQS-1M)
API-1104 Multiple Qualif ication Branch Fillet Weld (WQS-1M)
Note: Seperate Forms are Required for API-1104
Butt Welds and Branch Fillet Welds.
API-1104 Multiple Low Hydrogen Butt Weld (WQS-1ML)
Both Butt and Branch Fillet Weld Tests must be
taken and pass destructive testing to qualify for
API-1104 Multiple Qualification.
API-1104 Multiple Low Hydrogen Branch Fillet Weld (WQS-1ML)
API-1104 Single Qualification Butt Weld (WQS-1S)
CFR 192 Appendix C Qualification (WQS-1C):
6" Butt Weld Test
Oxy-Acetylene Qualif ication (WQS-1C):
6" Branch Weld Test
Connections To Main Test
API-1104 Gas Tungsten Arc Welding (GTAW):
GTAW Butt Weld
API-1104 Gas Metal Arc Welding (GMAW):
GMAW Butt Weld
Small Diameter Service Lines Test
GTAW Branch Weld
GMAW Branch Weld
Six-Month Check Weld:
__________________
Type of Qualification Held:
__________________________________________________________________________
Original Qualification Date:
_______________________________________________________________________________________________
WPQR Qualifying Under (For new test only):
Butt Weld:
_______________________________________________________________________________________________________________
Branch/Circumferential Fillet:
________________________________________________________________________________________________
Testing Data:
Test Location:
________________________________________
Welding Time:
_______________________________
Date: ____________________
Weather Condition:
Temp.: ___________________
_________________
Amps:
Make of Welding Machine: ______________________________
Voltage:
Brand of Electrodes:
Pipe Mfr.: _________________
Wall Thickness:
___________________________________
____________________________
Pipe/Fitting Specs.:
Tensile: _____________________
__________________________________
Hour: ____________________
________________
___________________
Pipe O.D.:
________________
Yield: _______________________________
Weld Type:___________________________________________________
(Butt Groove or Branch Fillet, Rolled or Fixed Position)
Bead No.:
1
5
6
7
Electrode Type:
__________
__________
__________
__________
__________
__________
__________
Electrode Size:
Direction:
Flame Characteristic:
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
__________
Visually Inspected For:
3
4
Process
Direction
Fit-Up
Penetration
Burn-Through
Undercutting
Cracks
Appearance
Visual Inspection Indicates Weld Is:
Test Observer:
2
Satisfactory
Unsatisf actory
___________________________________________
Title: ______________________________________________________
(Please Print)
Original Approved by:
Utility Operating Council
*Separate forms are required for Butt Welds and Branch/Circumferential Fillet Welds
Page 1 of 2
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Record (Form WQR)
Reference:
API–1104, CFR 192 Subpart E
Issue Date:
June 13, 2006
Effective Date:
Technical Data for Tensile Coupons:
Coupon Number:
1
Coupon Width:
___________
Coupon Thickness:
___________
Coupon Area:
___________
Maximum Load:
___________
Maximum Tensile:
___________
Average Tensile:
___________
June 13, 2006
2
___________
___________
___________
___________
___________
___________
Revision Date:
May 25, 2010
WPS No.: _________________________________________________
3
4
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
___________
Remarks: Indicate whether Coupons Passed or Failed and Reason for failure
Tensile Coupons:
Nick-Break Coupons:
1. _______________________________________________________
1. _____________________________________________________
2. _______________________________________________________
2. _____________________________________________________
3. _______________________________________________________
3. _____________________________________________________
4. _______________________________________________________
4. _____________________________________________________
Root Bend Coupons:
1. _______________________________________________________
2. _______________________________________________________
3. _______________________________________________________
4. _______________________________________________________
5. _______________________________________________________
6. _______________________________________________________
Face Bend Coupons:
1. _____________________________________________________
2. _____________________________________________________
3. _____________________________________________________
4. _____________________________________________________
Appendix C Connections to Main Test: Tested By: _______________________________
Destructive tests indicate Weld is:
Tested By:
Sati sfactory
Sati sfactory
Unsati sfactory
Unsati sfactory
_________________________________
Date: ____________________
Location: _________________________________
(Do Not Print)
NON-DESTRUCTIVE TEST DATA
Remarks:
Inadequate Penetration: _____________________________________________________________________________________________________
Incomplete Fusion: _________________________________________________________________________________________________________
Burn-Through: _____________________________________________________________________________________________________________
Slag Inclusions: ___________________________________________________________________________________________________________
Porosity or Gas Pockets: ____________________________________________________________________________________________________
Cracks: __________________________________________________________________________________________________________________
Undercutting: _____________________________________________________________________________________________________________
Accumulation of Discontinuities: ______________________________________________________________________________________________
Non-destructive Test Indicates Weld Is:
Sati sfactory
Unsati sfactory
Tested By: ________________________
Certification No.: ____________________
Date: ______________
Location: __________________
Name of Testing Company: __________________________________________________________________________________________________
ATMOS USE ONLY
Remarks: __________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________
___________________________________________________________________________________________________________________________
Qualif ied
Disqualified
Certified By: ________________________________________
Date: __________________________
Welding Inspector
Original Approved by:
Utility Operating Council
*Separate forms are required for Butt Welds and Branch/Circumferential Fillet Welds
Page 2 of 2
Utility Operations Handbook
Section: Appendixes
Subject: Appendix L – Qualifying Visual Welding Inspectors by Representation
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date:
Chapter: 5
5.1
REPRESENTATION OF VISUAL WELDING INSPECTORS
Visual Welding Inspectors that are to be qualified under this program are required to have
a representative. The representative will be an Atmos Energy or Contractor Designee.
Designee’s are responsible for insuring that all Visual Welding Inspectors in their area of
responsibility are qualified under this program and the Visual Welding Inspector maintains
a current qualification permit. The designee is responsible for coordinating all qualification
and renewal training. The Designee will be responsible for any and all cost associated
with the training, testing and expenses incurred for the qualification of Visual Welding
Inspectors.
Original Approved by:
Utility Operating Council
Page 1 of 1
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Table of Contents
Visual Welding Inspector Qualification
Section 1
Welding Inspection Overview
Section 2
Welding Terminology and Definitions
Section 3
Welding Metallurgy and Chemistry
Section 4
Non-Destructive Testing
Section 5
Welding Acceptance Standards
Section 6
Welding Inspector Responsibilities
Section 7
Original Approved by:
Utility Operating Council
Page 1 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 1
Visual Welding Inspector Qualification
SCOPE
This Welding Inspection Program includes Visual Welding Inspection of all production welds by Atmos
Energy personnel and its Contractors. An individual qualified as a welding inspector will function as a
Company quality representative with the responsibility to inspect and judge the acceptability of
production welds on Company Facilities according to a written specification. All codes and standards
require a written welding procedure specification (WPS). The specification provides the welder and
welding inspector with the complete details of how the welding processes are to be applied. You should
remember that a WPS is the recipe for a welded joint. The welding inspector must understand both the
limitations and intent of the specification to be able to achieve the required quality and not delay the
welding process without proper cause.
All Visual Welding Inspection performed on Atmos Energy Facilities shall be performed by an Atmos
Energy Employee or an Atmos Energy Approved Contractor who has been qualified in conformance with
API-1104, Nineteenth Edition, Section 8.3 where applicable. The use of an Atmos Energy Employee or
an Atmos Energy Approved Contractor will be determined by each Atmos Energy Division. The
individual shall be qualified by completing a written and hands-on test in accordance with the applicable
procedure specification. The purpose of the Visual Welding Inspection qualification test is to determine
the ability of a person to make sound judgments and decisions of butt and fillet welds.
The Visual Welding Inspector shall be the only person authorized by this program to certify that a welder
has performed production welding to a specific procedure specification using Visual Inspection.
COURSE OBJECTIVES
This course consists of two days of training. Upon successful completion of the training course, you will
be knowledgeable of Atmos Energy’s welding guidelines and API-1104 to perform the responsibilities
required by a visual welding inspector to:
Inspect and judge the quality of production welds on Company Facilities for compliance with the
Company Welding Procedure Specifications.
Inspect and judge the image quality of radiographic film used for the non-destructive testing of
production welds on Company Facilities for compliance with the applicable Codes, Standards and
Specifications.
Insure that the acceptability of a weld is determined according to the acceptance standards in
Section 9 of API-1104.
Assure that all aspects of the welding and non-destructive testing operations are performed in a
safe and professional manner.
Original Approved by:
Utility Operating Council
Page 2 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 1
REFERENCES
American Petroleum Institute (API) 1104, 19th Edition, September 1999, Welding of Pipelines and
Related Facilities
American Welding Society QC1:2006
Code of Federal Regulations Title 49 Part 192
Atmos Energy Corp. Welding Procedure Specifications
QUALIFICATION REQUIREMENTS
This course will be prepared and administered by the Technical Training Group. A written test consisting
of approximately 50 multiple choice questions is required. Some of the questions require you to
demonstrate your knowledge by inspecting and judging samples of welds. A score of 70% is required to
pass. Individual’s who may qualify to take this course may include, but not be limited to; Welders, Crew
Foreman, Crew Leads, Field Construction Coordinators, Engineering Technicians, Field Technicians,
and Compliance Reps. Other individual’s not mentioned above, who may be qualified by having a
background or knowledge in welding may be selected. Each Division will be responsible for identifying
an individual’s qualifications. An individual who successfully completes this course will be qualified as a
visual welding inspector to visually inspect welds on Atmos Energy Facilities. A Visual Welding Inspector
may be required to re-qualify if a question arises about his competence.
VISION REQUIREMENTS
If corrective lenses are used during any portion of the test, then corrective lenses will
become a requirement for inspecting welds on Atmos Energy Facilities.
QUALIFICATION DURATION
The Atmos Energy visual welding inspector qualification shall be effective for three years. For a visual
welding inspector to remain qualified, he shall demonstrate his abilities by retesting prior to the expiration
date on his current qualification card.
RETESTING
Individuals who fail to meet the minimum score may be given further opportunities to qualify by retaking
the course as directed by the training facilitator and individual’s supervisor. Questions that are
incorrectly answered will be addressed with the individual to identify the correct answer.
Original Approved by:
Utility Operating Council
Page 3 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 2
Welding Inspection Overview
WELDING INSPECTION REQUIREMENT
Atmos Energy operates under the authority of various State Commissions. These Commissions have
adopted various parts from the Code of Federal Regulations (CFR) as the rules by which gas companies
operating in the United States are required to operate their systems. CFR Part 192 covers and provides
references to API-1104 for the aspects of welding that will be discussed in this course. CFR Part 192
and the provided references are the law. Compliance is mandatory.
CFR 192.241(a) states:
Visual inspection of welding must be conducted to insure that:
(1) The welding is performed in accordance with the welding procedure; and
(2) The weld is acceptable under paragraph (c) of this section.
(Paragraph (c) references the inspection standards in Section 9 of API-1104)
This means that welding being performed on a natural gas pipeline system in the United States is
required to be visually inspected for conformance with a Welding Procedure Specification and the
inspection results must meet the minimum requirements of API-1104, Section 9.
A Welding Procedure Specification (WPS) is a qualified document that lists all the details for making a
weld.
API-1104, Section 9 is a qualified document that lists the limits for imperfections found in welds.
All welding performed on an Atmos Energy Facility shall be visually inspected at sufficient intervals to
verify that the welding meets the requirements of CFR 192.241(a). Welding that is specified for
inspection by x-ray or other non-destructive testing methods must be approved for such testing by means
of visual inspection. Visual inspection is the first order of importance. X-ray and other non-destructive
testing are to serve only as a backup to visual inspection to detect flaws and defects that are not visible
to the naked eye. X-ray and other non-destructive testing is not a replacement for an adequate program
of visual inspection, and should not be used as such.
Original Approved by:
Utility Operating Council
Page 4 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 2
WELDING INSPECTION PRACTICE
This Visual Welding Inspection Program shall be applied to all Atmos Energy welding operations in all
Divisions of Operations of the Enterprise. Unless otherwise specified, as directed by Technical Services,
the following practices shall be adhered to.
Transmission Pipeline
(1) All welds on a transmission pipeline must be visually inspected by a qualified visual welding
inspector other than the welder himself in accordance with this program.
(2) To effectively perform the inspection duties, it is necessary for the qualified welding inspector to
observe as many individual stages of the welding process as possible and at sufficient intervals to
make rational and adequate judgments of the welding process being performed by the welder.
(3) The Visual Welding Inspector shall fill out the Visual Welding Inspection Report (Form WIR) for all
completed welds inspected on an Atmos Energy Facility. The WIR shall be maintained as part of
the Project Closing Package.
Distribution and Distribution/Transmission
(1) All welds on a Distribution/Transmission (D/T) pipeline (where the MAOP produces a hoop stress
of 20 percent or more of SMYS) must be visually inspected by a qualified visual welding inspector
other than the welder himself in accordance with this program.
(2) All welds on a Distribution pipeline (where the MAOP produces a hoop stress of less than 20
percent of SMYS) may be visually inspected by the welder making the weld with the absence of a
visual welding inspector. The welder shall be qualified under this program as a visual welding
inspector to perform self inspection. If a qualified visual welding inspector other than the welder
is on the job site, the inspection authority shall be given to that inspector.
(3) The Welder who is qualified as a visual welding inspector or other qualified visual welding
inspector shall fill out the Visual Welding Inspection Report (Form WIR) for all completed welds
inspected on an Atmos Energy Facility. The Form WIR shall be maintained as part of the Project
Closing Package.
Original Approved by:
Utility Operating Council
Page 5 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 3
Welding Terminology and Definitions
When visual welding inspection is being performed, one of the more important aspects of the welding
inspector’s job is to communicate with the welder before welding, during welding and after welding. The
welding inspector needs to effectively reveal the inspection findings to the welder and understand his
responses or questions.
Another part of the welding inspector’s job is to review and interpret the welding specification pertaining to
the welded fabrication.
While most of the terms used apply to the actual welding operation, it is important for the welding
inspector to understand other definitions that apply to related operations. For example, the welding
inspector should understand how to describe the various weld joint configurations and elements of the
fitting process. After welding is completed, the welding inspector may need to describe the location of
some welding discontinuity that has been discovered. If the discontinuity requires repair, it is important
that the welding inspector accurately describe the location of the problem, so the welder will know where
the repair is to be made.
Types of Joints
Before welding begins, the welding inspector should inspect the weld joint configuration and fit-up. This is
one of the most important aspects of welding inspection, because potential problems that are discovered
at this stage can be corrected more economically. When performing a joint inspection, the welding
inspector needs to know the differences between the various types of weld joints. A weld Joint is the
junction of members or edges of members that are to be joined or have been joined. There are two basic
types of weld joints for pipe, Butt and Fillet. The butt joint describes the configuration when two sections
of pipe, a section of pipe and a fitting, or two fittings to be joined are aligned in the same plane and are
connected at their ends. There are many different configurations of butt joints that are used for joining.
The Atmos Energy Welding Specifications utilize the Standard V-Bevel Butt Joint.
There are two basic fillet joint configurations that are used on pipe, the T-Joint and Lap Joint. The Atmos
Energy Welding Specifications utilize both of these joints.
The T-Joint is used on pipe for making branch connections where the two members are aligned in
perpendicular planes and the edge of one member is joined to the planar surface of the other member.
An example would be making a branch connection.
The Lap joint is used on pipe for installing appurtenances around the circumference of the pipe. The joint
is made when the two members are aligned in parallel planes, overlapping each other to form a double
thickness region. An example would be installing a full circle repair sleeve.
Original Approved by:
Utility Operating Council
Page 6 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 3
Weld Joint Elements
Once the type of joint has been identified, the welding inspector may need to further describe the exact
configuration for the various elements and features of a particular joint. Some of theses elements include
the root opening, root face, groove face, bevel angle and groove angle.
#1 Root Opening
Also called the gap it is the separation between the members at the joint root.
#2 Root Face
Also commonly called the land it is the portion of the groove face adjacent to the joint root.
#3 Groove Face
The surface of a member included in the groove.
#4 Bevel Angle
The angle between the bevel of a joint member and a plane perpendicular to the surface of the
member.
#5 Groove Angle
The total included angle of the groove between the members.
Because these elements are essential variables, the welding inspector should actually inspect them and
judge their compliance with the Atmos Energy Welding Specifications.
Original Approved by:
Utility Operating Council
Page 7 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 3
Types of Welds
There are two types of welds that the Atmos Energy Welding Specifications refers to. These consist of:
Butt Single V-Groove Welds; and
Circumferential Fillet Welds
A Butt Single V-Groove Weld is where two members are joined by welding from one side only the two
abutting members. The Butt Single V-Groove Weld is used with the Standard V-Bevel Butt Joint for
making butt welds on pipe with a wall thickness of 3/4" and less on Atmos Energy Facilities using Atmos
Energy Welding Specifications. Note: Other groove designs such as a U-Groove or J-Groove may be
required for making butt welds on pipe with a wall thickness greater than 3/4".
The Circumferential Fillet Weld is a weld of approximately triangular cross section joining two surfaces
approximately at right angles to each other in a T-Joint or Lap Joint. This type of weld is most commonly
used throughout the industry for various applications and is used for making hot taps, branch connections
and installing full encirclement fittings on Atmos Energy Facilities using Atmos Energy Welding
Specifications. Note: The circumferential fillet weld is not a type of joint; rather, it is a particular type of
weld that can be applied to a T-Joint or Lap Joint.
Weld Elements
When welding inspection is being performed, the welding inspector should describe the conditions that
exist when reporting inspection findings. The Butt Single V-Groove Weld has several primary elements.
Some of these elements include the weld face, weld toe, weld root, root surface, face reinforcement and
root reinforcement.
Weld Face
The exposed surface of a weld on the side from which the welding was performed.
Weld Toe
The junction of the weld face and the base material surface.
Weld Root
The portion of weld opposite the weld face at which the junction of the weld root intersects the base
material surface.
Root Surface
The exposed surface of the weld opposite the side from which the welding was performed and is
bound by the weld root.
Face Reinforcement
Also called the weld crown, it is the weld reinforcement on the side of a joint from which the welding
was performed.
Root Reinforcement
The weld reinforcement opposite the side of a joint from which the welding was performed.
Both the face and root reinforcement represents that portion of the weld metal that extends beyond the
surface of the base material.
Original Approved by:
Utility Operating Council
Page 8 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 3
Just as groove welds have elements for various parts, standard terminology exists for various parts of fillet
welds. As with the groove weld, the surface of the weld that the welding inspector will evaluate is referred
to as the weld face. The junctions of the weld face with the base material are called the weld toes. The
farthest penetration of the weld metal into the joint is called the weld root. The distance from the weld toe
to the joint root is called the fillet weld leg. The weld throat is generally the shortest distance between the
weld root and the face of the fillet weld.
There are also other terms relating to the fusion and penetration of the weld metal into the base material.
These features are difficult for the visual welding inspector to check without further destructive or nondestructive examination. In general, fusion refers to the actual melting together of the filler metal and the
base material, or of the base material only. Penetration relates to the distance that the weld metal has
progressed into the joint.
Note: The degree of penetration achieved has a direct effect on the strength of the joint and is
related to the weld size.
Original Approved by:
Utility Operating Council
Page 9 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 3
Weld Size
For butt welds, weld size is the distance the weld metal extends from the weld face into the joint and is
exclusive of any weld reinforcement. For a complete penetration butt v-groove weld, the weld size will be
equal to the thickness of the thinner of the two members joined, because there is no credit given for any
weld reinforcement present.
To determine the size of a fillet weld, you must first determine whether the finished weld configuration is
convex or concaved. The profile of the weld would be convex if the weld face exhibits some buildup
causing it to appear slightly curved outward. This is referred to as the amount of convexity. Convexity in
a fillet weld is comparable with weld reinforcement in a groove weld. If the weld face was sunken or
dished in, the profile is determined to be concave.
For either convex or concave, the fillet weld size for equal leg fillet welds is described as the leg lengths of
the largest isosceles (two legs of equal length) right triangle which can be inscribed within the fillet weld
cross section. There are three key terms used when measuring the size fillet welds.
1. The theoretical throat is described as the distance from the beginning of the joint root perpendicular to
the hypotenuse (side of the triangle opposite the right angle) of the largest right triangle that can be
inscribed with the cross section of a fillet weld.
Note: this dimension is based on the assumption that the root opening is equal to zero.
2. The effective throat can be defined as the minimum distance minus any convexity between the weld
root and the face of the fillet weld.
The effective throat takes into account any additional joint penetration which may be present.
3. The actual throat is described as the shortest distance between the weld root and the face of the fillet
weld.
The actual throat takes into account both the joint penetration and any additional convexity present at
the weld face. For a concave fillet weld, the effective throat and the actual throat are equal since there
is no convexity present.
Weld Application Terms
The welding inspector should be familiar with the elements associated with the actual application of welds.
These elements include the Root Bead, Hot Pass, Filler Bead and Cover Bead.
Root Bead
Also called the stringer, it is the first pass applied to initially join two members. The root bead is applied
to butt welds. It may also be applied to fillet welds where full penetration is required on one of the
members (usually a branch fitting). This bead is usually applied using the drag technique, where the
electrode is drawn into the groove without any weaving motion.
Original Approved by:
Utility Operating Council
Page 10 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 3
Hot Pass
The second pass applied, but is not always considered as being a type of bead. The hot pass is
designed not to add molten metal to the joint but to be applied at a higher amperage using somewhat of
a stepping technique to burn out any remaining slag tracks (also called wagon tracks) and to help
condition the root bead. On very thin wall pipe the hot pass usually acts as the filler bead.
Filler Bead
Is usually the third pass applied and is designed to fill the groove to just below the surface of the pipe.
The filler bead is usually applied with a slight weaving technique. The number of filler beads required to
fill the groove depends on the thickness of the material being welded and the groove area on the pipe.
Cover Bead
Also called the cap it is the final bead applied to complete the weld. The cover bead can be applied in
various motions and is usually applied by a weaving motion. The cover bead must present a neat
workman like appearance.
Original Approved by:
Utility Operating Council
Page 11 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 4
Welding Metallurgy and Chemistry
Welding metallurgy deals with the changes that occur in the structure of steel when it is introduced to the
various mechanical and thermal effects of a welding process. The basic structure of steel and how that
structure can be affected by these forces and temperature determines the amount of change of the
mechanical properties or weldability of the steel. The weldability of steel refers to its ability to be welded.
It greatly influences weld quality and is an important factor in choosing which welding specification to
use. The better the weldability of steel, the easier the steel can be fabricated into a suitable designed
structure that will perform satisfactorily.
Welding chemistry deals with the chemical interaction between the base material, filler metal and other
chemicals present at the joint during the welding process. The ability of the base material and filler metal
to fuse together without any adverse chemical effects is an important factor in determining weldability.
Pipe grades are determined by the chemical composition and mechanical properties associated with the
pipe and is defined by the American Petroleum Institute (API-5L 2000 Standard). This information is
usually stenciled on the pipe in various locations. Certified Mill Test Reports (CMTR’s) are produced to
provide the properties for the type and grade of pipe. These CMTR’s are based on actual test results
performed on the pipe and should be received along with the pipe from the supplier.
Specified Minimum Yield Strength (SMYS)
API-1104 defines pipe materials to be grouped as follows:
a. Specified minimum yield strength less than or equal to 42,000 psi.
b. Specified minimum yield strength greater than 42,000 psi but less than 65,000 psi.
c. Specified minimum yield strength greater than or equal to 65,000 psi.
The number in the X grade is the minimum yield strength divided by 1000. X-42 pipe has a minimum
yield strength of 42,000 p.s.i. X-60 has a minimum yield strength of 60,000 p.s.i.
Yield strength is a point at which steel stretches to a certain limit and then can return to its original shape.
Yield strength is measured in pounds of force applied to a 1 square inch cross section. A 1 inch square
bar made from 35,000 SMYS material should be able to support 35,000 pounds without yielding. The
yield strength for different grades of steel is controlled by chemical means.
It is important that welding inspectors know the percentage of SMYS that a pipeline being welded on will
operate at.
MAOP (maximum allowable operating pressure)
The pressure that CFR 192 allows the pipeline to operate at.
Formula for 100% Hoop Stress of SMYS
P = (Y x 2) * T / D
Formula for percent SMYS
X=D/P
Where:
P = pressure that produces 100% hoop stress in psig
Y = yield strength in psi
D = outside diameter of the pipe in inches
T = normal wall thickness, in inches
Where:
X = percent SMYS
D = MAOP
P = 100% hoop stress (from formula above)
Original Approved by:
Utility Operating Council
Page 12 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 5
Non-Destructive Testing
Non-destructive testing is a general term used to identify the methods used for the evaluation of welds
and adjacent areas without destroying the weldment. The integrity of welds is verified principally by visual
inspection. Even for welds that are engineered specified for inspection by other non-destructive testing
methods, visual inspection still constitutes the primary part for quality control. Therefore, visual inspection
is of the first order of importance. The purpose of nondestructive testing is to serve as a backup to visual
inspection and to detect flaws and defects that are not visible to the naked eye. Nondestructive testing is
not a replacement for an adequate program of visual inspection, and should not be used as such.
The welding inspector must be familiar with and understand the purpose and application of the
nondestructive testing methods and the fundamental conditions for their use. The visual welding
inspector has the responsibility as a Company quality representative to determine that nondestructive
testing performed on production welds on Company Facilities will be performed within the Codes,
Standards and Specifications governing nondestructive testing. There are many methods of nondestructive testing such as radiographic examination, magnetic particle examination and dye penetrant
examination to name a few. For the purpose of this course the following basic nondestructive testing
method for radiographic examination will be discussed.
Radiographic Examination (RT)
Radiographic examination is used extensively for weld testing. Radiographic examination has the ability
to detect subsurface discontinuities. Radiation from x-rays or gamma rays is used to pass through steel
pipe. While passing through the pipe, a certain amount of radiation will be expended. The radiation
reaching the film will be a function of the pipe density and its thickness. In the absence of internal
discontinuities or flaws, the emerging radiation will affect the film uniformly, causing an uniform amount of
film blackening. In the event there is a discontinuity in the radiation path, increased radiation will reach
the film and a greater blackening of the film will result. If there is an increase in wall thickness due to weld
reinforcement or burn through or an increase in density due to inclusions, less radiation will reach the film
and a reduction in the film blackening will result. The variations in film image blackening allow meaningful
interpretations to be made.
A detailed procedure for the production of images shall be established and recorded for producing any
radiographic images on film through the use of X-rays or gamma rays. Radiographic film produced by the
use of the detailed procedure shall have the density, clarity, and contrast required by API-1104.
Original Approved by:
Utility Operating Council
Page 13 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 5
Radiographic Interpretation
All radiographic examinations performed on Atmos Energy Facilities shall be performed by an individual
qualified in conformance with The American Society for Nondestructive Testing, Recommended Practice
No. SNT-TC-1A or an approved non-destructive testing firm acceptable to Atmos Energy, where
applicable.
Welding Inspectors are not qualified or required to interpret radiographic examination film.
However, the welding inspector should be familiar with the requirements for producing quality
interpretations and the acceptance standards for discontinuities found on radiographic film. In addition,
the welding inspector should also be conversant with the principles of interpretation in order to be able to
evaluate the radiographer’s report.
The interpretation of a radiograph involves identifying the images resulting from various light and dark
regions on the film. The dark regions represent the more easily penetrated parts of the weld such as thin
sections or areas of less thickness and most types of discontinuities. The lighter regions represent the
more difficult areas to penetrate such as the thick sections or where there is an increase in wall thickness
due to weld reinforcement. Interpretation is usually performed in a dark room by placing the radiograph in
front of a relatively bright light source. The room lighting must be reduced so that there are no reflections
off the film surface which may obscure the interpreter’s view of the radiographic images.
Original Approved by:
Utility Operating Council
Page 14 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 5
Radiographic Procedures
All radiography performed on Atmos Energy Facilities shall be conducted within the guidelines as
specified in API-1104, Section 11. As a minimum, a procedure for film radiography shall include the
following in detail for steel pipe:
A. Radiation Source – There are two types of radiation sources commonly used in weld inspection.
These are X-ray machines and radioactive isotopes. X-radiation is produced by machines which
range from portable, low energy units capable of radiographing relatively thin objects to very large
linear accelerators capable of radiographing steel welds up to 20 inches thick. Gamma radiation is
emitted by radioisotopes, the two most common being Cobalt 60 and Iridium 192. Cobalt 60 will
effectively penetrate up to approximately 5 inch thick steel. Iridium 192 is effectively limited to a steel
thickness of approximately 3 inches.
B. Intensifying Screens – A layer of material placed in contact with the film to increase the effect of the
radiation, thus shortening the exposure.
C. Radiographic Film – Radiographic film is generally similar to that of photographic film. The substrate
is thicker, and while it is coated on both sides, the development chemicals and procedures are
identical to those used in photography. It consists of transparent plastic, coated with fine crystals of
silver bromide (emulsion). The grain size of silver bromide emulsion determines speed and sensitivity
of the film. The emulsion is sensitive to radiation just as photographic film is to light.
The film is
exposed in light proof cassettes. Thin lead screens or intensifiers are placed in front and behind the
film to screen out stray and scattered radiation that can render interpretation more difficult.
Developing or chemically processing the film converts the image produced on the film emulsion by
exposure to radiation into a visible, permanent image. Radiographic film is sold in various lengths and
widths.
D. Exposure Geometry – Whether single-wall exposure for single-wall viewing (SWE/SWV), double-wall
exposure for single-wall viewing (DWE/SWV), or double-wall exposure for double-wall viewing
(DWE/DWV); the source to film distance, object to film distance, and source size directly affect the
degree of cloudiness and geometrical unsharpness of a radiograph. Codes and standards used in
industrial radiography require that geometrical unsharpness be limited.
E. Exposure Conditions – Whether milliampere or curie minutes, the x-ray voltage, amperage and the
exposure time.
F. Processing – Whether automatic or manual; the time and temperature for development and the time
for stop bath or rinsing, fixing, washing and drying details.
G. Penetrameters – For hole type penetrameters: the type, material, identifying number and essential
hole, and the shim material and thickness. For wire type penetrameters: the type material, identifying
ASTM set letter, and essential wire diameter.
H. Heat Shields – Material type, thickness and the distance from the film side of the heat shield to the
pipe surface.
Original Approved by:
Utility Operating Council
Page 15 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 5
Radiographic Exposure Acceptance
The determinants of film exposure quality are based on sensitivity and image density. Sensitivity is
determined by the use of Image Quality Indicators (IQI) or penetrameters. Image density is based on a
logarithmic ratio of the light applied to the film and that emerging on the other side. The radiographic
exposure acceptance is based on the following criteria:
1. The proper selection and ability to clearly see the prescribed and properly located penetrameter
image and the essential hole or wire diameter on the exposed film.
2. The image shall be free from fog and processing irregularities that could mask the image of actual
imperfections.
3. A satisfactory identification system.
4. An acceptable technique setup.
5. Compatibility with acceptance standards.
Penetrameters
Penetrameters are used to indicate the sensitivity and quality of a radiograph. There are two basic
types of penetrameters; the hole type and the wire type. The hole type as shown in Figure P1 is more
commonly used over the wire type.
Hole Type Penetrameters
The selection of the proper hole type penetrameter is based on the thickness of the pipe wall or the
weld thickness and its identifying number. Table P1 identifies the proper selection of ASTM E 1025
hole type penetrameters. Table P2 identifies the proper selection of Standard Penetrameters. If the
choice of penetrameters is based on weld thickness, shims made of material that are radiographically
similar to that of the pipe material and equivalent in thickness to the average weld buildup shall be
placed under the penetrameter. If the choice of penetrameter is based on pipe wall thickness, shims
are not required. Note: Penetrameters thinner than those specified in the below tables may be used,
provided the required radiographic sensitivity is obtained.
The radiographic images of the hole type penetrameter’s outline, identifying numbers and essential
hole shall all appear clearly. The essential holes for both ASTM E 1025 and Standard penetrameters
shall have a diameter of two times (2T) the thickness of the penetrameter. The 2T essential hole in
Standard Penetrameters need not be less than 1/16 inch in diameter.
Original Approved by:
Utility Operating Council
Page 16 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 5
Table P1 – ASTM E 1025 Penetrameter Selection Chart
Pipe Wall or Weld Thickness
Maximum Penetrameter Thickness
Inches
Millimeters
Inches
Millimeters
Identifying Number
0 – 0.250
0 – 6.4
0.0125
0.32
12
> 0.250 – 0.375
> 6.4 – 9.5
0.0150
0.38
15
> 0.375 – 0.500
> 9.5 – 12.7
0.0175
0.44
17
> 0.500 – 0.750
> 12.7 – 19.1
0.0200
0.51
20
> 0.750 – 1.000
> 19.1 – 25.4
0.0250
0.64
25
> 1.000 – 2.000
> 25.4 – 50.8
0.0300
0.76
30
Table P2 – Standard Penetrameter Selection Chart
Pipe Wall or Weld Thickness
Maximum Penetrameter Thickness
Inches
Millimeters
Inches
Millimeters
Identifying Number
0 – 0.250
0 – 6.4
0.0050
0.13
5
> 0.250 – 0.375
> 6.4 – 9.5
0.0075
0.19
7
> 0.375 – 0.500
> 9.5 – 12.7
0.0100
0.25
10
> 0.500 – 0.625
> 12.7 – 15.9
0.0125
0.32
12
> 0.625 – 0.750
> 15.9 – 19.1
0.0150
0.38
15
> 0.750 – 0.875
> 19.1 – 22.2
0.0175
0.44
17
> 0.875 – 1.000
> 22.2 – 25.4
0.0200
0.51
20
> 1.000 – 1.250
> 25.4 – 31.8
0.0250
0.64
25
> 1.250 – 1.500
> 31.8 – 38.1
0.0300
0.76
30
> 1.500 – 2.000
> 38.1 – 50.8
0.0350
0.89
35
Original Approved by:
Utility Operating Council
Page 17 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 5
Wire Type Penetrameters
If wire type penetrameters are used their selection is usually based on the thickness of the weld.
Table P3 identifies the proper selection for ASTM E 747 Wire Type Penetrameters. Note that smaller
wire diameter Penetrameters other than those specified in Table P3 may be used, provided the
required radiographic sensitivity is obtained. The radiographic images of the wire type penetrameter’s
identifying style number and ASTM set letter shall appear clearly. The image of the essential wire
diameter shall appear clearly across the entire area of interest.
Table P3 – ASTM E 747 Wire Type Penetrameter Selection Chart
Pipe Wall or Weld Thickness
Essential Wire Diameter
Inches
Millimeters
Inches
Millimeters
ASTM Letter Set
0 – 0.250
> 0.250 – 0.375
> 0.375 – 0.500
> 0.500 – 0.750
> 0.750 – 1.000
> 1.000 – 2.000
0 – 6.4
> 6.4 – 9.5
> 9.5 – 12.7
> 12.7 – 19.1
> 19.1 – 25.4
> 25.4 – 50.8
0.008
0.010
0.013
0.016
0.020
0.025
0.20
0.25
0.33
0.41
0.51
0.64
A
A or B
B
B
B
B
Original Approved by:
Utility Operating Council
Page 18 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 5
Penetrameter Placement
Hole Type Penetrameters
When a completed weld is radiographed in a single exposure using a source inside the piping, at least
four (4) penetrameters placed parallel to the weld and spaced approximately equally around the
circumference shall be used. For the Double Wall Exposure/Double Wall Viewing (DWE/DWV)
procedure, one penetrameter shall be placed on the source side of the pipe and adjacent to the weld
so that its image is not superimposed onto the weld image. For Double Wall Exposure/Single Wall
Viewing (DWE/SWV) or Single Wall Exposure/Single Wall Viewing (SWE/SWV) procedures requiring
multiple exposures for complete inspection of the weld, and where the length of film to be interpreted
is greater than 5 inches, two (2) penetrameters placed parallel to the weld and located on the film side
shall be used. One (1) shall be within 1 inch of the end of the film length to be interpreted and the
other shall be located at the center of the film. When the film length to be interpreted is 5 inches or
less, one (1) penetrameter shall be placed on the film side, parallel to the weld and located at the
center of the film length to be interpreted. When a repaired weld is radiographed, at least one (1)
penetrameter shall be placed adjacent to each repaired area.
Wire Type Penetrameters
The number and Location of wire type penetrameters shall be the same as described for the hole type
penetrameters except that the wires shall be placed across the weld and perpendicular to the weld
length.
Penetrameter Placement With the Use of Heat Shields
Penetrameters may be placed on a heat shield rather than in contact with the pipe provided that the
acceptability of such penetrameter placement is demonstrated prior to production testing.
Identification of Images
All radiographed images shall be clearly identified by the use of lead numbers, lead letters, markers or
other identification so that the proper weld and any imperfections in it can be quickly and accurately
located. Atmos Energy may specify the identification procedure to be used. Whenever more than one
image is used to inspect a weld, identification markers shall appear on each image and adjacent images
shall overlap. The last reference marker on each end of the image shall appear on the appropriate
adjacent images in a way that establishes that no part of the weld has been omitted.
Film
All unexposed film shall be stored in a clean dry place where the conditions will not detrimentally affect
the emulsion. If any question arises about the condition of any unexposed film, sheets from the front
and back of each package or a length of film equal to the circumference of each original roll shall be
processed in a normal manner without exposure to light or radiation. If the processed film shows fog,
the entire box or roll from which the test film was removed shall be discarded, unless additional tests
prove that the remaining film in the box or roll is free from pre-exposure fog.
Original Approved by:
Utility Operating Council
Page 19 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 5
Film Viewing Equipment
Film viewing equipment or illuminator shall be of the variable high-intensity type and shall be capable of
properly viewing film densities to adequately interpret the images. It shall be equipped to prevent light,
coming from around the outer edge of the radiograph or through low density portions of the radiograph,
from interfering with interpretations.
Film Viewing Facilities
Viewing facilities shall provide subdued background lighting of an intensity that will not cause
troublesome reflections, shadows or glare on the radiograph.
Radiation Protection
The radiographer shall be responsible for the protection and monitoring of every person working with or
near radiation sources. The protection and monitoring shall comply with applicable federal, state and
local regulations. Prior to any radiographs being taken, the radiographer shall post signs or other
suitable markers that indicates radiation is being used. The signs shall be placed accordingly around
the restricted area. A radiation restricted area can range from 30 to over 130 feet depending on the size
of radiation source being used.
Nondestructive Testing Frequencies
Pipelines that are to be operated at a pressure that produces a hoop stress of 20 percent or more of its
specified minimum yield strength (SMYS) must be nondestructively tested, except that welds that are
visually inspected and approved by a qualified welding inspector need not be nondestructively tested if:
(1) The pipe has a nominal diameter of less than 6 inches; or
(2) The pipeline is to be operated at a pressure that produces a hoop stress of less than 40 percent of
SMYS and the welds are so limited in number that nondestructive testing is impractical.
When nondestructive testing is required, the following percentages of each day’s field butt welds, listed in
Table N1 and selected at random by Atmos Energy must be nondestructively tested over their entire
circumference.
Table N1 - Nondestructive Testing Frequency Schedule
Class 1 locations
Class 2 locations
Class 3 locations
Class 4 locations
River crossings
Railroad crossings
At least 10 percent
At least 15 percent
100 percent, unless impracticable at least 90 percent
100 percent, unless impracticable at least 90 percent
100 percent, unless impracticable at least 90 percent
100 percent, unless impracticable at least 90 percent
Public highway rights-of-way, including tunnels,
bridges and overhead road crossings
100 percent, unless impracticable at least 90 percent
Pipeline tie-ins
100 percent
Original Approved by:
Utility Operating Council
Page 20 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Welding Acceptance Standards
Welding discontinuities are imperfections in welds. A sound or perfect weld would not have any
discontinuities; however, welds are not perfect and imperfections can exist in varying degrees. There is a
temptation to call discontinuities defects, but the terminology for these terms should be carefully defined
and distinguished. Some discontinuities are acceptable, where a defect is rejectable and must be
rejected. A discontinuity becomes a defect when it exceeds the acceptable limits imposed by the
acceptance standards, in this case the Acceptance Standards for Non-destructive Testing found in
Chapter 9 of API-1104. An imperfection of lesser magnitude is still a discontinuity, but is not considered a
defect.
The welding inspector’s primary job is to inspect and judge a weld to see if it meets the requirements of a
specification and/or other code or standard. In order for him to accomplish this task, he must be familiar
with the acceptance standards that list the acceptable limits for discontinuities. The following acceptance
standards in which are applicable to visual inspection shall be used to judge welds on Atmos Energy
Facilities.
The acceptance standards listed in Chapter 9 of API-1104 apply to imperfections found by radiographic,
magnetic particle, liquid penetrant and ultrasonic test methods. They may also be applied to visual
inspection. For visual inspection of production welds, not all of the acceptance standards can be applied,
such as inadequate penetration of the root bead. The acceptance of this standard must be determined by
a means other than visual inspection; however, the criteria should be understood by the welding
inspector.
Original Approved by:
Utility Operating Council
Page 21 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Inadequate Penetration Without High-Low
Inadequate penetration without high-low (IP) is defined as the incomplete filling of the weld root. This
condition is shown in FIGURE 1. IP shall be considered a defect should any of the following conditions
exist:
a. The length of an individual indication of IP exceeds 1 inch.
b. The aggregate length of indications of IP in any continuous 12 inch length of weld exceeds 1 inch.
c. The aggregate length of indications of IP exceeds 8 percent of the weld length in any weld less than
12 inches in length.
Inadequate Penetration Due to High-Low
Inadequate penetration due to high-low (IPD) is defined as the condition that exists when one edge of the
root is exposed (or unbonded) because adjacent pipe or fitting joints are misaligned. This condition is
shown in FIGURE 2. IPD shall be considered a defect should any of the following conditions exist:
a. The length of an individual indication of IPD exceeds 2 inches.
b. The aggregate length of indications of IPD in any continuous 12 inch length of weld exceeds 3
inches.
Original Approved by:
Utility Operating Council
Page 22 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Inadequate Cross Penetration
Inadequate cross penetration (ICP) is defined as a subsurface imperfection between the first inside pass
and the first outside pass that is caused by inadequately penetrating the vertical land faces. This
condition is shown in FIGURE 3. ICP shall be considered a defect should any of the following conditions
exist:
a. The length of an individual indication of ICP exceeds 2 inches.
b. The aggregate length of indications of ICP in any continuous 12 inch length of weld exceeds 2
inches.
Incomplete Fusion
Incomplete fusion (IF) is defined as a surface imperfection between the weld metal and the base material
that is open to the surface. This condition is shown in FIGURE 4. IF shall be considered a defect should
any of the following conditions exist:
a. The length of an individual indication of IF exceeds 1 inch.
b. The aggregate length of indications of IF in any continuous 12 inch length of weld exceeds 1 inch.
c. The aggregate length of indications of IF exceeds 8 percent of the weld length in any weld less than
12 inches in length.
Original Approved by:
Utility Operating Council
Page 23 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Incomplete Fusion Due to Cold Lap
Incomplete fusion due to cold lap (IFD) is defined as an imperfection between two adjacent weld beads or
between the weld metal and the base metal that is not open to the surface. This condition is shown in
FIGURE 5. IFD shall be considered a defect should any of the following conditions exist:
a. The length of an individual indication of IFD exceeds 2 inches.
b. The aggregate length of indications of IFD in any continuous 12 inch length of weld exceeds 2
inches.
c. The aggregate length of indications of IFD exceeds 8 percent of the weld length.
Internal Concavity
Internal concavity (IC) is defined as a bead that is properly fused to and completely penetrates the pipe
wall thickness along both sides of the bevel, but whose center is somewhat above the inside surface of
the pipe wall. The magnitude of concavity is the perpendicular distance between the axial extension of the
pipe wall surface and the lowest point on the weld bead surface. This condition is shown in FIGURE 6.
a. Any length of IC is acceptable, provided the density of the radiographic image of the IC does not
exceed that of the thinnest adjacent parent material.
b. Areas of IC that exceed the density of the thinnest adjacent parent material shall be evaluated to the
criteria for burn-through.
Original Approved by:
Utility Operating Council
Page 24 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Burn Through
A burn through (BT) is defined as a portion of the root bead where excessive penetration has caused the
weld puddle to be blown into the pipe. This condition is shown in FIGURE 7. For pipe with an outside
diameter greater than or equal to 2.375 inches, a BT shall be considered a defect should any of the
following conditions exist:
a. The maximum dimension exceeds 1/4 inch and the density of the BT’s image exceeds that of the
thinnest adjacent parent material.
b. The maximum dimension exceeds the thinner of the nominal wall thicknesses joined and the density
of the BT’s image exceeds that of the thinnest adjacent parent material.
c. The sum of the maximum dimensions of separate BT’s whose image density exceeds that of the
thinnest adjacent parent material exceeds 1/2 inch in any continuous 12 inch length of weld or the
total weld length, whichever is less.
For Pipe with an outside diameter less than 2.375 inches, a BT shall be considered a defect should any
of the following conditions exist:
a. The maximum dimension exceeds 1/4 inch and the density of the BT’s image exceeds that of the
thinnest adjacent parent material.
b. The maximum dimension exceeds the thinner of the nominal wall thicknesses joined and the density
of the BT’s image exceeds that of the thinnest adjacent parent material.
c. More than one BT of any size is present and the density of more than one of the images exceeds
that of the thinnest adjacent parent material.
Original Approved by:
Utility Operating Council
Page 25 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Slag Inclusions
A slag inclusion is defined as a nonmetallic solid entrapped in the weld metal or between the weld metal
and the parent material. Elongated slag inclusions (ESIs); e.g., continuous or broken slag lines or wagon
tracks usually found at the fusion zone. This condition is shown in FIGURE 8. Isolated slag inclusions
(ISIs) are irregularly shaped and may be located anywhere in the weld. This condition is shown in
FIGURE 9. For evaluation purposes, when the size of a radiographic indication of slag is measured, the
indication’s maximum dimension shall be considered its length. For pipe with an outside diameter greater
than or equal to 2.375 inches, slag inclusions shall be considered a defect should any of the following
conditions exist:
a. The length of an ESI indication exceeds 2 inches.
Note: Parallel ESI indications separated by approximately the width of the root bead (wagon tracks)
shall be considered a single indication unless the width of either of them exceeds 1/32 inch. In that
event, they shall be considered separate indications.
b. The aggregate length of ESI indications in any continuous 12 inch length of weld exceeds 2 inches.
c. The width of an ESI indication exceeds 1/16 inch.
d. The aggregate length of ISI indications in any continuous 12 inch length of weld exceeds 1/2 inch.
e. The width of an ISI indication exceeds 1/8 inch.
f. More than four ISI indications with the maximum width of 1/8 inch are present in any continuous 12
inch length of weld.
g. The aggregate length of ESI and ISI indications exceeds 8 percent of the weld length.
For pipe with an outside diameter less than 2.375 inches, slag inclusions shall be considered a defect
should any of the following conditions exist:
a. The length of an ESI indication exceeds three times the thinner of the nominal wall thickness joined.
Note: Parallel ESI indications separated by approximately the width of the root bead (wagon tracks)
shall be considered a single indication unless the width of either of them exceeds 1/32 inch. In that
event, they shall be consider3ed separate indications.
b. The width of an ESI indication exceeds 1/16 inch.
c. The aggregate length of ISI indications exceeds two times the thinner of the nominal wall
thicknesses joined and the width exceeds one-half the thinner of the nominal wall thickness joined.
d. The aggregate length of ESI and ISI indications exceeds 8 percent of the weld length.
Original Approved by:
Utility Operating Council
Page 26 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Porosity
Porosity is defined as gas trapped by solidifying weld metal before the gas has a chance to rise to the
surface of the molten puddle and escape. This condition is shown in FIGURE 10. Porosity is generally
spherical but may be elongated or irregular in shape, such as piping (wormhole) porosity. When the size
of the radiographic indication produced by a pore is measured, the maximum dimension of the indication
shall apply to the following criteria:
Individual or scattered porosity (P) shall be considered a defect should any of the following conditions
exist:
a. The size of an individual pore exceeds 1/8 inch.
b. The size of an individual pore exceeds 25 percent of the thinner of the nominal wall thickness joined.
c. The distribution of scattered porosity exceeds the concentration permitted by FIGURES 13 or 14.
Cluster Porosity is typically caused when flux coated electrodes are contaminated with moisture. The
moisture turns into a gas when heated and becomes trapped in the weld during the welding process. This
condition is shown in FIGURE 11. Cluster porosity may appear just like regular porosity in a radiograph
but the indications will be grouped close together. Cluster porosity (CP) that occurs in any pass except
the finish pass shall be considered a defect should any of the following conditions exist:
a. The size of an individual pore exceeds 1/8 inch.
b. The size of an individual pore exceeds 25 percent of the thinner of the nominal wall thickness joined.
c. The distribution of cluster porosity exceeds the concentration permitted by FIGURES 13 or 14.
Cluster Porosity (CP) that occurs in the finish pass shall be considered a defect should any of the
following conditions exist:
a. The diameter of the cluster exceeds 1/2 inch.
b. The aggregate length of CP in any continuous 12 inch length of weld exceeds 1/2 inch.
c. An individual pore within a cluster exceeds 1/16 inch.
Hollow-bead porosity (HB) is defined as elongated linear porosity that occurs in the root pass. This
condition is shown in FIGURE 12. HB shall be considered a defect should any of the following conditions
exist:
a. The length of an individual indication of HB exceeds 1/2 inch.
b. The aggregate length of indications of HB in any continuous 12 inch length of weld exceeds 2
inches.
c. Individual indications of HB, each greater than 1/4 inch in length, are separated by less than 2
inches.
d. The aggregate length of all indications of HB exceeds 8 percent of the weld length.
Original Approved by:
Utility Operating Council
Page 27 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Original Approved by:
Utility Operating Council
Page 28 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Original Approved by:
Utility Operating Council
Page 29 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Cracks
Cracks (C) can occur anywhere within or around the heat affected zone or in the weld itself. This
condition is shown in FIGURE 15. Cracks (C) shall be considered a defect should any of the following
conditions exist:
a. The crack, of any size or location in the weld, is not a shallow crater crack or star crack.
b. The crack is a shallow crater crack or star crack with a length that exceeds 5/32 inch.
Note: Shallow crater cracks or star cracks are located at the stopping point of the weld beads and
are the result of weld metal contractions during solidification.
Original Approved by:
Utility Operating Council
Page 30 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 6
Undercutting
Undercutting is defined as a groove melted into the parent material at the toe or root of the weld and left
unfilled by weld metal. This condition is shown in FIGURE 16. Undercutting adjacent to the cover pass
(EU) or root pass (IU) shall be considered a defect should any of the following conditions exist:
a. The aggregate length of indications of EU and IU, in any combination, in any continuous 12 inch
length of weld exceeds 2 inches.
b. The aggregate length of indications of EU and IU, in any combination, exceeds one-sixth of the weld
length.
When visual and mechanical means are used to determine depth, undercutting adjacent to the cover pass
(EU) or root pass (IU) shall be considered a defect should any of the following conditions exist:
a. The depth of EU greater than 1/32 inch or greater than 12.5 percent of the pipe wall thickness,
whichever is smaller.
b. The depth of EU greater than 1/64 inch or between 6 percent and 12.5 percent of the pipe wall
thickness, whichever is smaller has a length of 2 inches in a continuous 12 inch weld length or onesixth the weld length, whichever is smaller.
Note: Undercutting with a depth of less than or equal to 1/64 inch or less than or equal to 6 percent of the
pipe wall thickness, whichever is smaller is acceptable, regardless of length.
When both mechanical and radiographic measurements are available, the mechanical measurements
shall govern.
Accumulation of Imperfections
The accumulation of imperfections may consist of a number of imperfections found in the weld. This
condition is shown in FIGURE 17. Excluding incomplete penetration due to high-low and undercutting,
any Accumulation of Imperfections (AI) shall be considered a defect should any of the following conditions
exist:
a. The aggregate length of indications in any continuous 12 inch length of weld exceeds 2 inches.
b. The aggregate length of indications exceeds 8 percent of the weld length.
Original Approved by:
Utility Operating Council
Page 31 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 7
Welding Inspector Responsibilities
The welding inspector holds a position of responsibility that is more about preventing defects rather than
finding them after they are made. All welding performed on an Atmos Energy Facility shall be visually
inspected at sufficient intervals to verify that the welding meets the requirements of CFR 192.241(a).
Strict observance of all policies, regulations and specifications, especially those pertaining to personal
conduct, safety and security is mandatory. The welding inspector should be impartial, render decisions
promptly, and be tolerant of the opinion of others during communications. It is important to remember to
rely on the facts when making decisions and to carefully evaluate differing opinions. To effectively
perform visual inspection, it is necessary to observe as many individual stages of the welding project as
possible. The various responsibilities of the welding inspector are categorized by when they occur;
before, during and after welding.
Before Welding
Check the welder’s qualification.
Check for the correct welding specification.
Review all applicable drawings and specifications.
Check the pipe, fittings and filler metals for proper specification.
Check the condition and storage of filler metals.
Check the condition and adequacy of the equipment to be used.
Check weld joint geometries.
Check weld joint fit-up.
Check weld joint cleanliness.
Check for any pre-heat/Interpass/post-heat treatment temperature.
During Welding
Check welding parameters and techniques for compliance with the welding specification.
Check the quality of the individual weld passes.
Check interpass cleaning.
Check interpass temperature requirements.
Check interpass time limits.
Original Approved by:
Utility Operating Council
Page 32 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 7
After welding
Check finished weld sizes and lengths.
Check dimensional accuracy of completed weldment.
Check finished weld appearance.
Verify that postweld heat-treatment has been performed satisfactory, if applicable.
Verify the certification of Non-Destructive Evaluation (NDE) personnel is in accordance with the
applicable requirements, if applicable.
Verify non-destructive testing safety checks, if applicable.
Evaluate non-destructive testing film for sensitivity and image density, if applicable.
Prepare and maintain visual inspection reports.
BEFORE WELDING
Welder Qualification Check
The Atmos Energy welding specifications require qualification of all welders prior to welding. It is the
welding inspector’s duty to verify that every welder who performs welding under these specifications
have been properly qualified in accordance with those requirements. It is important for the welding
inspector to monitor the welder, to ensure that they are working within the scope of their qualification with
respect to such variables as base material type, thickness, position of welding, filler metal type and size,
etc. It is important to remember that the main objective for the welder qualification check is to ensure
that the welder is adequate for the intended purpose of performing the welding operation and should
make every effort to avoid unnecessary re-qualification tests.
Correct Welding Specification
The welding procedure specification (WPS) details the steps by which the welding of a specific joint or
weldment is to be accomplished. It provides the prescribed values or ranges of values for all the
controllable variables in the process and specifies all materials to be used. The welding specification
determines the mechanical properties of the welded joint. It is important that the welding inspector verify
that the correct welding specification has been selected for the specific job.
Review Drawings and Specifications
Drawings and specifications should be studied in advance so that the welding inspector is aware of the
construction details and the specifics of the welding operation. The welding inspector should note which
materials are to be used in the weldment and whether any of them require special treatment for
satisfactory welding. Any special treatment should be clearly stated in the specification.
Check the Pipe, Fittings and Filler Metals for Proper Specification.
The welding inspector should identify and verify that all the materials including the filler metals that will be
used meet the requirements as specified on the welding specification. The Certified Mill Test Report
(CMTR) should be checked against the welding specification.
Original Approved by:
Utility Operating Council
Page 33 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 7
Check the Condition and Storage of Filler Metals.
The welding inspector should check the condition and storage of the filler metals to be used. Damaged
and/or deteriorated filler metals should be discarded. Cellulose filler metal should be kept clean and dry
and stored in their original container or a non-heated container. Low-hydrogen filler metals must be
stored in an electrically heated, vented and thermostatically controlled storage oven to maintain their low
moisture content once their original shipping container has been opened.
Check the Condition and Adequacy of the Equipment Being Used.
The welding inspector should check all welding equipment, including that to be used for testing for
operational capability, calibration and safety. Ammeters and voltmeters on welding machines should be
checked for accuracy. The equipment should be checked to make certain it has the necessary output
capacity to satisfy the welding specification requirements. Welding leads, gas hoses, extension cords,
etc. should be checked to ensure they are in good condition.
Check Weld Joint Geometries.
The tolerances for weld joint geometries should be checked against the welding specification to ensure
compliance. The inspection responsibilities include examination of the un-welded joint geometry,
including root face dimensions and groove angles.
Check Weld Joint Fit-up.
The welding inspector should check the fit-up of the members to be welded. For butt joints, alignment
and root opening are important. It is important to remember that welds are subject to distortion as a
result of weld shrinkage stresses. The joint fit-up should not be modified from the welding specification
without engineering approval.
Check Weld Joint Cleanliness.
When welding, the cleanliness of the base material surfaces in and adjacent to the joint is a critical
factor. Welding over contamination such as oil, grease, paint, rust, moister, etc. will most likely result in
porosity in the weld. This contamination could also lead to the occurrence of incomplete fusion, or even
cracking. It is imperative that the welding inspector check the cleanliness of the weld joint prior to
welding.
Check for Any Pre-heat/Interpass/Post-heat Treatment Temperature.
The welding inspector should check the requirements for special heating requirements against the
welding specification, if applicable. Pre-heat may be required for weather and/or non-weather related
conditions and should be checked using approved tools such as digital temperature gauges or
pyrometers.
Original Approved by:
Utility Operating Council
Page 34 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 7
DURING WELDING
Check Welding Parameters and Techniques for Compliance with the Welding
Specification.
The welding inspector must rely on the welding specification to guide visual inspection of the welding
process. The welding inspector must monitor the production welding to ensure that it is being performed
in accordance with all aspects of the welding procedure specification.
Check the Quality of the Individual Weld Passes.
One aspect of welding inspection is the visual examination of the individual weld passes as they are
being deposited. Any surface discontinuities can be detected and corrected at this time. It is also
important to note any weld profile irregularities that may hinder subsequent weld passes. If one of the
intermediate passes exhibits a very convex profile when deposited (creating a deep notch at its toe) may
prevent the next pass from properly fusing at that location. The welding inspector could request that
grinding be performed at this point to ensure that thorough fusion is attained on the next pass.
Checking in-process welding quality is especially critical in the case of a root bead. In most situations,
this portion of the weld cross section represents the most difficult welding condition, especially in the
case of a butt weld. In conditions of high restraint, the shrinkage stresses from welding may result in a
fracture if the root pass is not thick enough to resist those stresses. The welding inspector should check
the root pass prior to any additional welding so that irregularities can be found and corrected as they
occur.
Check Interpass Cleaning.
The welding inspector should check and evaluate the cleanliness of intermediate weld passes during the
welding operation. If the welder fails to properly clean the weld between individual passes, there is a
possibility that slag inclusions and/or incomplete fusion could result. Proper cleaning may be hindered
when the weld exhibits a convex profile that prevents sufficient cleaning to remove the slag coating.
Additional grinding to remove the objectionable profile and to facilitate proper cleaning may then be
necessary.
Check Interpass Time Limits.
The welding inspector should check and monitor the time that is expected to lapse between passes,
especially the time between the finished root bead and the start of the hot pass. Time limits between
passes may be critical to the integrity and conditioning of the applied bead and should be maintained.
Original Approved by:
Utility Operating Council
Page 35 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 7
AFTER WELDING
Check Finished Weld Appearance
Upon completion of a weld, the welding inspector must examine the weld to ensure that all of the
required steps have been properly performed according to the specifications to produce a quality weld.
CFR 192.241a.2 requires that each completed weld that is to be put into service; either distribution or
transmission must be acceptable under the API-1104 Standard. API-1104, Section 9, Standards of
Acceptability must be used to visually inspect and judge the weld’s quality. If all of the steps have been
performed as required, the postweld examination should confirm that the weld is of sufficient quality and
size and will perform as expected in its intended service. The finished weld must present a neat
workmanlike appearance.
Check Finished Weld Sizes and Configurations
During the visual examination, the welding inspector should measure the weld to determine that it is of
sufficient size as specified on the welding specification. A primary concern for groove welds is whether
or not the groove is filled flush with the base material surfaces and has the required reinforcement. Any
underfill or lowcap that is present must be corrected by the deposit of additional weld metal.
Excessive weld reinforcement must be removed to maintain the specified height and blend smoothly with
the adjacent base material.
Fillet welds are usually examined with the aid of a fillet weld gauge. Standard measuring devices could
be used to determine the weld size, although fillet weld gauges facilitate accurate measurement of the
fillet weld. The fillet weld legs should be of equal lengths or as specified on the welding specification and
should meet the specified profile.
Check Dimensional Accuracy of Completed Weldment.
The dimensional accuracy of the completed weldment should be checked to determine if any shrinkage
stresses from the welding may have caused the overall size of the part to change. Dimensional
evaluation will also determine whether any distortion resulted from welding. The localized heat of
welding could cause the members to be distorted or misaligned with respect to other components of the
weldment. These measurements will determine if the amount of distortion that is present is enough to
cause the part to be unusable and rejected.
Original Approved by:
Utility Operating Council
Page 36 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 7
Verify Certification of Non-Destructive Evaluation (NDE) Personnel, if applicable.
Some welds may need to be examined upon completion using other non-destructive examination in
addition to visual inspection. Non-destructive testing personnel must be certified to Level I, II or III in
accordance with the recommendations of the American Society for Non-destructive Testing,
Recommended Practice No. SNT-TC-1A, ACCP or any other recognized national certification program
that shall be acceptable to Atmos Energy for the test method used. Only Level II or Level III personnel
shall interpret test results.
A CWI certification does not qualify an individual to perform non-destructive examinations. The
welding inspector is required to verify that the NDE was performed by a qualified individual in the
specified manner. Non-destructive examination of welds must be performed according to written
specifications by qualified individuals.
Verify Nondestructive Safety Checks, if applicable
When nondestructive testing is required, the use of radiographic materials poses a health hazard to all
personnel working in and around the testing site. The radiographer has the responsibility for setting up
the safety zone with the required hazard signs. The welding inspector may question the radiographer,
making sure the appropriate radiation warning signs have been posted and boundaries have been laid
out.
Evaluate non-destructive testing film for sensitivity and image density, if applicable.
After the radiographer has exposed and interpreted the film, the welding inspector should inspect the
sensitivity and density of the image by evaluating the image of the Image Quality Indicators (IQI) or
penetrameter. The penetrameter image and essential hole must be clearly visible. Discontinuities
and/or flaws found in the radiographic image by the radiographer shall be reported to the welding
inspector. The welding inspector shall determine the disposition of the weld.
Prepare and Maintain Visual Inspection Reports
Code work requires record keeping. Whether specified or not, complete records such as detailed notes
or formal inspection reports should be kept by every welding inspector. Each weld shall be documented
on the Visual Welding Inspection Report (Form WIR). If further record recordings are required for the
welding operation or for a specific project, the welding inspector should make these recordings on a
blank sheet and attach it to the Form WIR. The welding inspector should check official records such as
drawings or additional specifications for completeness and accuracy and make certain that the records
are available. Non-destructive testing film should be reviewed and documented for clarity and be
retained by Atmos Energy. Records should be as detailed as necessary and should be written in ink.
Errors should be crossed out with a single line; not erased, and the corrections should be made
accordingly and initialed by the welding inspector. Copies of the reports should be distributed to all
involved parties, and the welding inspector should maintain a copy for his records, should some question
later arise.
Original Approved by:
Utility Operating Council
Page 37 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 7
SAFETY
Since welding inspectors usually work in the same environment as the welder, they can be exposed to
the same safety hazards such as; shock, eye hazards, ultraviolet light, fumes, particulate matter in the
air, etc. The welding inspector must observe all Company safety practices and impose those practices to
others that are on site at all times. The following general safety precautions must be enforced while
performing Visual Welding Inspection to protect personnel, public and property:
Good housekeeping is essential to avoid injuries. The welding inspector must ensure that the
work site is organized in a safe and workable manner.
Welding leads, gas hoses and extension cords must be arranged not to provide a tripping hazard
or be in the path of vehicular traffic.
Trash and debris must be properly disposed of.
Traffic and warning devices must be properly displayed.
Approved personnel protective clothing and devices shall be used.
Only approved welding and cutting equipment shall be used.
Extension cords, welding leads and gas hoses shall not be used if frayed, cracked, repaired with
tape or otherwise damaged.
Welding helmets or head shields containing the appropriate filter and cover plates shall be used
by the welder.
Safety glasses, goggles or face shields shall be worn.
Properly fitted, flame resistant ear plugs or ear muffs must be worn whenever operations pose
such risks.
Proper ventilation of the work site must be maintained to protect from excess exposure of welding
fumes and gases.
Nondestructive testing procedures and policies must be enforced and adhered to.
Gas cylinders must be located outside the work area and properly secured.
Safety belts and lifelines must be used when required.
Proper safety devices must be utilized to protect personnel and public from potential welding
hazards.
Original Approved by:
Utility Operating Council
Page 38 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Visual Welding Inspector Qualification
Reference: API–1104, CFR 192 Subpart E
Issue Date: January 1, 2008 Effective Date: January 1, 2008 Revision Date: May 25, 2010
Chapter: 6
Section: 7
SPECIFICATION GUIDELINES
The following guidelines are common to all Atmos Energy Welding Procedure Specifications and must be
followed during all welding operations.
1.
Welding shall not be performed when the quality of the weld would be impaired by prevailing
weather conditions, including but not limited to airborne moisture, blowing sand or high winds.
Wind shields should be used where practical.
2.
There shall be two welders used to apply the first pass when the nominal diameter of the pipe is
greater than 14”. One or two welders may be used for the remaining passes to complete the
weld.
3.
There shall be complete penetration of the first pass on butt welds and branch connections with
1/32” to 1/16” inside penetrated build-up.
4.
Tack welds shall be considered as first pass segments and should be a minimum of 1” long.
5.
The maximum convexity of the cover pass face shall range from 1/16” to 1/8”.
6.
No portion of the cover pass face shall be concaved lower than the weld toes or tie-in.
7.
Lacing or excessive weaving the cover pass is prohibited.
8.
The starting point of two successive passes shall be offset a minimum of 1/2”.
9.
Insert patching or spot welding is prohibited.
10.
A stripper or short bead shall be used to fill up low areas or pinholes in the cover pass.
11.
Stripper beads must be at least 1” long.
12.
Spotting or filing to repair pinholes is prohibited.
13.
Peening of weld passes is prohibited.
14.
Arc burns on pipe and appurtenances are prohibited and must be repaired.
15.
Ground clamps shall be securely attached to the pipe.
16.
Welders shall identify their welds by marking their initials along side the weld using a greaseless
crayon.
17. When welding pipe and materials of two separate material groups, the procedure specification for
the higher strength group shall be used.
18. The surfaces to be welded shall be smooth, uniform and free from laminations, tears, scale, slag,
grease, paint and other deleterious material that might adversely affect the welding process.
Original Approved by:
Utility Operating Council
Page 39 of 39
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welding Procedure Specification Outline
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 7
1st Letter
Designation
S
M
T
*O(F/R)
Welding Process
SMAW
GMAW
GTAW
Oxyacetylene (Fixed or Rolled)
2nd Number
Designation
4
6
7
8
Pipe Grades
X-42 And Less
X-46 Thru X60
X-65
X-70
*For Division Specific Use Only
3rd Number
Designation
1
2
3
5th Letter
Designation
A
C
L
H
W
S
Pipe Wall Thickness
4th Letter
Designation
G
F
Less Than 3/16”
3/16” Thru 3/4"
Weld Type
Butt V-Groove
Branch/Circumferential Fillet
As Specified - (Numbered)
Electrodes
E-6010 (5P+)
E-6010 (5P+) / E-8010G (70+)
E-6010 (5P+) / E-7018 (H4R)
6th Letter
Designation
X
R
Position (GMAW Only)
Fixed
Rolled
E-7018 (H4R) and/or Higher
ER-70S-6 (.035 Solid)
As Specified - (Numbered)
Example #1: WPS - S62GA
Shielded Metal Arc Welding
Pipe Grades X-46 Through X-60
Wall Thickness 3/16” Thru 3/4"
Butt/V-Groove Weld
E-6010G (5P+) Electrodes
Example #2: WPS - T63GS-1
Gas Tungsten Arc Welding
Pipe Grades X-46 Through X-60
Wall Thickness Details on Specification
Butt/V-Groove Weld
Electrode Details on Specification
Example #3: WPS - O41GS-2
Oxyacetylene Torch
Pipe Grades X-42 and Less
Wall Thickness Less Than 3/16”
Butt/V-Groove Weld
Electrode Details on Specification
Note: These Welding Procedures satisfy normal operating conditions. Special conditions requiring
changes to these procedures where allowed by API-1104 will be documented as an appendage to these
procedures by Technical Services or a new Welding Procedure will be qualified by the Technical
Services. If special treatment is required for the purpose of controlling the welding operation, a Technical
Services, Engineering Specification containing the special treatment should be utilized with these
procedures where applicable as determined by the Technical Services, Engineering Departments.
Original Approved by:
Utility Operating Council
Page 1 of 1
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welding Procedure Specification Selection Guide
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 8
Guide No.: WPS-SG1
8.1
GENERAL
The following guide provides a selection of approved welding procedure specifications for use
on Atmos Energy Facilities. These specifications have been qualified and adopted for use on
both new construction and in-service maintenance welding. Prior to welding on any in-service
pipeline, the operating conditions and integrity of the pipeline must be checked and evaluated to
determine if there are any conditions that may affect the welding operation and will require the
use of low-hydrogen electrodes. These conditions may include operating pressure, wall
thickness, flow rate and any other conditions that would increase the likelihood of rapid cooling
of welds. When any of the following conditions are present the appropriate low hydrogen
welding procedure specification shall be selected.
a. Transmission pipelines unless approved by Technical Services.
b. Distribution mains operating greater than 100 psig unless approved by Technical Services.
c. Pipelines with a history of welds cracking.
d. Any other pipeline where there is a concern of burn through or hydrogen embrittlement.
8.2
WELDER QUALIFICATION REQUIREMENTS
Welding performed according to these procedure specifications shall meet the following criteria:
a. Welders qualified under API-1104 Multiple may weld on all Transmission and Distribution
pipelines where low-hydrogen welding is not required.
b. Welders qualified under API-1104 Multiple Low-Hydrogen may weld on all Transmission
and Distribution pipelines where low-hydrogen welding is required.
c. Welders qualified under CFR 192, Appendix C may weld on Distribution pipelines 12” and
less in diameter that are to be operated at a pressure that produces a hoop stress of less
than 20 percent of SMYS and where Low-Hydrogen welding is not required. Intermediate
and high pressure pipelines operating at a MAOP that produces a hoop stress of less than
20 percent SMYS must be evaluated for conditions that may be beyond the capacity of the
Appendix C welder’s length of qualification experience.
Note: Conditions requiring the use of low hydrogen electrodes may also require the use of
special treatments to control the welding operation. An Engineering specification for such
conditions specifying the recommended heat treatment, speed of travel, voltage and other
pertinent information shall be attached as an addendum and used with these
specifications. Contact Technical Services if you have any questions.
Original Approved by:
Utility Operating Council
Page 1 of 6
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welding Procedure Specification Selection Guide
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 8
Guide No.: WPS-SG1
Shielded Metal-Arc Welding (SMAW)
Specification
Number
Piping and Material
Specification
Wall Thickness
Joint
Design
WPS-S41GA
Less than or Equal to 42,000 PSI
Less Than 3/16”
Butt
WPS-S41GL
Less than or Equal to 42,000 PSI
Less Than 3/16”
Butt
WPS-S41FA
Less than or Equal to 42,000 PSI
Less Than 3/16”
Fillet
WPS-S41FL
Less than or Equal to 42,000 PSI
Less Than 3/16”
Fillet
WPS-S42GA
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Butt
WPS-S42GL
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Butt
WPS-S42FA
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Fillet
WPS-S42FL
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Fillet
WPS-S43GC-1
Less than or Equal to 42,000 PSI
>3/4" through 1-3/4”
Butt
WPS-S43GC-1Y
Less than or Equal to 42,000 PSI
to Less then or Equal to 52,000
PSI
>3/4" through 1-3/4”
Butt
WPS-S43GC-2
Less than or Equal to 42,000 PSI
>3/4" through 1-3/4”
Butt
WPS-S43GC-2Y
Less than or Equal to 42,000 PSI
to Less then or Equal to 52,000
PSI
>3/4" through 1-3/4”
Butt
Less than or Equal to 42,000 PSI
>3/4" through 1-3/4”
Fillet
WPS-S43FC-1
Filler Metal
Passes
Minimum
Passes
3
E6010/5P+
All
E6010/5P+
E7018/H4R
E6010/5P+
1st , 2nd
Remaining
All
E6010/5P+
E7018/H4R
E6010/5P+
1st , 2nd
Remaining
All
E6010/5P+
E7018/H4R
E6010/5P+
1st , 2nd
Remaining
All
E6010/5P+
E7018/H4R
E6010/5P+
1st , 2nd
Remaining
1st, 2nd
E8010-G/70+
Remaining
E6010/5P+
1st, 2nd
E8010-G/70+
Remaining
E6010/5P+
1st, 2nd
E8010-G/70+
Remaining
E6010/5P+
1st, 2nd
E8010-G/70+
Remaining
3
3
3
3
3
3
3
17
14
14
14
E6010/5P+
1st, 2nd
E8010-G/70+
Remaining
10
WPS-S61GA
Greater than 42,000 PSI, Less
than 65,000 PSI
Less Than 3/16”
Butt
E6010/5P+
All
3
WPS-S61GL
Greater than 42,000 PSI, Less
than 65,000 PSI
Less Than 3/16”
Butt
E6010/5P+
E7018/H4R
1st , 2nd
Remaining
3
WPS-S61FA
Greater than 42,000 PSI, Less
than 65,000 PSI
Less Than 3/16”
Fillet
E6010/5P+
All
3
Greater than 42,000 PSI, Less
than 65,000 PSI
E6010/5P+
1st , 2nd
WPS-S61FL
Less Than 3/16”
Fillet
E7018/H4R
Remaining
Original Approved by:
3
Utility Operating Council
Page 2 of 6
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welding Procedure Specification Selection Guide
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 8
Guide No.: WPS-SG1
Shielded Metal-Arc Welding (SMAW)
WPS-S62GA
Greater than 42,000 PSI, Less than
65,000 PSI
3/16” through 3/4"
Butt
WPS-S62GC
Greater than 42,000 PSI, Less than
65,000 PSI
3/16” through 3/4"
Butt
WPS-S62GL
Greater than 42,000 PSI, Less than
65,000 PSI
3/16” through 3/4"
Butt
WPS-S62FA
Greater than 42,000 PSI, Less than
65,000 PSI
3/16” through 3/4"
Fillet
WPS-S62FC
Greater than 42,000 PSI, Less than
65,000 PSI
3/16” through 3/4"
Fillet
WPS-S62FL
Greater than 42,000 PSI, Less than
65,000 PSI
3/16” through 3/4"
Fillet
WPS-S72GC
Equal to 65,000 PSI
3/16” through 3/4"
Butt
WPS-S72GL
Equal to 65,000 PSI
3/16” through 3/4"
Butt
WPS-S72FC
Equal to 65,000 PSI
3/16” through 3/4"
Fillet
WPS-S72FL
Equal to 65,000 PSI
3/16” through 3/4"
Fillet
WPS-S82GC
Equal to 70,000 PSI
3/16” through 3/4"
Butt
WPS-S82FC
Equal to 70,000 PSI
3/16” through 3/4"
Fillet
WPS-S82FL
Equal to 70,000 PSI
3/16” through 3/4"
Butt
E6010/5P+
All
3
E6010/5P+
1st , 2nd
E8010-G/70+
Remaining
E6010/5P+
1st , 2nd
E7018/H4R
Remaining
E6010/5P+
All
E6010/5P+
1st , 2nd
E8010-G/70+
Remaining
E6010/5P+
1st , 2nd
E7018/H4R
Remaining
3
3
3
E6010/5P+
1st , 2nd
E8010-G/70+
Remaining
E6010/5P+
1st , 2nd
E7018/H4R
Remaining
E6010/5P+
1st , 2nd
E8010-G/70+
Remaining
E8010-G/70+
1st , 2nd
E7018/H4R
Remaining
E6010/5P+
1st, 2nd
E8010-G/70+
Remaining
E6010/5P+
1st, 2nd
E8010-G/70+
Remaining
E6010/5P+
1st, 2nd
E7018/H4R
Remaining
3
3
3
3
3
3
4
4
4
Pre-fabrication Shop - Shielded Metal-Arc Welding (SMAW)
The following Welding Specifications are restricted to Shop Fabrication use only. Contact
Technical Services for information on the use of these specifications.
WPS-S62GC-PF
Greater than 42,000 PSI, Less
than 65,000 PSI
Original Approved by:
3/16” through 3/4"
Butt
E6010/5P+
E8010-G/70+
1st , 2nd
Remaining
6
Utility Operating Council
Page 3 of 6
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welding Procedure Specification Selection Guide
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 8
Guide No.: WPS-SG1
Gas Metal-Arc Welding (GMAW)
The following Welding Specifications have been adopted for use in fabrication of installations
and components within a shop environment. Contact Technical Services for information on the
use of these specifications.
Specification
Number
Piping and Material
Specification
Wall Thickness
Joint
Position
Design
Filler
Metal
Passes
Minimum
Passes
WPS-M41FW
Less than or Equal to 42,000 PSI
Less Than 3/16”
Fillet
Fixed
ER70S-6
All
2
WPS-M41GWR
Less than or Equal to 42,000 PSI
Less Than 3/16”
Butt
Rolled
ER70S-6
All
2
WPS-M41GWX
Less than or Equal to 42,000 PSI
Less Than 3/16”
Butt
Fixed
ER70S-6
All
2
WPS-M42FW
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Fillet
Fixed
ER70S-6
All
2
WPS-M42GWR
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Butt
Rolled
ER70S-6
All
2
WPS-M42GWX
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Butt
Fixed
ER70S-6
All
2
WPS-M61FW
Greater than 42,000 PSI, Less
than 65,000 PSI
Less Than 3/16”
Fillet
Fixed
ER70S-6
All
2
WPS-M61GWR
Greater than 42,000 PSI, Less
than 65,000 PSI
Less Than 3/16”
Butt
Rolled
ER70S-6
All
2
WPS-M61GWX
Greater than 42,000 PSI, Less
than 65,000 PSI
Less Than 3/16”
Butt
Fixed
ER70S-6
All
2
WPS-M62FW
Greater than 42,000 PSI, Less
than 65,000 PSI
3/16” through 3/4"
Fillet
Fixed
ER70S-6
All
2
WPS-M62GWR
Greater than 42,000 PSI, Less
than 65,000 PSI
3/16” through 3/4"
Butt
Rolled
ER70S-6
All
2
WPS-M62GWX
Greater than 42,000 PSI, Less
than 65,000 PSI
3/16” through 3/4"
Butt
Fixed
ER70S-6
All
2
Original Approved by:
Utility Operating Council
Page 4 of 6
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welding Procedure Specification Selection Guide
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 8
Guide No.: WPS-SG1
Oxyacetylene Welding
The following Welding Specifications are restricted to Division specific use only. Contact
Technical Services for information on the use of these specifications.
Specification
Number
Piping and Material
Specification
Wall Thickness
Joint
Design
Filler
Metal
Passes
Minimum
Passes
WPS-O41GS
Less than or Equal to 42,000 PSI
Less Than 3/16”
Butt
RG60
All
1
WPS-OR41GS
Less than or Equal to 42,000 PSI
Less Than 3/16”
Butt
RG60
All
1
WPS-O41FS
Less than or Equal to 42,000 PSI
Less Than 3/16”
Fillet
RG60
All
1
WPS-O41GS Plus
Less than or Equal to 42,000 PSI
Less Than 3/16”
Butt
RG60
All
1
WPS-OR41GS Plus
Less than or Equal to 42,000 PSI
Less Than 3/16”
Butt
RG60
All
1
WPS-O42FS
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Fillet
RG60
All
2
WPS-O42GS
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Butt
RG60
All
2
WPS-OR42GS
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Butt
RG60
All
2
Original Approved by:
Utility Operating Council
Page 5 of 6
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welding Procedure Specification Selection Guide
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 8
Guide No.: WPS-SG1
Gas Tungsten Metal-Arc Welding
Specification
Number
Piping and Material
Specification
Wall Thickness
Joint
Design
Filler Metal
Passes
Minimum
Passes
WPS-T42GS-1
Less than or Equal to 42,000 PSI
3/16” through 3/4"
Butt
ER-316/316L
All
3
Original Approved by:
Utility Operating Council
Page 6 of 6
Utility Operations Handbook
Section: Appendixes
Subject: Appendix L – Inspection and Testing of Production Welds
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 9
9.1
GENERAL
All welds made on Atmos Energy Facilities shall be inspected by non-destructive means or
by removing the welds and subjecting them to destructive mechanical tests.
Non-destructive testing may consist of visual inspection, radiographic inspection or other
method specified by Atmos Energy. The method used shall produce indications of defects
that can be accurately interpreted and evaluated. If necessary, a combination of inspection
methods to determine the flaw size shall be required.
Destructive testing shall consist of the removal of completed welds, the sectioning of them
into specimens and the examination of the specimens. The specimens shall be prepared
and examined in accordance with the qualifying standard for which the weld was applied.
9.2
METHODS OF INSPECTION
All welding shall be visually inspected to assure the welding operation is being performed in
accordance with the welding procedure specification and acceptance standards. Form WIR,
Visual Welding Inspection Report, shall be used to document the visual inspection of welds
made on Atmos Energy Facilities. The Form WIR shall be completed by the qualified
welding inspector performing the inspections. Welds inspected shall be documented as
Satisfactory, Unsatisfactory or Non-Applicable. For welds documented as Unsatisfactory, an
explanation of the defect found and the steps taken to repair the defect shall be noted.
In addition to visual inspection, if a flaw can not be accurately identified, the use of Magnetic
Particle Testing or Liquid Penetrant Testing shall be utilized. Indications produced by these
testing methods shall be interpreted and evaluated by a Welding Inspector qualified to Level
II or III in accordance with the American Society for Nondestructive Testing, Recommended
Practice No. SNT-TC-1A, ACCP or any other recognized national certification program
acceptable to Atmos Energy to determine its acceptability. The Welding Inspector may
reject any weld that does not appear to meet the acceptance standards for which it is being
inspected.
9.3
RIGHTS OF REJECTION
All nondestructive test methods are limited in the information that can be derived from the
indications they produce. Atmos Energy may therefore reject any weld that appears to meet
the acceptance standards, if in the opinion of the Welding Inspector the depth of the
imperfection may be detrimental to the weld.
Original Approved by:
Utility Operating Council
Page 1 of 2
Utility Operations Handbook
Section: Appendixes
Subject: Appendix L – Inspection and Testing of Production Welds
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 9
9.4
INSPECTION FREQUENCY
The frequency of inspection shall be determined by Atmos Energy in accordance with CFR
192. Welds on the Atmos Energy System that are to be operated at a pressure that
produces a hoop stress of 20 percent or more of SMYS (Specified Minimum Yield Strength)
must be non-destructively tested in accordance with the following chart, at a minimum.
Welds on the Atmos Energy System made on pipe with a nominal diameter of less than 6
inches or if the pipeline is to be operated at a pressure that produces a hoop stress of less
than 40 percent of SMYS and the welds are so limited in number that would make it
impractical for non-destructive testing, may be visually inspected and approved by a
qualified welding inspector.
Class 1 Locations
Class 2 Locations
Class 3 Locations
Class 4 Locations
At Least 10 Percent
At Least 15 Percent
100 Percent
100 Percent
In Class 3 and Class 4 locations, at crossings of major or navigable rivers, offshore and
within railroad and public highway rights-of-way, including tunnels, bridges and overhead
road crossings where it would be impracticable to obtain 100 percent, at least 90 percent
shall be tested. Pipeline tie-ins, including tie-ins of replacement sections shall be 100
percent tested.
Original Approved by:
Utility Operating Council
Page 2 of 2
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Repair and Removal of Defects
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 10
10.1
GENERAL
The acceptability of a weld that is visually inspected and/or nondestructively tested is
determined according to the standards in Section 9 of API Standard 1104. Each weld that is
unacceptable under Section 9 of API Standard 1104 must be removed or repaired. The
following welding repair procedures shall be followed whenever a repair is to be made.
10.2
AUTHORIZATION FOR REPAIR
During welding, non-completed welding defects other than cracks, in the root and filler
beads may be reworked and repaired with prior Welding Inspector authorization. Defects
other than cracks, in the cover bead may be reworked and repaired as specified by the
procedure specification without prior inspector authorization. All rework repairs on noncompleted welds shall be made using the same procedure specification in which the weld
was made and the rework repairs shall meet the standards of acceptability given by the
qualifying standard. The Welding Inspector has authority to judge all rework repair(s) and
require the rework repair(s) is/are unsatisfactory.
Once the weld has been completed and a defect that requires repair is found from final
visual inspection or other non-destructive means shall first be approved by the Welding
Inspector. If the Welding Inspector determines that the defect can be repaired, the welder
will be allowed to remove the defect by grinding it away to expose sound metal and the
repair area shall be preheated between 250 to 300 degrees Fahrenheit and re-welded using
the same welding procedure specification in which the weld was initially made. If the
repaired area does not meet the standards of acceptability, then the entire weld shall be cut
out and replaced. There shall be only one (1) attempt for the repair of welds.
A welder having two or more repairs or if there is a question about his competence may be
required to re-qualify.
10.3
REPAIR AND REMOVAL OF ARC BURNS
Arc burns shall be removed by grinding or cut out as a cylinder. If an arc burn is removed by
grinding, the arc burn must be completely removed and the remaining wall thickness must
meet the tolerances as specified in the wall thickness chart.
Original Approved by:
Utility Operating Council
Page 1 of 3
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Repair and Removal of Defects
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 10
10.4
REPAIR AND REMOVAL OF OTHER ANOMALIES
Anomalies such as dents, gouges and manufacturing defects in a weld or on the pipe wall
that do not meet the standards of acceptability shall be repaired by cutting the anomaly out
as a cylinder.
10.5
AUTHORIZATION FOR IN-SERVICE REPAIR
Contact Technical Services prior to making any in-service repair.
If feasible, all repairs should be made by taking the main or pipeline out of service and
removing the defect as a cylinder from the pipeline.
If the main or pipeline cannot be taken out of service then:
(A) A non-leaking defect within a weld or on the pipe wall may be repaired by grinding
the defect away. If after grinding, the pipe wall thickness is less than that listed in the
following Wall Thickness Chart or if the weld is less than 1/8 inch thick the installation
of a full-encirclement split-sleeve shall be installed over the defect area. The repair
sleeve shall be welded according to the appropriate welding procedure specification
for installing a pressure containing repair sleeve.
(B) A leaking defect within a weld or on the pipe wall may be repaired by installing fullencirclement split-sleeve over the defect area. The repair sleeve shall be welded
according to the appropriate welding procedure specification for installing a pressure
containing repair sleeve.
Original Approved by:
Utility Operating Council
Page 2 of 3
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Repair and Removal of Defects
Reference: API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: May 25, 2010
Chapter: 10
API-5L - Tolerances for Line Pipe Wall Thickness
* Tolerance
(Percent of Specified Wall Thickness)
Size
Type of Pipe
Grade B or Lower
Grade X42 or Higher
Less Than or Equal to 2-7/8”
All
+20.0, -12.5
+15.0, -12.5
Greater Than 2-7/8” and Less Than 20”
All
+15.0, -12.5
+15.0, -12.5
Greater Than or Equal to 20”
Welded
+17.5, -12.5
+19.5, -8.0
Greater Than or equal to 20”
Seamless
+15.0, -12.5
+17.5, -10.0
* Where negative tolerances smaller than those listed are specified by Atmos, the positive tolerance shall
be increased to the applicable total tolerance range in percent less the wall thickness negative tolerance.
10.6
REMOVAL AND PREPARATION FOR REPAIR
Before repairs are made, injurious defects shall be entirely removed to sound metal. All slag
and scale shall be removed. If preheat treatment is required, the procedure specification
detailing the procedure shall be used.
10.7
TESTING OF REPAIRS
Repaired areas shall be re-inspected by the same means previously used in finding the
defect. The Welding Inspector may require re-inspection of a weld containing a repair by
non-destructive means.
10.8
AUTHORIZATION AND PROCEDURE FOR REPAIR OF CRACKS
All cracks excluding small crater cracks or star cracks no larger than 5/32” shall be cut out
and removed as a cylinder. There are no exceptions for the repair of cracks on Atmos
Energy Facilities.
Original Approved by:
Utility Operating Council
Page 3 of 3
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
1 SCOPE
2.4 This butt weld shall be made on pipe whose
This Welder Qualification Test Specification
provides the details and processes for a multiple
qualification welder to fabricate and weld pipe
and materials to determine the ability of the
welder to make sound butt and fillet welds.
This Test Specification is in accordance with
Procedure Qualification Record No. PQR-S42GA
or PQR-S62GC for butt welds and Procedure
Qualification Record No. PQR-S42FA or PQRS62FC for fillet welds. These procedures have
been qualified and approved by Technical
Services in accordance with API Standard 1104,
Nineteenth Edition, September 1999.
A welder who successfully completes this
qualification test shall be qualified to weld in all
positions; on all wall thicknesses, joint designs
and fittings; and on all pipe diameters within the
limits of the essential variables as described by
the qualifying standard.
The following specifications shall be adhered to
except where a change is specifically authorized
by Technical Services as provided by the
qualifying Standard.
2 PROCESS AND GUIDELINES
2.1 This test specification applies to welding
diameter is at least 12-3/4 inches in
diameter and whose wall thickness is at
least 1/4 inch without a backing strip.
2.5 The pipe shall be supported so that typical
flat, vertical and overhead welds are
produced.
2.6 The time allowed to complete this Butt Weld
Test shall be 2 hours. The Welding
Inspector may adjust this time period at his
discretion.
Branch Fillet Weld Test
2.7 The welder shall layout, cut, fit and weld a
full-size branch-to-pipe connection.
2.8 This test shall be made with pipe whose
diameter is a least 12-3/4 inches and whose
wall thickness is a least 1/4 inch.
2.9 A full size hole shall be cut in the run-pipe.
There shall be no more than a 1/16 inch lip
inside the branch.
2.10 The weld shall be made with the run-pipe
axis in the fixed horizontal position and the
branch-pipe axis extending vertically
downward from the run-pipe.
2.11 The time allowed to complete this Branch
performed by the manual Shielded MetalArc Welding (SMAW) process for all passes.
Fillet Weld Test shall be 3 hours. The
Welding Inspector may adjust this time
period at his discretion.
2.2 For this multiple qualification, a welder shall
2.12 There shall be complete penetration of the
successfully complete the following two
tests:
Butt Weld Test
2.3 The welder shall make a butt weld in the
fixed position with the axis of the pipe in the
horizontal plane.
first pass with 1/32” to 1/16” inside
penetrated build-up.
2.13 Tack welds shall be considered as first
pass segments and should be a minimum
of 1” long.
2.14 The crown of the cover pass shall be 1/32"
to 1/16" higher than the pipe wall for the
butt weld.
Original Approved by:
Utility Operating Council
Page 1 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
2.15 No portion of the cover pass shall be
concaved lower than the pipe wall.
3 JOINT DESIGN – BUTT WELD
3.1 This specification applies to a standard V-
2.16 The cover pass shall overlap the beveled
Bevel butt joint as shown in the following
diagram.
groove by approximately 1/16” on each
side for the butt weld.
2.17 Lacing or excessive weaving the cover
pass is prohibited.
2.18 The starting point of two successive
passes shall be offset a minimum of 1/2”.
2.19 Insert patching or spot welding is
prohibited.
2.20 A stripper or short bead shall be used to fill
up low areas or pinholes in the cover pass.
2.21
2.22
2.23
2.24
2.25
3.2 The angle of bevel shall be approximately
30 degrees with an included angle of
approximately 60 degrees.
Stripper beads must be at least 1” long.
Spotting or filing of pinholes is prohibited.
Peening of weld passes is prohibited.
Arc burns are prohibited.
3.3 The size of the root face or land shall be
1/16”
1/32”.
3.4 The root opening or the space between the
Ground clamps shall be securely attached
to the pipe.
abutting members shall be approximately
1/16”.
2.26 The cover pass should be applied to
3.5 Pipe ends may be beveled by machine tool,
produce a substantially uniform crown
around the entire circumference of the
pipe.
machine oxygen cutting or manual oxygen
cutting. Bevels shall be ground reasonably
smooth and uniform to remove any
discontinuities.
2.27 The cover pass shall present a neat
workman-like appearance.
3.6 Power tools shall be used for grinding when
beveling is required.
2.28 The completed weld shall be thoroughly
3.7 Bevel dimensions shall conform to the joint
brushed and cleaned.
2.29 Each Welder shall identify his work by
design in accordance with this specification.
marking his initials along side the
completed weld with a greaseless lumber
crayon.
Original Approved by:
Utility Operating Council
Page 2 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
4 JOINT DESIGN – BRANCH FILLET
WELD
4.1 This specification applies to a fillet weld joint
as shown in the following diagram.
5 PIPE SPECIFICATIONS
5.1 This test specification applies to the welding
of pipe segments 12-3/4” in diameter with a
0.250” wall thickness that conforms to a
specification with a minimum yield strength of
less than or equal to 60,000 pounds per
square inch, including but not limited to the
following:
API Specification 5L, Grades A and B;
ASTM A-106, Grades A and B;
ASTM A-53, Grades A and B;
ASTM A-234, Grades A and B
API Specification 5LX, Grade 42 through Grade 60;
MSS-SP-75, Grade Y-46 through Grade Y-60;
MSS-SP-44, Grade F-46 through Grade F-60
5.2 Butt
weld pipe segments shall be
approximately 9” long. The run pipe segment
for the fillet weld shall be approximately 18”
long and the branch segment for the fillet
weld shall be approximately 9” long.
4.2 The angle of bevel on the fabricated branch
pipe shall range from approximately 30
degrees to 45 degrees.
4.3 The size of the root face or land on the
fabricated branch pipe bevel shall be
approximately 1/16”.
4.4 The root opening or the space between the
fabricated branch pipe and the run pipe
shall be approximately 1/16”.
6
6.1 This test specification applies to the use of
filler metal that conforms to Group 1, AWS
Specification A5.1 and Group 2, AWS
Specification A5.5 for coated electrodes. The
welding inspector may select the appropriate
filler metal to use from the following chart
according to the production application by the
welder.
4.5 Pipe ends may be beveled by machine tool,
machine oxygen cutting or manual oxygen
cutting. Bevels shall be ground reasonably
smooth and uniform to remove any
discontinuities.
4.6 Power tools shall be used for grinding and
when beveling is required.
Original Approved by:
FILLER METAL, AMPERAGE, SIZE,
NUMBER OF BEADS AND
ELECTRICAL CHARACTERISTICS
6.2 A minimum number of three passes is
required for this test specification. Each pass
should be approximately 3/32” to 5/32” thick.
Utility Operating Council
Page 3 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
6.3 Filler metals used with this specification
shall have been properly stored in
containers designed for the filler metals to
eliminate contamination from water, grease,
dirt, drying out or collecting moisture and
shall be protected from these elements
during the welding operation. Damaged or
deteriorated filler metals shall not be used
with this specification.
6.4 The following chart applies to and identifies
Electrode
Size
Selection
Electrode
Type
Minimum
Number
Sequence of
Passes
3/32” - 1/8”
E6010
5P+
1
1st Pass
Root
3/32” - 5/32”
E6010
5P+
1
2nd Pass
Hot-Pass
1
As Required
3rd Pass
Filler/Cover Pass
As Required
E6010
5P+
5/32” - 3/16”
the
electrode
classification,
brand,
amperage range, voltage range, current and
polarity for this test specification.
AWS
Electrode Amperage Voltage
Class
Current
Size
Range
Range
Brand
E6010
5P+
3/32”
E6010
5P+
40-70
E8010G
70+
Polarity
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
65-130
E8010-G
70+
1/8”
75-130
E6010
5P+
90-175
E8010-G
70+
5/32”
90-185
E6010
5P+
3/16”
140-225
E8010-G
70+
6.5 The following selection chart and diagrams
identifies the electrode sizes, type, minimum
number and sequence of passes of each
completed weld for this specification.
Original Approved by:
Utility Operating Council
Page 4 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
7 PIPE POSITION
7.1 This test specification applies to fixed
11 CLEANING AND/OR GRINDING
11.1 This test specification applies to the use of
position welding.
either power or hand tools to remove all
rust, dirt and other foreign matter before
starting the welding test, during the
welding test and after the welding test is
completed.
7.2 All pipe components being joined shall be
secured against movement with adequate
clearance around the joint.
7.3 The working clearance around the pipe at
the weld should not be less than 16” above
the ground.
11.2 Power Tools shall be used for grinding and
8 DIRECTION OF WELDING
8.1 This specification applies to welding being
12 PRE-HEAT AND POST-HEAT
TREATMENT
12.1 When the ambient temperature is less than
performed in the downhill direction from top
to bottom for all passes.
cleaning the first and second pass.
40 degrees Fahrenheit the pipe material
surrounding the weld area shall be preheated to obtain a temperature of
approximately 70 degrees Fahrenheit to
remove excess moisture and dry the pipe
material prior to the welding operation.
9 TIME BETWEEN PASSES
9.1 This test specification applies to a maximum
time between the completion of the first
pass and the start of the second pass to no
more than 5 minutes.
9.2 The time between the completion of the
second pass and the third pass shall be
determined by the Welding Inspector, but
shall be no more than 30 minutes.
9.3 There shall be no accelerated cooling of any
13 SPEED OF TRAVEL
13.1 This test specification applies to a speed of
travel not to exceed 18" per minute for any
pass.
13.2 The following chart indicates the range for
pass.
10 ALIGNMENT
10.1 For pipe with the same nominal wall
speed of travel in inches per minute for
each pass.
Pass
Range of Speed
thickness, the alignment offset shall not
exceed 1/16".
1st
4-18
2nd
4-18
10.2 For pipe with dimensional variations,
3rd
4-18
alignment offset greater than 1/16" shall be
equally
distributed
around
the
circumference of the pipe.
10.3 Hammering on pipe materials to obtain
proper alignment or line-up is prohibited.
Original Approved by:
Utility Operating Council
Page 5 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
14 PREPARATION AND TESTING OF
BUTT WELD
14.1 Pipe beveling shall be applied and/or
checked for
specification.
conformance
with
14.12 The inspector will visually inspect the
completed weld. If the completed weld
passes inspection the inspector will
instruct the welder in cutting out the
destructive test coupons.
this
14.2 Clean, fit-up and tack the test segments
together. The test specimen may be
moved/rolled for fit-up.
14.3 After tacking, the test specimen shall be
15 PREPERATION AND TESTING OF
FILLET WELD
15.1 The run pipe shall be measured and
placed in the 5G position (horizontal) and
fixed to prevent movement.
marked in the approximate center of the
pipe for a full size opening to be cut out for
the connection of the branch pipe.
14.4 Welding may begin after the test specimen
15.2 The marked opening of the run pipe shall
has been placed into the fixed position.
be cut out by hand.
14.5 After the first pass has been applied and
15.3 Clean, fit-up and tack the test segments
cleaned inside and out, welding must stop
and the inspector must be summoned for
inspection of the first pass.
together. The test specimen may be
moved/rolled for fit-up.
14.6 After the inspector has inspected and
15.4 After tacking, the test specimen shall be
placed with the run pipe in the 5G position
(horizontal) and the branch pipe extending
vertically downward. The test specimen
shall be fixed in this position to prevent
movement.
approved the first pass, the second pass
may be started.
14.7 When the second pass has been applied
and cleaned, welding must stop and the
inspector must be summoned to inspect
the second pass.
15.5 Welding may begin after the test specimen
14.8 After the inspector has inspected and
15.6 After the first pass has been applied and
approved the second pass, the weld may
be completed.
cleaned inside and out, welding must stop
and the inspector must be summoned for
inspection of the first pass.
has been placed into the fixed position.
14.9 After completing the weld, check for
pinholes and make the necessary repairs.
Filing down the cover pass to remove
pinholes is prohibited.
15.7 After the inspector has inspected and
14.10 Other discontinuities found shall be
15.8 When the second pass has been applied
approved for repair by the inspector
before any repairs are made.
and cleaned, welding must stop and the
inspector must be summoned to inspect
the second pass.
approved the first pass, the second pass
may be started.
14.11 When you are satisfied that the weld is
complete, you must summon the
inspector. No further work on the weld
will be allowed at this point.
Original Approved by:
15.9 After the inspector has inspected and
approved the second pass, the weld may
be completed.
Utility Operating Council
Page 6 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
15.10 After completing the weld, check for
16.8 The coupons marked for nick-break shall
pinholes and make the necessary repairs.
Filing down the cover pass to remove
pinholes is prohibited.
be notched in the center of the weld on
each side of the coupon approximately
1/8” deep with a hand saw.
15.11 Other discontinuities found shall be
16.9 The coupons marked for root-bend shall
approved for repair by the inspector
before any repairs are made.
have the cover and root ground down
smooth to the base metal. Grinding into
the base metal will cause for
disqualification.
See the following
diagrams.
15.12 When you are satisfied that the weld is
complete, you must summon the
inspector. No further work on the weld
will be allowed at this point.
15.13 The inspector will visually inspect the
completed weld. If the completed weld
passes inspection the inspector will
instruct the welder in cutting out the
destructive test coupons.
17 PREPARING TEST COUPONS FOR
FILLET WELD
17.1 There shall be 4 test coupons cut from the
test weld.
17.2 These coupons shall be nick-break
specimens.
16 PREPARING TEST COUPONS FOR
BUTT WELD
16.1 There shall be 6 test coupons cut from the
test weld.
17.3 The inspector will designate the locations
of the test coupons.
17.4 Each coupon shall be approximately 2
inches wide and approximately 4 inches
long.
16.2 These coupons shall include 2 tensile, 2
nick-break and 2 root-bend specimens.
17.5 Each coupon shall be notched on each
16.3 The inspector will designate the locations
side of the weld with a cutting torch to
obtain approximately 1 inch of weld area
for testing.
of the test coupons.
16.4 Each coupon shall be approximately 1 inch
wide and approximately 9 inches long.
17.6 Each coupon shall be notched in the
center of the weld and on each side of the
weld, center of the cap to center of the root
approximately 1/8 inch deep with a hand
saw.
16.5 Each coupon shall be marked to determine
its type. T for tensile, N for nick and R for
root.
16.6 Clean and grind the coupons to remove all
slag and rough edges.
17.7 Clean and grind the coupons to remove all
16.7 The coupons marked for tensile require no
further preparation.
Original Approved by:
slag and rough edges. See the following
diagrams.
Utility Operating Council
Page 7 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
18 WELDER QUALIFICATION RECORD
18.1 The Welding Inspector shall fill out the
18.3 The WQR Form shall be forwarded to
WQR Form in detail for each test and
submit the forms and test specimens to an
approved testing facility for destructive
testing.
18.4 The WQR Form for contractors may be
Technical Services for processing.
processed and maintained by an external
database however, this database shall be
accessible by Atmos Energy.
18.2 The destructive test results shall be
recorded in detail on the WQR Form.
Original Approved by:
Utility Operating Council
Page 8 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
Original Approved by:
Utility Operating Council
Page 9 of 10
Utility Operations Handbook
Section:
Appendixes
Appendix L – Welder Qualification Test Specification
Subject:
Reference API–1104, CFR 192 Subpart E
:
Issue Date: June 13, 2006
Effective Date: June 13, 2006
Revision Date: May 25, 2010
Specification No.: WQS-1M
Original Approved by:
Utility Operating Council
Page 10 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
1 SCOPE
This Welder Qualification Test Specification
provides the details and processes for a multiple
qualification welder to fabricate and weld inservice pipe and materials to determine the ability
of the welder to make sound butt welds.
This Test Specification is in accordance with
Procedure Qualification Record No. PQR-S42GL
for butt welds and Procedure Qualification Record
No. PQR-S42FL for fillet welds. These procedures
have been qualified and approved by Technical
Services in accordance with API Standard 1104,
Nineteenth Edition, September 1999.
A welder who successfully completes this
qualification test shall be qualified to weld in all
positions; on all wall thicknesses, joint designs and
fittings; and on all pipe diameters within the limits
of the essential variables as described by the
qualifying standard.
The following specifications shall be adhered to
except where a change is specifically authorized
by Technical Services as provided by the
qualifying Standard.
2 PROCESS AND GUIDELINES
2.1 This test specification applies to maintenance
in-service welding performed by the manual
Shielded Metal-Arc Welding (SMAW) process
for all passes.
b. This butt weld shall be made on pipe whose
diameter is at least 12-3/4 inches in diameter
and whose wall thickness is at least 1/4 inch
without a backing strip.
c. The pipe shall be supported so that typical
flat, vertical and overhead welds are
produced.
d. The time allowed to complete this Butt Weld
Test shall be 2 hours. The Welding Inspector
may adjust this time period at his discretion.
Branch Fillet Weld Test
a. The welder shall layout, cut, fit and weld a
full-size branch-to-pipe connection.
b. This test shall be made with pipe whose
diameter is a least 12-3/4 inches and whose
wall thickness is a least 1/4 inch.
c. A full size hole shall be cut in the run-pipe.
There shall be no more than a 1/16 inch lip
inside the branch.
d. The weld shall be made with the run-pipe axis
in the fixed horizontal position and the
branch-pipe axis extending vertically
downward from the run-pipe.
e. The time allowed to complete this Branch
Fillet Weld Test shall be 3 hours. The
Welding Inspector may adjust this time period
at his discretion.
2.3 There shall be complete penetration of the
2.2 For this multiple qualification, a welder shall
first pass with 1/32” to 1/16” inside penetrated
build-up.
successfully complete the following two tests:
2.4 Tack welds shall be considered as first pass
Butt Weld Test
a. The welder shall make a butt weld in the fixed
position with the axis of the pipe in the
horizontal plane.
segments and should be a minimum of 1”
long.
2.5 The crown of the cover pass shall be 1/32" to
1/16" higher than the pipe wall for the butt
weld.
2.6 No portion of the cover pass shall be
concaved lower than the pipe wall.
Original Approved by:
Utility Operating Council
Page 1 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
2.7 The cover pass shall overlap the beveled
groove by approximately 1/16” on each side
for the butt weld.
3 JOINT DESIGN – BUTT WELD
3.1 This specification applies to a standard VBevel butt joint as shown in the following
diagram.
2.8 Lacing or excessive weaving the cover pass
is prohibited.
2.9 The starting point of two successive passes
shall be offset a minimum of 1/2”.
2.10 Insert patching or spot welding is prohibited.
2.11 A stripper or short bead shall be used to fill
up low areas or pinholes in the cover pass.
2.12
2.13
2.14
2.15
2.16
Stripper beads must be at least 1” long.
Spotting or filing of pinholes is prohibited.
Peening of weld passes is prohibited.
3.2 The angle of bevel shall be approximately 30
degrees with an included
approximately 60 degrees.
Arc burns are prohibited.
Ground clamps shall be securely attached
to the pipe.
1/32”.
3.4 The root opening or the space between the
abutting members shall be approximately
1/16”.
2.18 The cover pass shall present a neat
workman-like appearance.
3.5 Pipe ends may be beveled by machine tool,
machine oxygen cutting or manual oxygen
cutting. Bevels shall be ground reasonably
smooth and uniform to remove any
discontinuities.
2.19 The completed weld shall be thoroughly
brushed and cleaned.
2.20 Each Welder shall identify his work by
marking his initials along side the
completed weld with a greaseless lumber
crayon.
of
3.3 The size of the root face or land shall be 1/16”
2.17 The cover pass should be applied to
produce a substantially uniform crown
around the entire circumference of the pipe.
angle
3.6 Power tools shall be used for grinding when
beveling is required.
3.7 Bevel dimensions shall conform to the joint
design in accordance with this specification.
Original Approved by:
Utility Operating Council
Page 2 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
4 JOINT DESIGN – BRANCH FILLET
WELD
5 PIPE SPECIFICATIONS
4.1 This specification applies to a fillet weld joint
of pipe segments 12-3/4” in diameter with a
0.250” wall thickness that conforms to a
specification with a minimum yield strength of
less than or equal to 42,000 pounds per
square inch, including but not limited to the
following:
API Specification 5L, Grades A and B;
API Specification 5LX, Grade 42;
ASTM A-106, Grades A and B;
ASTM A-53, Grades A and B;
ASTM A-234, Grades A and B
5.2 Butt weld pipe segments shall be
approximately 9” long. The run pipe segment
for the fillet weld shall be approximately 18”
long and the branch segment for the fillet
weld shall be approximately 9” long.
as shown in the following diagram.
4.2 The angle of bevel on the fabricated branch
pipe shall range from approximately 30
degrees to 45 degrees.
4.3 The size of the root face or land on the
fabricated branch pipe bevel shall be
approximately 1/16”.
5.1 This test specification applies to the welding
6 FILLER METAL, AMPERAGE, SIZE,
NUMBER OF BEADS AND
ELECTRICAL CHARACTERISTICS
6.1 This test specification applies to the use of
filler metal that conforms to Group 1, AWS
Specification A5.1 and Group 3, AWS
Specification A5.1 or A5.5 for coated
electrodes.
E6010 5P+ and E7018
electrodes shall be selected.
4.4 The root opening or the space between the
fabricated branch pipe and the run pipe shall
be approximately 1/16”.
4.5 Pipe ends may be beveled by machine tool,
machine oxygen cutting or manual oxygen
cutting. Bevels shall be ground reasonably
smooth and uniform to remove any
discontinuities.
6.2 A minimum number of three passes is
required for this test specification. Each pass
should be approximately 3/32” to 5/32” thick.
4.6 Power tools shall be used for grinding and
when beveling is required.
Original Approved by:
Utility Operating Council
Page 3 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
Electrode
Size
Selection
Electrode
Type
Minimum
Number
Sequence of
Passes
3/32” - 3/16”
E6010
5P+
1
1st Pass
Root
3/32” - 3/16”
E6010
5P+
1
2nd Pass
Hot-Pass
3/32” - 3/16”
E7018
H4R
1
As Required
3rd Pass
Filler/Cover Pass
As Required
6.3 Filler metals used with this specification shall
have been properly stored in containers
designed for the filler metals to eliminate
contamination from water, grease, dirt, drying
out or collecting moisture and shall be
protected from these elements during the
welding operation. Damaged or deteriorated
filler metals shall not be used with this
specification.
6.4 The following chart applies to and identifies
the electrode classification, brand, amperage
range, voltage range, current and polarity for
this test specification.
AWS
Class
Brand
Electrode Amperage Voltage
Current
Size
Range
Range
E6010
5P+
40-70
3/32”
E7018
H4R
E6010
5P+
E7018
H4R
E6010
5P+
E7018
H4R
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
70-110
65-130
1/8”
90-160
90-175
5/32”
130-210
E6010
5P+
140-225
3/16”
E7018
H4R
Polarity
180-300
6.5 The following selection chart and diagrams
identifies the electrode sizes, type, minimum
number and sequence of passes of each
completed weld for this specification.
Original Approved by:
Utility Operating Council
Page 4 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
7 PIPE POSITION
10.3 Hammering on pipe materials to obtain
proper alignment or line-up is prohibited.
7.1 This test specification applies to fixed position
welding.
11 CLEANING AND/OR GRINDING
7.2 All pipe components being joined shall be
secured against movement with adequate
clearance around the joint.
11.1 This test specification applies to the use of
either power or hand tools to remove all
rust, dirt and other foreign matter before
starting the welding test, during the welding
test and after the welding test is completed.
7.3 The working clearance around the pipe at the
weld should not be less than 16” above the
ground.
11.2 Power Tools shall be used for grinding and
cleaning the first and second pass.
8 DIRECTION OF WELDING
8.1 This specification applies to welding being
performed in the downhill direction from top to
bottom for the 1st and 2nd passes. The 3rd
and/or remaining passes shall be performed
in the uphill direction from bottom to top.
12 PRE-HEAT AND POST-HEAT
TREATMENT
12.1 When the ambient temperature is less than
40 degrees Fahrenheit the pipe material
surrounding the weld area shall be preheated to obtain a temperature of
approximately 70 degrees Fahrenheit to
remove excess moisture and dry the pipe
material prior to the welding operation.
9 TIME BETWEEN PASSES
9.1 This test specification applies to a maximum
time between the completion of the first pass
and the start of the second pass to no more
than 5 minutes.
9.2 The time between the completion of the
second pass and the third pass shall be
determined by the Welding Inspector, but
shall be no more than 30 minutes.
9.3 There shall be no accelerated cooling of any
13 SPEED OF TRAVEL
13.1 This test specification applies to a speed of
travel not to exceed 18" per minute for any
pass.
13.2 The following chart indicates the range for
pass.
10 ALIGNMENT
speed of travel in inches per minute for
each pass.
Pass
Range of Speed
10.1 For pipe with the same nominal wall
1st
4-18
thickness, the alignment offset shall not
exceed 1/16".
2nd
4-18
10.2 For pipe with dimensional variations,
3rd
4-18
alignment offset greater than 1/16" shall be
equally
distributed
around
the
circumference of the pipe.
Original Approved by:
Utility Operating Council
Page 5 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
WQS-1ML (Low Hydrogen)
14 PREPARATION AND TESTING OF
BUTT WELD
14.11 When you are satisfied that the weld is
complete, you must summon the inspector.
No further work on the weld will be allowed
at this point.
14.1 Pipe beveling shall be applied and/or
checked for
specification.
Revision Date:
conformance
with
this
14.12 The inspector will visually inspect the
completed weld. If the completed weld
passes inspection the inspector will
instruct the welder in cutting out the
destructive test coupons.
14.2 Clean, fit-up and tack the test segments
together. The test specimen may be
moved/rolled for fit-up.
14.3 After tacking, the test specimen shall be
placed in the 5G position (horizontal) and
fixed to prevent movement.
14.4 Welding may begin after the test specimen
15 PREPERATION AND TESTING OF
FILLET WELD
15.1 The run pipe shall be measured and
has been placed into the fixed position.
marked in the approximate center of the
pipe for a full size opening to be cut out for
the connection of the branch pipe.
14.5 After the first pass has been applied and
cleaned inside and out, welding must stop
and the inspector must be summoned for
inspection of the first pass.
15.2 The marked opening of the run pipe shall
14.6 After the inspector has inspected and
15.3 Clean, fit-up and tack the test segments
approved the first pass, the second pass
may be started.
together. The test specimen may be
moved/rolled for fit-up.
14.7 When the second pass has been applied
15.4 After tacking, the test specimen shall be
and cleaned, welding must stop and the
inspector must be summoned to inspect the
second pass.
placed with the run pipe in the 5G position
(horizontal) and the branch pipe extending
vertically downward. The test specimen
shall be fixed in this position to prevent
movement.
be cut out by hand.
14.8 After the inspector has inspected and
approved the second pass, the weld may
be completed.
15.5 Welding may begin after the test specimen
has been placed into the fixed position.
14.9 After completing the weld, check for
pinholes and make the necessary repairs.
Filing down the cover pass to remove
pinholes is prohibited.
15.6 After the first pass has been applied and
cleaned inside and out, welding must stop
and the inspector must be summoned for
inspection of the first pass.
14.10 Other discontinuities found shall be
approved for repair by the inspector before
any repairs are made.
Original Approved by:
15.7 After the inspector has inspected and
approved the first pass, the second pass
may be started.
Utility Operating Council
Page 6 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
15.8 When the second pass has been applied
16.6 Clean and grind the coupons to remove all
and cleaned, welding must stop and the
inspector must be summoned to inspect the
second pass.
16.7 The coupons marked for tensile require no
15.9 After the inspector has inspected and
16.8 The coupons marked for nick-break shall be
approved the second pass, the weld may
be completed.
slag and rough edges.
further preparation.
notched in the center of the weld on each
side of the coupon approximately 1/8” deep
with a hand saw.
15.10 After completing the weld, check for
pinholes and make the necessary repairs.
Filing down the cover pass to remove
pinholes is prohibited.
16.9 The coupons marked for root-bend shall
have the cover and root ground down
smooth to the base metal. Grinding into the
base metal will cause for disqualification.
See the following diagrams.
15.11 Other discontinuities found shall be
approved for repair by the inspector before
any repairs are made.
15.12 When you are satisfied that the weld is
complete, you must summon the inspector.
No further work on the weld will be allowed
at this point.
15.13 The inspector will visually inspect the
completed weld. If the completed weld
passes inspection the inspector will
instruct the welder in cutting out the
destructive test coupons.
17 PREPARING TEST COUPONS FOR
FILLET WELD
17.1 There shall be 4 test coupons cut from the
test weld.
17.2 These
coupons
specimens.
shall
be
nick-break
17.3 The inspector will designate the locations of
the test coupons.
17.4 Each coupon shall be approximately 2
16 PREPARING TEST COUPONS FOR
BUTT WELD
16.1 There shall be 6 test coupons cut from the
inches wide and approximately 4 inches
long.
17.5 Each coupon shall be notched on each side
of the weld with a cutting torch to obtain
approximately 1 inch of weld area for
testing.
test weld.
16.2 These coupons shall include 2 tensile, 2
nick-break and 2 root-bend specimens.
16.3 The inspector will designate the locations of
17.6 Each coupon shall be notched in the center
of the weld and on each side of the weld,
center of the cap to center of the root
approximately 1/8 inch deep with a hand
saw.
the test coupons.
16.4 Each coupon shall be approximately 1 inch
wide and approximately 9 inches long.
16.5 Each coupon shall be marked to determine
17.7 Clean and grind the coupons to remove all
its type. T for tensile, N for nick and R for
root.
slag and rough edges. See the following
diagrams.
Original Approved by:
Utility Operating Council
Page 7 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
18 WELDER QUALIFICATION RECORD
18.1 The Welding Inspector shall fill out the
WQR Form in detail for each test and
submit the forms and test specimens to an
approved testing facility for destructive
testing.
18.3 The WQR Form shall be forwarded to
Technical Services for processing.
18.4 The WQR Form for contractors may be
processed and maintained by an external
database however, this database shall be
accessible by Atmos Energy.
18.2 The destructive test results shall be
recorded in detail on the WQR Form.
Original Approved by:
Utility Operating Council
Page 8 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
Original Approved by:
Utility Operating Council
Page 9 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – Welder Qualification Test Specification
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006
Specification No.:
Effective Date: June 13, 2006
Revision Date:
WQS-1ML (Low Hydrogen)
Original Approved by:
Utility Operating Council
Page 10 of 10
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62GA
1
2.2
SCOPE
This Welding Procedure Specification provides
the details and processes for welding pipe and
materials in accordance with Procedure
Qualification Record No. PQR-S62GA. The
Procedure Qualification Record has been
qualified and approved by Technical Services
in accordance with API Standard 1104,
Nineteenth Edition, September 1999.
This Specification and Qualification Record
shall be maintained by Technical Services and
shall remain in effect and valid for as long as
the mechanical properties of the pipe and
materials used as hereby defined, conforms to
this specification.
All welds made in accordance with this
specification were qualified by destructive
testing and documented on the Procedure
Qualification Record to demonstrate that
suitable mechanical properties and soundness
of the welds could be made. It is intended that
all work performed in accordance with this
specification shall meet or exceed the
requirements of the qualifying Standard.
The following specifications shall be adhered to
except where a change is specifically
authorized by Technical Services as provided
by the qualifying Standard.
2
2.1
PROCESS AND GUIDELINES
This specification applies to welding
performed by the manual Shielded MetalArc Welding (SMAW) process for all
passes.
Original Approved by:
Procedure No.: PQR-S62GA
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
All welding shall be performed by a person
certified to the applicable procedure when
using this specification.
Welding shall not be performed when the
quality of the weld would be impaired by
prevailing weather conditions, including but
not limited to airborne moisture, blowing
sand or high winds. Wind shields should be
used where practical.
There shall be complete penetration of the
first pass with 1/32” to 1/16” inside
penetrated build-up.
Tack welds shall be considered as first
pass segments and should be a minimum
of 1” long.
The crown of the cover pass shall be 1/32"
to 1/16" higher than the pipe wall.
No portion of the cover pass shall be
concaved lower than the pipe wall.
The cover pass shall overlap the beveled
groove by approximately 1/16” on each
side.
Lacing or excessive weaving the cover pass
is prohibited.
The starting point of two successive passes
shall be offset a minimum of 1/2”.
Insert patching or spot welding is
prohibited.
A stripper or short bead shall be used to fill
up low areas or pinholes in the cover pass.
Stripper beads must be at least 1” long.
Utility Operating Council
Page 1 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62GA
2.14
2.15
2.16
2.17
3
3.1
3.2
3.3
4
4.1
Spotting or filing of pinholes is prohibited.
Peening of weld passes is prohibited.
Arc burns are prohibited.
Ground clamps shall be securely attached
to the pipe.
Procedure No.: PQR-S62GA
5
5.1
5.2
PIPE AND FITTING MATERIALS
This specification applies to the welding of
piping and materials that conforms to a
specification with a minimum yield strength
of greater than 42,000 pounds per square
inch and less than 65,000 pounds per
square inch, including but not limited to the
following:
API Specification 5LX,
Grade 46 through Grade 60;
MSS-SP-75,
Grade Y-46 through Grade Y-60;
MSS-SP-44,
Grade F-46 through Grade F-60
When welding pipe and materials of two
separate material groups, the procedure
specification for the higher strength group
shall be used.
5.3
5.4
5.5
5.6
5.7
5.8
The surfaces to be welded shall be smooth,
uniform and free from laminations, tears,
scale, slag, grease, paint and other
deleterious material that might adversely
affect the welding process.
JOINT DESIGN
This specification applies to a standard VBevel butt joint as shown in the following
diagram.
The angle of bevel shall be approximately
30 degrees with an included angle of
approximately 60 degrees for pipe with a
wall thickness less than or equal to 3/4".
The size of the root face or land shall be
1/16” 1/32”.
The root opening or the space between the
abutting members shall be approximately
1/16”.
Field beveling by machine tool, machine
oxygen cutting or manual oxygen cutting
shall be ground reasonably smooth and
uniform to remove any discontinuities.
Power tools shall be used for grinding when
field beveling is required.
Mill bevel dimensions shall conform to the
joint design in accordance with this
specification.
Field bevel dimensions shall conform to the
joint design in accordance with this
specification.
DIAMETERS AND WALL
THICKNESSES
This specification applies to all pipe sizes in
diameter with a 3/16" through 3/4” nominal
wall thickness.
Original Approved by:
Utility Operating Council
Page 2 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62GA
6
6.1
6.2
6.3
FILLER METAL, AMPERAGE, SIZE,
NUMBER OF BEADS AND
ELECTRICAL CHARACTERISTICS
This specification applies to the use of filler
metal that conforms to Group 1, AWS
Specification A5.1 for coated electrodes.
A minimum number of three passes has
been qualified for this specification as
shown in Figure 1. Each pass should be
approximately 3/32” to 3/16” thick. If more
than three passes is required to complete
the weld and the pipe nominal wall
thickness is in accordance with this
specification, additional passes may be
applied to complete the weld using the
same type electrode from the selection
chart. The bead sequence for additional
passes is shown in Figure 2.
Filler metals used with this specification
shall have been properly stored in
containers designed for the filler metals to
eliminate contamination from water, grease,
dirt, drying out or collecting moisture and
shall be protected from these elements
during production welding. Damaged or
deteriorated filler metals shall not be used
with this specification.
Original Approved by:
Procedure No.: PQR-S62GA
6.4
The following chart applies to and identifies
the electrode classification, brand,
amperage range, voltage range, current
and polarity for this specification.
AWS
Class
Brand
Electrode Amperage Voltage
Current
Size
Range
Range
Polarity
E6010
5P+
3/32”
40-70
12-34
DC
Electrode
Reverse Positive
E6010
5P+
1/8”
65-130
12-34
DC
Electrode
Reverse Positive
E6010
5P+
5/32”
90-175
12-34
DC
Electrode
Reverse Positive
E6010
5P+
3/16”
140-225
12-34
DC
Electrode
Reverse Positive
6.5
The following selection chart and diagram
identifies the electrode sizes, type,
minimum number and sequence of passes
of each completed weld for this
specification.
Electrode
Size
Selection
Electrode
Type
Minimum
Number
Sequence of
Passes
3/32” - 3/16”
E6010
5P+
1
1st Pass
Root
3/32” - 3/16”
E6010
5P+
1
2nd Pass
Hot-Pass
3/32” - 3/16”
E6010
5P+
1
As Required
3rd Pass
Filler/Cover Pass
As Required
Utility Operating Council
Page 3 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62GA
Procedure No.: PQR-S62GA
9
9.1
9.2
9.3
TIME BETWEEN PASSES
This specification applies to a maximum
time between the completion of the first
pass and the start of the second pass to no
more than 5 minutes.
The time between the completion of the
second pass and all other passes shall not
exceed 72 hours unless otherwise
specified.
There shall be no accelerated cooling of
any pass.
10 NUMBER OF WELDERS
10.1 For pipe with a nominal diameter of 14” and
less, one welder may be used with this
specification for all passes.
7
7.1
7.2
7.3
7.4
8
8.1
PIPE POSITION
This specification applies to fixed position
welding.
All pipe components being joined shall be
secured against movement with adequate
clearance around the joint.
The working clearance around the pipe at
the weld should not be less than 16” for
above ground welding.
The working clearance around the pipe
should be large enough to provide
adequate access to the joint for trench or
bell hole welding.
DIRECTION OF WELDING
This specification applies to welding being
performed in the downhill direction from top
to bottom for all passes.
Original Approved by:
10.2 There shall be two welders used with this
specification to apply the first pass when
the nominal diameter of the pipe is greater
than 14”. One or two welders may be used
for the remaining passes to complete the
weld.
11 TYPE AND REMOVAL OF LINE-UP
CLAMP
11.1 This specification does not apply to the use
of line-up clamps, either internal or external.
However, if conditions make the use of a
lineup clamp necessary, then the following
shall apply.
11.2 It is recommended that the first pass be
completed before releasing the line-up
clamp however, if it becomes necessary to
remove the clamp before the first pass is
completed, at least 50 percent of the first
pass shall then be completed and in
approximately equal segments and spaced
Utility Operating Council
Page 4 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62GA
approximately
equally
circumference of the pipe.
Original Approved by:
around
Procedure No.: PQR-S62GA
the
Utility Operating Council
Page 5 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62GA
11.3 First pass segments used in connection
with external line-up clamps shall have an
aggregate length of at least 50 percent of
the pipe circumference before the clamp is
released.
11.4 If internal line-up clamps are used and
conditions make it difficult to prevent
movement of the pipe or if the weld will be
unduly stressed, the first pass shall be
completed before the clamp is released.
12 ALIGNMENT
12.1 For pipe with the same nominal wall
thickness, the alignment offset shall not
exceed 1/16".
12.2 For pipe with dimensional variations,
alignment offset greater than 1/16" shall be
equally
distributed
around
the
circumference of the pipe.
12.3 Hammering on pipe materials to obtain
proper alignment or line-up is prohibited.
13 CLEANING AND/OR GRINDING
13.1 This specification applies to the use of
either power or hand tools to remove all
rust, dirt and other foreign matter before
starting the welding process, during the
welding process and after the welding
process is completed.
13.2 Power Tools shall be used for grinding and
cleaning the first and second pass.
Procedure No.: PQR-S62GA
14.2 When the ambient temperature is less than
40 degrees Fahrenheit the pipe material
surrounding the weld area shall be preheated to obtain a temperature of
approximately 70 degrees Fahrenheit to
remove excess moisture and dry the pipe
material prior to the welding operation.
14.3 If the use of special treatment is required to
control the welding operation due to a
condition not weather related, an
Engineering specification for such condition
specifying
the
recommended
heat
treatment, speed of travel, voltage and
other pertinent information shall be
attached as an addendum and used with
this specification.
15 SPEED OF TRAVEL
15.1 This specification applies to a speed of
travel not to exceed 18" per minute for any
pass.
15.2 The following chart indicates the range for
speed of travel in inches per minute for
each pass.
Pass
Range of Speed
1st
4-18
2nd
4-18
3rd
As Required
4-18
14 PRE-HEAT AND POST-HEAT
TREATMENT
14.1 This specification does not apply to the use
of pre-heat and/or post-heat treatment for
conditions not weather related.
Original Approved by:
Utility Operating Council
Page 6 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62GA
16 DESIGN AND PREPARATION OF
WELDING
16.1 Pipe beveling shall be applied and/or
checked for conformance with this
specification.
16.2 The first pass should be applied by an
adequate technique to obtain full
penetration for this process.
16.3 The second pass shall be applied by an
adequate technique with sufficient heat to
burn out any remaining under-cutting tracks
and float any remaining slag to the surface
for this process.
Procedure No.: PQR-S62GA
16.7 The cover pass shall present a neat
workman-like appearance.
16.8 The completed weld shall be thoroughly
brushed and cleaned.
16.9 Each Welder shall identify his work by
marking his initials along side the
completed weld with a greaseless lumber
crayon.
16.4 The third pass should be applied by an
adequate technique to fill and/or cover the
groove for this process.
16.5 Filler passes should be applied as
necessary to fill and obtain a substantially
uniform cross section around the entire
circumference of the pipe.
16.6 The cover pass should be applied to
produce a substantially uniform crown
around the entire circumference of the pipe.
Original Approved by:
Utility Operating Council
Page 7 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Procedure
N
Specification No.: WPS-S62FL
1
2.2
SCOPE
This Welding Procedure Specification provides
the details and processes for welding pipe and
materials in accordance with Procedure
Qualification Record No. PQR-S62FL. The
Procedure Qualification Record has been
qualified and approved by Technical Services in
accordance with API Standard 1104,
Nineteenth Edition, September 1999.
This Specification and Qualification Record
shall be maintained by Technical Services and
shall remain in effect and valid for as long as
the mechanical properties of the pipe and
materials used as hereby defined, conforms to
this specification.
All welds made in accordance with this
specification were qualified by destructive
testing and documented on the Procedure
Qualification Record to demonstrate that
suitable mechanical properties and soundness
of the welds could be made. It is intended that
all work performed in accordance with this
specification shall meet or exceed the
requirements of the qualifying Standard.
The following specifications shall be adhered to
except where a change is specifically
authorized by Technical Services as provided
by the qualifying Standard.
2
2.1
PROCESS AND GUIDELINES
This specification applies to welding
performed by the manual Shielded MetalArc Welding (SMAW) process for all passes.
Original Approved by:
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
PQR-S62FL
All welding shall be performed by a person
certified to the applicable procedure when
using this specification.
Welding shall not be performed when the
quality of the weld would be impaired by
prevailing weather conditions, including but
not limited to airborne moisture, blowing
sand or high winds. Wind shields should be
used where practical.
There shall be complete penetration of the
first pass on branch connections with 1/32”
to 1/16” inside penetrated build-up.
Tack welds shall be considered as first pass
segments and should be a minimum of 1”
long.
The leg sizes for the cover pass on branch
connections shall range from 3/16" to 3/4"
as determined by the thickness of the pipe
wall.
The maximum convexity of the cover pass
face shall range from 1/16” to 1/8”.
No portion of the cover pass face shall be
concaved lower than the weld toes or tie-in.
Lacing or excessive weaving the cover pass
is prohibited.
The starting point of two successive passes
shall be offset a minimum of 1/2”.
Insert patching or spot welding is prohibited.
A stripper or short bead shall be used to fill
up low areas or pinholes in the cover pass.
Stripper beads must be at least 1” long.
Spotting or filing of pinholes is prohibited.
Utility Operating Council
Page 1 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Procedure
N
Specification No.: WPS-S62FL
2.15 Peening of weld passes is prohibited.
2.16 Arc burns on pipe and appurtenances are
prohibited.
2.17 Ground clamps shall be securely attached to
the pipe.
3
3.1
3.2
3.3
4
4.1
PIPE AND FITTING MATERIALS
This specification applies to the welding of
piping and materials that conforms to a
specification with a minimum yield strength
of greater than 42,000 pounds per square
inch and less than 65,000 pounds per
square inch, including but not limited to the
following:
API Specification 5LX,
Grade 46 through Grade 60;
MSS-SP-75,
Grade Y-46 through Grade Y-60;
MSS-SP-44,
Grade F-46 through Grade F-60
5
PQR-S62FL
JOINT DESIGN
5.1
5.2
5.3
5.4
5.5
When welding pipe and materials of two
separate material groups, the procedure
specification for the higher strength group
shall be used.
The surfaces to be welded shall be smooth,
uniform and free from laminations, tears,
scale, slag, grease, paint and other
deleterious material that might adversely
affect the welding process.
This specification applies to fillet weld joints
on fabricated branch connections and
appurtenances installed on pipe as shown in
the following diagram.
The angle of bevel on the fabricated branch
pipe shall range from approximately 30
degrees to 45 degrees.
The size of the root face or land on the
fabricated branch pipe bevel shall be
approximately 1/16”.
The root opening or the space between the
fabricated branch pipe and the run pipe
shall be approximately 1/16”.
Appurtenances that are to be pressurized
and required to have a circumferential joint
fillet weld and where the wall thickness of
the appurtenance is greater than the pipe
wall thickness shall meet the following
requirements:
a. The ends shall be square, deburred
and smooth. Beveling is not required.
b. The face or land width shall not to
exceed 1.5 times the thickness of the
header pipe.
c. Appurtenances that are designed with a
gap to allow for out of roundness in the
header pipe shall be designed to where
the gap does not exceed 1/8”.
DIAMETERS AND WALL
THICKNESSES
This specification applies to all pipe sizes in
diameter with a 3/16" through 3/4" nominal
wall thickness.
Original Approved by:
Utility Operating Council
Page 2 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Procedure
N
Specification No.: WPS-S62FL
6.2
6.3
6.4
6
6.1
FILLER METAL, AMPERAGE, SIZE,
NUMBER OF BEADS AND
ELECTRICAL CHARACTERISTICS
This specification applies to the use of filler
metal that conforms to Group 1, AWS
Specification A5.1 and Group 3, AWS
Specification A5.1 or A5.5 for coated
electrodes.
Original Approved by:
PQR-S62FL
A minimum number of three passes has
been qualified for this specification as
shown in Figure 1. Each pass should be
approximately 3/32” to 3/16” thick. If more
than three passes is required to complete
the weld and the pipe nominal wall
thickness is in accordance with this
specification, additional passes may be
applied to complete the weld using the
same type electrode from the selection
chart. The bead sequence for additional
passes is shown in Figure 2.
The leg dimension of a circumferential fillet
weld shall not be less than 1.0 times the
pipe wall thickness plus the gap and should
not exceed 1.4 times the pipe wall thickness
plus the gap. The fillet weld should not be
carried out fully to the shoulder of the face
or land of the appurtenance.
The following chart applies to completed
fillet weld leg dimensions based on the
header pipe wall thickness. The dimension
is measured from the top of the header pipe
wall to the top of the completed weld leg
and subtracting the gap between the
appurtenance and the top of the header
pipe wall. Where applicable, the dimensions
have been rounded to the nearest 1/16 inch.
Utility Operating Council
Page 3 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Procedure
N
Specification No.: WPS-S62FL
Circumferential Fillet Weld – Leg Size Chart
Header
Pipe Wall
Thickness
Leg Size
(Minimum)
Leg Size
(Maximum)
6.5
Gap
Decimal Fraction Decimal Fraction
0.154”
0.188”
3/16”
0.250”
1/4"
Plus Gap
0.156”
0.188”
3/16”
0.250”
1/4"
Plus Gap
0.188”
0.188”
3/16”
0.250”
1/4"
Plus Gap
0.203”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.216”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.219”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.237”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.238”
0.250”
1/4”
0.312”
5/16”
Plus Gap
6.6
Filler metals used with this specification
shall have been properly stored in
containers designed for the filler metals to
eliminate contamination from water, grease,
dirt, drying out or collecting moisture and
shall be protected from these elements
during production welding. Damaged or
deteriorated filler metals shall not be used
with this specification.
The following chart applies to and identifies
the
electrode
classification,
brand,
amperage range, voltage range, current and
polarity for this specification.
AWS
Class
Brand
E6010
5P+
0.250”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.279”
0.312”
5/16”
0.375”
3/8”
Plus Gap
E7018
H4R
0.280”
0.312”
5/16”
0.375”
3/8”
Plus Gap
E6010
5P+
0.281”
0.312”
5/16”
0.375”
3/8”
Plus Gap
E7018
H4R
0.312”
0.312”
5/16”
0.437”
7/16”
Plus Gap
0.322”
0.375”
3/8”
0.437”
7/16”
Plus Gap
E6010
5P+
0.344”
0.375”
3/8”
0.437”
7/16"
Plus Gap
E7018
H4R
0.365”
0.375”
3/8”
0.500”
1/2"
Plus Gap
E6010
5P+
0.375”
0.375”
3/8”
0.500”
1/2"
Plus Gap
0.500”
0.500”
1/2”
0.687”
11/16”
Plus Gap
0.625”
0.625”
5/8”
0.875
7/8”
Plus Gap
0.750”
0.750”
3/4"
1.062
1-1/16”
Plus Gap
PQR-S62FL
E7018
H4R
Electrode Amperage Voltage
Current
Size
Range
Range
40-70
3/32”
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
12-34
DC
Electrode
Reverse Positive
70-110
65-130
1/8”
90-160
90-175
5/32”
130-210
140-225
3/16”
180-300
Polarity
Note: Contact Engineering for wall thicknesses
not shown above.
Original Approved by:
Utility Operating Council
Page 4 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Procedure
N
Specification No.: WPS-S62FL
6.7
PQR-S62FL
The following selection chart and diagram
identifies the electrode sizes, type, minimum
number and sequence of passes of each
completed weld for this specification.
Electrode
Size
Selection
Electrode
Type
Minimum
Number
Sequence of
Passes
3/32” - 3/16”
E6010
5P+
1
1st Pass
Root
3/32” - 3/16”
E6010
5P+
1
2nd Pass
Hot-Pass
3/32” - 3/16”
E7018
H4R
1
As Required
3rd Pass
Filler/Cover Pass
As Required
7
8
PIPE POSITION
8.1
8.2
8.3
8.4
Original Approved by:
This specification applies to fixed position
welding.
All pipe components being joined shall be
secured against movement with adequate
clearance around the joint.
The working clearance around the pipe at
the weld should not be less than 16” for
above ground welding.
The working clearance around the pipe
should be large enough to provide adequate
access to the joint for trench or bell hole
welding.
Utility Operating Council
Page 5 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Procedure
N
Specification No.: WPS-S62FL
9
9.1
DIRECTION OF WELDING
This specification applies to welding being
performed in the downhill direction from top
to bottom for the 1st and 2nd passes. The
3rd and/or remaining passes shall be
performed in the uphill direction from bottom
to top.
10 TIME BETWEEN PASSES
10.1 This specification applies to a maximum
time between the completion of the first
pass and the start of the second pass to no
more than 5 minutes.
10.2 The time between the completion of the
second pass and all other passes shall not
exceed 72 hours unless otherwise specified.
10.3 There shall be no accelerated cooling of any
pass.
11 NUMBER OF WELDERS
11.1 For pipe with a nominal diameter of 14” and
less, one welder may be used with this
specification for all passes.
11.2 There shall be two welders used with this
specification to apply the first pass when the
nominal diameter of the pipe is greater than
14”. One or two welders may be used for
the remaining passes to complete the weld.
12 TYPE AND REMOVAL OF LINE-UP
CLAMP
PQR-S62FL
13 ALIGNMENT
13.1 This specification does not apply to offset
alignment.
13.2 Branch pipe shall be vertically centered and
aligned onto the run pipe.
13.3 Appurtenances installed on pipe shall
adequately fit to the pipe surface.
13.4 Hammering on pipe materials to obtain
proper alignment is prohibited.
14
CLEANING AND/OR GRINDING
14.1 This specification applies to the use of either
power or hand tools to remove all rust, dirt
and other foreign matter before starting the
welding process, during the welding process
and after the welding process is completed.
14.2 Power tools shall be used for grinding and
cleaning the first and second pass.
15 PRE-HEAT AND POST-HEAT
TREATMENT
15.1 This specification does not apply to the use
of pre-heat and/or post-heat treatment for
conditions not weather related.
15.2 When the ambient temperature is less than
40 degrees Fahrenheit the pipe material
surrounding the weld area shall be preheated to obtain a temperature of
approximately 70 degrees Fahrenheit to
remove excess moisture and dry the pipe
material prior to the welding operation.
12.1 This specification does not apply to the use
of line-up clamps.
12.2 The pipe shall be supported from movement
and stress while the first pass is being
applied.
Original Approved by:
Utility Operating Council
Page 6 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Procedure
N
Specification No.: WPS-S62FL
15.3 If the use of special treatment is required to
control the welding operation due to a
condition not weather related, an
Engineering specification for such condition
specifying
the
recommended
heat
treatment, speed of travel, voltage and other
pertinent information shall be attached as an
addendum and used with this specification.
16 SPEED OF TRAVEL
16.1 This specification applies to a speed of
travel not to exceed 18" per minute for any
pass.
16.2 The following chart indicates the range for
speed of travel in inches per minute for each
pass.
Pass
1st
2nd
3rd
As Required
Range of Speed
4-18
4-18
4-18
17 DESIGN AND PREPARATION OF
WELDING
17.1 Pipe beveling shall be applied when
applicable and/or checked for conformance
with this specification.
17.2 The pipe shall be secured from movement
to conform to this specification.
17.3 For circumferential fillet welds, the pipe wall
thickness should be verified to determine
the proper fillet leg size.
17.4 The first pass should be applied by an
adequate technique to obtain full
penetration for this process.
Original Approved by:
PQR-S62FL
17.5 The second pass should be applied by an
adequate technique with sufficient heat to
burn out the remaining under-cutting tracks
and float any remaining slag to the surface
for this process.
17.6 The third pass should be applied by an
adequate technique to fill and/or as the
cover pass penetrating into the pipe walls
for this process.
17.7 Filler passes should be applied as
necessary to fill and obtain a substantially
uniform cross section around the entire
circumference of the pipe.
17.8 The cover pass should be applied to
produce a substantially uniform crown
around the entire circumference of the pipe.
17.9 The cover pass shall present a neat
workman-like appearance.
17.10 The completed weld shall be thoroughly
brushed and cleaned.
17.11 Each Welder shall identify his work by
marking his initials along side the
completed weld with a greaseless lumber
crayon.
Utility Operating Council
Page 7 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62FA
1
2.2
SCOPE
This Welding Procedure Specification provides
the details and processes for welding pipe and
materials in accordance with Procedure
Qualification Record No. PQR-S62FA. The
Procedure Qualification Record has been
qualified and approved by Technical Services
in accordance with API Standard 1104,
Nineteenth Edition, September 1999.
This Specification and Qualification Record
shall be maintained by Technical Services and
shall remain in effect and valid for as long as
the mechanical properties of the pipe and
materials used as hereby defined, conforms to
this specification.
All welds made in accordance with this
specification were qualified by destructive
testing and documented on the Procedure
Qualification Record to demonstrate that
suitable mechanical properties and soundness
of the welds could be made. It is intended that
all work performed in accordance with this
specification shall meet or exceed the
requirements of the qualifying Standard.
The following specifications shall be adhered
to except where a change is specifically
authorized by Technical Services as provided
by the qualifying Standard.
2
2.1
PROCESS AND GUIDELINES
This specification applies to welding
performed by the manual Shielded MetalArc Welding (SMAW) process for all
passes.
Original Approved by:
Procedure No.: PQR-S62FA
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
All welding shall be performed by a person
certified to the applicable procedure when
using this specification.
Welding shall not be performed when the
quality of the weld would be impaired by
prevailing weather conditions, including but
not limited to airborne moisture, blowing
sand or high winds. Wind shields should
be used where practical.
There shall be complete penetration of the
first pass on branch connections with 1/32”
to 1/16” inside penetrated build-up.
Tack welds shall be considered as first
pass segments and should be a minimum
of 1” long.
The leg sizes for the cover pass on branch
connections shall range from 3/16" to 3/4"
as determined by the thickness of the pipe
wall.
The maximum convexity of the cover pass
face shall range from 1/16” to 1/8”.
No portion of the cover pass face shall be
concaved lower than the weld toes or tie-in.
Lacing or excessive weaving the cover
pass is prohibited.
The starting point of two successive passes
shall be offset a minimum of 1/2”.
Insert patching or spot welding is
prohibited.
A stripper or short bead shall be used to fill
up low areas or pinholes in the cover pass.
Stripper beads must be at least 1” long.
Spotting or filing of pinholes is prohibited.
Utility Operating Council
Page 1 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62FA
2.15 Peening of weld passes is prohibited.
2.16 Arc burns on pipe and appurtenances are
prohibited.
2.17 Ground clamps shall be securely attached
to the pipe.
3
3.1
3.2
3.3
4
4.1
PIPE AND FITTING MATERIALS
This specification applies to the welding of
piping and materials that conforms to a
specification with a minimum yield strength
of greater than 42,000 pounds per square
inch and less than 65,000 pounds per
square inch, including but not limited to the
following:
API Specification 5LX,
Grade 46 through Grade 60;
MSS-SP-75,
Grade Y-46 through Grade Y-60;
MSS-SP-44,
Grade F-46 through Grade F-60
Procedure No.: PQR-S62FA
5
5.1
5.2
5.3
5.4
5.5
JOINT DESIGN
This specification applies to fillet weld joints
on fabricated branch connections and
appurtenances installed on pipe as shown
in the following diagram.
The angle of bevel on the fabricated branch
pipe shall range from approximately 30
degrees to 45 degrees.
The size of the root face or land on the
fabricated branch pipe bevel shall be
approximately 1/16”.
The root opening or the space between the
fabricated branch pipe and the run pipe
shall be approximately 1/16”.
Appurtenances that are to be pressurized
and required to have a circumferential joint
fillet weld and where the wall thickness of
the appurtenance is greater than the pipe
wall thickness shall meet the following
requirements:
When welding pipe and materials of two
separate material groups, the procedure
specification for the higher strength group
shall be used.
The surfaces to be welded shall be smooth,
uniform and free from laminations, tears,
scale, slag, grease, paint and other
deleterious material that might adversely
affect the welding process.
a. The ends shall be square, deburred
and smooth. Beveling is not required.
b. The face or land width shall not to
exceed 1.5 times the thickness of the
header pipe.
c. Appurtenances that are designed with
a gap to allow for out of roundness in
the header pipe shall be designed to
where the gap does not exceed 1/8”.
DIAMETERS AND WALL
THICKNESSES
This specification applies to all pipe sizes
in diameter with a 3/16" through 3/4"
nominal wall thickness.
Original Approved by:
Utility Operating Council
Page 2 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62FA
6
6.1
FILLER METAL, AMPERAGE, SIZE,
NUMBER OF BEADS AND
ELECTRICAL CHARACTERISTICS
This specification applies to the use of filler
metal that conforms to Group 1, AWS
Specification A5.1 for coated electrodes.
Original Approved by:
Procedure No.: PQR-S62FA
6.2
A minimum number of three passes has
been qualified for this specification as
shown in Figure 1. Each pass should be
approximately 3/32” to 3/16” thick. If more
than three passes is required to complete
the weld and the pipe nominal wall
thickness is in accordance with this
specification, additional passes may be
applied to complete the weld using the
same type electrode from the selection
chart. The bead sequence for additional
passes is shown in Figure 2.
6.3
The leg dimension of a circumferential fillet
weld shall not be less than 1.0 times the
pipe wall thickness plus the gap and should
not exceed 1.4 times the pipe wall
thickness plus the gap. The fillet weld
should not be carried out fully to the
shoulder of the face or land of the
appurtenance.
6.4
The following chart applies to completed
fillet weld leg dimensions based on the
header pipe wall thickness. The dimension
is measured from the top of the header
pipe wall to the top of the completed weld
leg and subtracting the gap between the
appurtenance and the top of the header
pipe wall. Where applicable, the
dimensions have been rounded to the
nearest 1/16 inch.
Utility Operating Council
Page 3 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62FA
Procedure No.: PQR-S62FA
Circumferential Fillet Weld – Leg Size Chart
Header
Pipe Wall
Thickness
Leg Size
(Minimum)
Leg Size
(Maximum)
6.5
Gap
Decimal Fraction Decimal Fraction
Filler metals used with this specification
shall have been properly stored in
containers designed for the filler metals to
eliminate contamination from water,
grease, dirt, drying out or collecting
moisture and shall be protected from these
elements during production welding.
Damaged or deteriorated filler metals shall
not be used with this specification.
The following chart applies to and identifies
the electrode classification, brand,
amperage range, voltage range, current
and polarity for this specification.
0.154”
0.188”
3/16”
0.250”
1/4"
Plus Gap
0.156”
0.188”
3/16”
0.250”
1/4"
Plus Gap
0.188”
0.188”
3/16”
0.250”
1/4"
Plus Gap
0.203”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.216”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.219”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.237”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.238”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.250”
0.250”
1/4”
0.312”
5/16”
Plus Gap
0.279”
0.312”
5/16”
0.375”
3/8”
Plus Gap
0.280”
0.312”
5/16”
0.375”
3/8”
Plus Gap
0.281”
0.312”
5/16”
0.375”
3/8”
Plus Gap
0.312”
0.312”
5/16”
0.437”
7/16”
Plus Gap
0.322”
0.375”
3/8”
0.437”
7/16”
Plus Gap
0.344”
0.375”
3/8”
0.437”
7/16"
Plus Gap
E7010
HYP+
0.365”
0.375”
3/8”
0.500”
1/2"
Plus Gap
E6010
5P+
0.375”
0.375”
3/8”
0.500”
1/2"
Plus Gap
0.500”
0.500”
1/2”
0.687”
11/16”
Plus Gap
0.625”
0.625”
5/8”
0.875
7/8”
Plus Gap
0.750”
0.750”
3/4"
1.062
1-1/16”
Plus Gap
6.6
AWS
Class
Brand
E6010
5P+
Electrode Amperage Voltage
Current
Size
Range
Range
3/32”
40-70
12-34
DC
Electrode
Reverse Positive
1/8”
65-130
12-34
DC
Electrode
Reverse Positive
5/32”
90-175
12-34
DC
Electrode
Reverse Positive
3/16”
140-225
12-34
DC
Electrode
Reverse Positive
E6010
5P+
E7010
HYP+
E6010
5P+
E7010
HYP+
Polarity
Note: Contact Engineering for wall thicknesses
not shown above.
Original Approved by:
Utility Operating Council
Page 4 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62FA
6.7
Procedure No.: PQR-S62FA
The following selection chart and diagram
identifies the electrode sizes, type,
minimum number and sequence of passes
of each completed weld for this
specification.
Electrode
Size
Selection
Electrode
Type
Minimum
Number
Sequence of
Passes
3/32” - 3/16”
E6010
5P+
1
1st Pass
Root
1
2nd Pass
Hot-Pass
1
As Required
3rd Pass
Filler/Cover Pass
As Required
E6010
5P+
3/32” - 3/16”
E7010
HYP+
3/32” - 3/16”
E6010
5P+
E7010
HYP+
8
8.1
8.2
8.3
8.4
7Original Approved by:
PIPE POSITION
This specification applies to fixed position
welding.
All pipe components being joined shall be
secured against movement with adequate
clearance around the joint.
The working clearance around the pipe at
the weld should not be less than 16” for
above ground welding.
The working clearance around the pipe
should be large enough to provide
adequate access to the joint for trench or
bell hole welding.
Utility Operating Council
Page 5 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62FA
9
9.1
DIRECTION OF WELDING
This specification applies to welding being
performed in the downhill direction from top
to bottom for all passes.
10 TIME BETWEEN PASSES
10.1 This specification applies to a maximum
time between the completion of the first
pass and the start of the second pass to no
more than 5 minutes.
10.2 The time between the completion of the
second pass and all other passes shall not
exceed 72 hours unless otherwise
specified.
10.3 There shall be no accelerated cooling of
any pass.
11 NUMBER OF WELDERS
11.1 For pipe with a nominal diameter of 14” and
less, one welder may be used with this
specification for all passes.
11.2 There shall be two welders used with this
specification to apply the first pass when
the nominal diameter of the pipe is greater
than 14”. One or two welders may be used
for the remaining passes to complete the
weld.
12 TYPE AND REMOVAL OF LINE-UP
CLAMP
12.1 This specification does not apply to the use
of line-up clamps.
12.2 The pipe shall be supported from
movement and stress while the first pass is
being applied.
Original Approved by:
Procedure No.: PQR-S62FA
13 ALIGNMENT
13.1 This specification does not apply to offset
alignment.
13.2 Branch pipe shall be vertically centered
and aligned onto the run pipe.
13.3 Appurtenances installed on pipe shall
adequately fit to the pipe surface.
13.4 Hammering on pipe materials to obtain
proper alignment is prohibited.
14
CLEANING AND/OR GRINDING
14.1 This specification applies to the use of
either power or hand tools to remove all
rust, dirt and other foreign matter before
starting the welding process, during the
welding process and after the welding
process is completed.
14.2 Power tools shall be used for grinding and
cleaning the first and second pass.
15 PRE-HEAT AND POST-HEAT
TREATMENT
15.1 This specification does not apply to the use
of pre-heat and/or post-heat treatment for
conditions not weather related.
15.2 When the ambient temperature is less than
40 degrees Fahrenheit the pipe material
surrounding the weld area shall be preheated to obtain a temperature of
approximately 70 degrees Fahrenheit to
remove excess moisture and dry the pipe
material prior to the welding operation.
Utility Operating Council
Page 6 of 7
Utility Operations Handbook
Section:
Appendixes
Subject:
Appendix L – WPWQI Program - Welding Specification Details
Reference:
API–1104, CFR 192 Subpart E
Issue Date: June 13, 2006 Effective Date: June 13, 2006 Revision Date: January 1, 2008
Specification No.: WPS-S62FA
15.3 If the use of special treatment is required to
control the welding operation due to a
condition not weather related, an
Engineering specification for such condition
specifying the recommended heat
treatment, speed of travel, voltage and
other pertinent information shall be
attached as an addendum and used with
this specification.
16 SPEED OF TRAVEL
16.1 This specification applies to a speed of
travel not to exceed 18" per minute for any
pass.
16.2 The following chart indicates the range for
speed of travel in inches per minute for
each pass.
Pass
1st
2nd
3rd
As Required
Range of Speed
4-18
4-18
4-18
17 DESIGN AND PREPARATION OF
WELDING
17.1 Pipe beveling shall be applied when
applicable and/or checked for conformance
with this specification.
17.2 The pipe shall be secured from movement
to conform to this specification.
17.3 For circumferential fillet welds, the pipe wall
thickness should be verified to determine
the proper fillet leg size.
17.4 The first pass should be applied by an
adequate technique to obtain full
penetration for this process.
Original Approved by:
Procedure No.: PQR-S62FA
17.5 The second pass should be applied by an
adequate technique with sufficient heat to
burn out the remaining under-cutting tracks
and float any remaining slag to the surface
for this process.
17.6 The third pass should be applied by an
adequate technique to fill and/or as the
cover pass penetrating into the pipe walls
for this process.
17.7 Filler passes should be applied as
necessary to fill and obtain a substantially
uniform cross section around the entire
circumference of the pipe.
17.8 The cover pass should be applied to
produce a substantially uniform crown
around the entire circumference of the
pipe.
17.9 The cover pass shall present a neat
workman-like appearance.
17.10 The completed weld shall be thoroughly
brushed and cleaned.
17.11 Each Welder shall identify his work by
marking his initials along side the
completed weld with a greaseless lumber
crayon.
Utility Operating Council
Page 7 of 7
ATMOS energy
Material Specification: MS1.01
Product Name: Polyethylene
Group Name: Pipe
Description: PE-2406/2708 & PE-3408/4710 Polyethylene Pipe and Tubing
Approved Application:
1.
General
1.1
2.
3.2
All sizes of PE-3408/4710, high density approved for all of the Louisisana Division. High
Density is approved in Middle Tennessee for service lines only. (Murfreesboro, Columbia,
Shelbyville and Franklin.)
Any other applications of PE-3408/4710, high density must be approved by Technical
Services.
Pipe Compound
4.1
5.
All sizes of PE-2406/2708, medium density approved for all operating division with the
exception of Louisiana.
High Density, PE-3408/4710
3.1
4.
PE-2406/2708 Yellow, Medium Density, PE-3408/4710 High Density, Polyethylene pipe and
tubing manufactured according to current ASTM D-2513 specifications. Hydrostatic design
basis ratings of 1250 psi at 73 °F and 1000 psi at 140 °F for PE-2406/2708 and 1600 PSI at
73 °F and 800 PSI at 140 °F for PE-3408/4710. Hydrostatic design must comply with
Plastic Pipe Institute (PPI) recommended basis.
Medium Density, PE-2406/2708
2.1
3.
Up to 80 PSIG Operating Pressure (100 PSIG for ½ CTS) for PE-2406/2708
Up to 100 PSIG Operating Pressure for PE-3408/4710
All polyethylene compound medium density and high desity must be classified according to
ASTM D 3350, Standard Specifications for Polyethylene Plastic Pipe and Fittings Material.
All compounds must be listed with the Plastics Pipe Institue.
Pipe Marking
5.1
All piping and tubing to be marked according to current ASTM D 2513 marking standards
including ASTM designation, SDR No., manufacturer’s name, “Gas Pipe” or similar
designation, size, lot number & manufacture date. High Density PE-3408/4710 pipe will be
marked with a vertical yellow stripe running the entire length of the pipe.
Date Issued:
Approved by:
01/31/03
Ed Ostrovich
Effective Date:
Written by:
07/07/05
P Tucker
Revision Date:
04/26/10
Revision: 3 Page:
1 of 3
ATMOS energy
Material Specification: MS1.01
Product Name: Polyethylene
Group Name: Pipe
Description: PE-2406/2708 & PE-3408/4710 Polyethylene Pipe and Tubing
Approved Application:
6.
Up to 80 PSIG Operating Pressure (100 PSIG for ½ CTS) for PE-2406/2708
Up to 100 PSIG Operating Pressure for PE-3408/4710
Pipe Dimensions
6.1
See table below.
Size
OD
SDR
½” CTS
0.625”
7
Wall
Thickness
0.090”
½” IPS
0.840”
7
0.120”
¾” IPS
1-1/4” IPS
1-1/4” IPS
2” IPS
3” IPS
1.050”
1.660”
1.660”
2.375”
3.500”
11
10
11
11
11
0.095”
0.166”
0.151”
0.216”
0.318”
4” IPS
6” IPS
8” IPS
12” IPS
4.500”
6.625”
8.625”
12.750”
11
11
11
11
0.409”
0.602”
0.784”
1.159”
7.
500’ Coils – Approved for insert only – Must be
approved by Technical Services
500’ Coils – Must be approved by Technical
Services
500’ Coils
500’ Coils
500’ Coils – (PE-3408/4710 Only)
40’ Joints - 250’ Coils and 500’ Coils
40’ Joints - Approved for repair only
Coils – Must be approved by Technical Services
40’ Joints – (various coil sizes for projects)
40’ Joints – (various coil sizes for projects)
40’ Joints
40’ Joints
Outdoor Storage Life
7.1
PE-2406/2708 Medium Density
7.1.1
7.1.2
7.1.3
7.2
8.
Shipping Unit
Performance Pipe has an unprotected outdoor storage rating of four (4) years.
JM Eagle (formerly US Poly/Uponor) and Poly Pipe have unprotected outdoor
storage rating of three (3) years.
Contact Technical Services when installing pipe that has been stored longer than three
(3) years.
PE-3408/4710 high density pipe and tubing to be rated for outdoor storage of ten (10) years.
Shipping Requirements
Date Issued:
Approved by:
01/31/03
Ed Ostrovich
Effective Date:
Written by:
07/07/05
P Tucker
Revision Date:
04/26/10
Revision: 3 Page:
2 of 3
ATMOS energy
Material Specification: MS1.01
Product Name: Polyethylene
Group Name: Pipe
Description: PE-2406/2708 & PE-3408/4710 Polyethylene Pipe and Tubing
Approved Application:
8.1
8.2
8.3
8.4
8.5
8.6
9.
Up to 80 PSIG Operating Pressure (100 PSIG for ½ CTS) for PE-2406/2708
Up to 100 PSIG Operating Pressure for PE-3408/4710
Company & Distributor shall not be required to accept pipe from the manufacturer whose
date of manufacture is more than one (1) year prior to date of delivery.
Company shall not be required to accept pipe from distributor whose date of manufacture is
more than two (2) years prior to date of delivery. Pipe whose date of manufacture is more
than two (2) years old but less than four (4) may be utilized with Technical Services
approval.
Pipe shall be protected from physical damage during shipment. No chains or metallic slings
shall come in direct contact with the pipe or tubing.
The Company reserves the right to reject shipment if there is obvious damage or defects, or
if pipe was poorly protected during shipment.
Manufacturer will notify receiver at least 24 hours prior to delivery.
Plastic end caps shall be installed on the open end of all pipe regardless of pipe size to
prevent entry of foreign material.
Approved Manufacturers
9.1
9.2
9.3
Performance Pipe
Poly Pipe (formerly Rinker)
JM Eagle (formerly US Poly/Uponor)
10. Note
10.1 Changes in pipe properties, manufacturing process(s), raw materials, quality control
procedures, etc. shall be approved by ATMOS Energy Corporation.
Date Issued:
Approved by:
01/31/03
Ed Ostrovich
Effective Date:
Written by:
07/07/05
P Tucker
Revision Date:
04/26/10
Revision: 3 Page:
3 of 3
ATMOS energy
Product Name: Pipe Steel
Description: Steel Pipe
Approved Application:
1.
Any situation where plastic pipe is not suitable – any above ground unencased pipe or higher pressure (where plastic pipe is not suitable)
applications.
Pipe Specifications
1.1
2.
Group Name:
Material Specification: MS1.03
Pipe
3/4 inch and Larger – Steel pipe manufactured and tested according to current API 5L,
PSL2, Plain End Beveled for Welding.
Mill Test Reports (MTR)
2.1
Mill test reports for pipe purchased are required and should be delivered to the
following:
Attention: Procurement Department
ATMOS Energy Corporation
700 Three Lincoln Centre
5430 LBJ Freeway
Dallas, TX 75240
3.
Pipe Marking
3.1
3.2
4.
Pipe to be marked by paint stenciling or rolling with manufacturer’s name or mark, API
monogram, size wall thickness, grade, weight per foot, manufacturing process, type of
steel.
Coating mill to mark outside of coating with the same information listed above as well as
stenciling information per ATMOS Material Specification for Fusion-Bond Epoxy Coating
for Steel Pipe Standard. See material specification 7.01.
Pipe Coating
4.1
4.2
Date Issued:
Approved by:
Pipe is to be coated per ATMOS Material Standard for Fusion-Bond Epoxy Coating
Standard No. 7.01 for Steel Pipe
For fabrication pipe, line pipe on bridge crossings or other above ground applications,
order bare pipe standard wall or heavier.
12/16/02
Ed Ostrovich
Effective Date:
Written by:
07/07/05
P Tucker
Revision Date:
06/08/09
Revision: 2 Page:
1 of 3
ATMOS energy
Product Name: Pipe Steel
Description: Steel Pipe
Approved Application:
5.
Any situation where plastic pipe is not suitable – any above ground unencased pipe or higher pressure (where plastic pipe is not suitable)
applications.
Pipe Dimensions
Nominal
Size
(inches)
¾
1
1-1/4
2
2
3
3
4
4
4
6
6
8
8
10
10
10
12
12
12
6.
Group Name:
Material Specification: MS1.03
Pipe
Outside
Diameter
(inches)
1.050
1.315
1.660
2.375
2.375
3.500
3.500
4.500
4.500
4.500
6.625
6.625
8.625
8.625
10.750
10.750
10.750
12.750
12.750
12.750
Wall Thickness
(inches)
Grade
(ksi)
0.113
0.133
0.140
0.154
0.218
0.188
0.216
0.156
0.188
0.237
0.188
0.280
0.188
0.322
0.203
0.344
0.365
0.250
0.281
0.375
35
35
35
42
42
42
42
42
42
42
42
42
42
52
42
42
60
42
60
60
Max Pressure
for 20% SMYS
(psig)
1,506
1,416
1,180
1,089
1,542
902
1,036
582
701
884
476
710
366
776
317
537
814
329
528
705
Design Note
6.1
Date Issued:
Approved by:
Table provides specifications for pipe that can be operated at pressures up to those
listed while still maintaining a hoop stress less than 20% SMYS. These specifications
cover most maximum allowable operating pressures in our Distribution systems. For
pipe operated at greater than 20% SMYS, pipe must be classified and operated as
transmission lines as per part 192, CFR. For pressure, hoop stress, size, etc.
configurations other than listed above, Engineering department will provide a special
design.
12/16/02
Ed Ostrovich
Effective Date:
Written by:
07/07/05
P Tucker
Revision Date:
06/08/09
Revision: 2 Page:
2 of 3
ATMOS energy
Product Name: Pipe Steel
Description: Steel Pipe
Approved Application:
7.
Group Name:
Material Specification: MS1.03
Pipe
Any situation where plastic pipe is not suitable – any above ground unencased pipe or higher pressure (where plastic pipe is not suitable)
applications.
Ordering Information
7.1
Projects less than 1,000 tons order through McJunkin Redman Corporation through the
web based ordering system. Orders greater than 1,000 tons contact the Supply Chain
Specialist or Shared Services Procurement Department.
7.2
Include the following specification in the description:
7.2.1 Nominal Size, Pipe Specification, Diameter, Wall Thickness, Yield Strength, and
suitable coating.
8.
Approved Manufacturers
8.1
The following manufacturers are approved:
8.1.1 American Steel
8.1.2 Belleville
8.1.3 Berg Steel
8.1.4 CSI
8.1.5 Dura Bond Pipe
8.1.6 Ipsco Steel
8.1.7 Koppel
8.1.8 Lonestar Steel
8.1.9 North Star
8.1.10 Tenaris
8.1.11 US Steel
8.1.12 Stupp
9.
Shipping Provisions
9.1
9.2
Date Issued:
Approved by:
Company reserves the right to reject shipment if there is obvious damage or defects, or
if the shipment is not properly protected.
Pipe shall be protected from physical damage during shipment. No chains or metallic
slings shall come in direct contact with pipe coating.
12/16/02
Ed Ostrovich
Effective Date:
Written by:
07/07/05
P Tucker
Revision Date:
06/08/09
Revision: 2 Page:
3 of 3
ATMOS energy
Product Name: Plug Valves
Description: Plug Valves
Approved Application:
1.
1.2
1.3
1.4
1.5
1.6
All plug valves shall meet the minimum requirements of MSS Standard Practice SP-78:
Cast Iron Plug Valves, Flanged and Threaded Ends.
Plug Valves must be manufactured from Class-B Grey Cast Iron Per ASTM A 126.
Flanges shall be per ANSI B16.1 and end to end dimensions per B16.10
Shell and seats to be hydrostatically tested to per the requirements of API-6D.
Valve must have a system to provide lubricant-sealant to the body-plug interface.
Valve shall have a permanent built in stop for plug rotation. Plug rotation must be
restricted to 90°. 2 inch operating heads and locking devices must be available from
manufacturer. (Unless designed to be non-lubricated)
Plug valve design shall provide for its lubrication at any line pressure (up to valve max
design pressure) in either fully open or fully closed position. Valve must be furnished
with lubricant which is suitable for natural gas and propane use. (Unless designed to be
non-lubricated)
Specifications 150# ANSI and above (Forged Steel)
2.1
2.2
2.3
2.4
2.5
3.
Transmission and Distribution Above and below Ground
Specifications 500 psig or Below (Semi-Steel)
1.1
2.
Group Name:
Material Specification: MS2.01
Valves
All valves shall meet the minimum requirements of MSS Standard Practice SP-55 :
Steel Castings for Valves, Flanges and Fittings.
Flanges shall conform to ANSI B16.5, and end to end dimensions per B16.10.
Shell and seats to be hydrostatically tested to the requirements of API-6D.
Valve must have a system to provide lubricant-sealant to the body-plug interface.
Valve shall have a permanent built in stop for plug rotation. Plug rotation must be
restricted to 90°.
Plug valve design shall provide for its lubrication at any line pressure (up to valve max
design pressure) in either fully open or fully closed position. Valve must be furnished
with lubricant which is suitable for natural gas and propane use.
Marking
3.1
Date Issued:
Approved by:
All valves shall be marked per MSS standard practice SP-25. Marking shall include
ANSI class rating, size, pressure rating (WOG) and valve model number.
02/15/09
Ed Ostrovich
Effective Date:
Written by:
02/15/09
P Tucker
Revision Date:
06/08/09
Revision: 3 Page:
1 of 2
ATMOS energy
Product Name: Plug Valves
Description: Plug Valves
Approved Application:
4.
Dresser
Flow Serve (Nordstrom)
Shipping
5.1
6.
Transmission and Distribution Above and below Ground
Approved Manufacturers
4.1
4.2
5.
Group Name:
Material Specification: MS2.01
Valves
Refer to material standard 7.01-11
Notes
6.1
Date Issued:
Approved by:
Threaded and Flange valves may not be used in below ground applications without
Technical Services review.
02/15/09
Ed Ostrovich
Effective Date:
Written by:
02/15/09
P Tucker
Revision Date:
06/08/09
Revision: 3 Page:
2 of 2
ATMOS energy
Product Name: Ball Valves – Steel
Group Name:
Description: Full and Reduced Port Ball Valves – Steel
Approved Application:
1.
For use in Transmission and Distribution pipelines.
Specifications
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
All valves shall meet the minimum requirements of API-6A, API-6D, MSS SP-70, MS SP-71,
MSS SP-78 or the equivalent.
Weld x Weld valves shall have ends machined per ANSI B16.25.
Flange ends shall be per ANSI B16.5 and end to end per B16.10.
Shell and seats to be hydrostatically tested to the requirements of API-6D
All valves will have a valve position indicator, and either a 2” curb key or gear operator as
specified by requisitioner. A locking deviced shall also be available. Valves shall be
available for weld x weld, flanged and/or screw installation.
Trunion Mounted Ball Valves shall be used at a compressor station.
Full port ball valves are to be used on pipelines, except if specified in construction drawings.
Engineering is to be contacted for exceptions.
Floating Ball Valve sizes shall be limited to the following applications:
2.8.1
2.8.2
2.8.3
3.
150# ANSI – 6” and smaller
300# ANSI – 6” and smaller
600# ANSI – 4” and smaller
Marking
3.1
4.
Transmission and Distribution
Application
1.1
2.
Material Specification: MS2.02
Valves
All valves shall be marked per MSS standard practice SP-25. Marking shall include ANSI
class rating, size, pressure rating (WOG) and valve model number
Approved Manufacturers
4.1
Trunion Mounted Ball Valves - Steel
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
Date Issued:
Approved by:
Cameron
Grove
Jamesbury
KF
PBV
TK
02/25/03
Ed Ostrovich
Effective Date: 02/25/03
Written by: P Tucker
Revision Date:
06/08/09
Revision: 4 Page:
1 of 2
ATMOS energy
Product Name: Ball Valves – Steel
Group Name:
Description: Full and Reduced Port Ball Valves – Steel
Approved Application:
4.1.7
4.2
Transmission and Distribution
WKM
Floating Ball Valves – Steel
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
5.
Material Specification: MS2.02
Valves
Balon
WKM
Jamesbury
KF
TK
Ballomax (For Distribution Application Use Only)
Kerotest (For Distribution Application Use Only)
Shipping
5.1
Refer to material standard 7.01-11
Date Issued:
Approved by:
02/25/03
Ed Ostrovich
Effective Date: 02/25/03
Written by: P Tucker
Revision Date:
06/08/09
Revision: 4 Page:
2 of 2
ATMOS energy
Product Name: Plastic Valves
Group Name:
Description: Full and Reduced Port Ball Valves - Polyethylene
Approved Application:
1.
1.2
1.3
1.4
1.5
1.6
All valves shall meet the minimum requirements of ANSI B16.4D, ASTM D-2513, ASTM
D-3261 or the equivalent.
Valves shall be made of PE 2406/2708, medium density resins or PE 3408/4710, high
density resins. They shall be manufactured with “Long” outlets to facilitate installation by
butt fusion.
All valves shall be equipped with internal shear pin for protection of over torque on
valve. The shear pin shall have a minimum torque of 90 ft. lb. to break pin.
All valves shall be equipped with a 2” square operating nut and shall be ¼ turn shut-off.
Valve shall have an indicator to show direction.
Approved methods of installation shall be butt fusion, socket fusion or electro fusion.
All valves should be full port poly valves only.
Marking
2.1
3.
PE Gas Systems, Below Ground installation Only – All Sizes
Detailed Specifications
1.1
2.
Material Specification: MS2.03
Valves
Valves shall be marked according to ASTM D-2513.
Approved Manufacturers
3.1
3.2
3.3
3.4
Date Issued:
Approved by:
Kerotest
Nordstrom
Perfection
R. W. Lyall
06/03/05
Ed Ostrovich
Effective Date:
Written by:
02/25/03
P Tucker
Revision Date:
06/08/09
Revision: 2 Page:
1 of 1
ATMOS energy
Product Name: Steel Gate Valve
Group Name:
Description: Distribution and Transmission Steel Gate Valves
Approved Application:
1.
1.2
1.3
1.4
1.5
1.6
1.7
All valves shall be marked per MSS standard practice SP-25. Marking shall include
ANSI class rating, manufacturer, size, pressure rating (WOG) and valve model number.
Approved Manufacturers
3.1
3.2
4.
Valve body shall be constructed of steel to ASTM A-216 specifications. Valve shall be
equipped with a 2” operating nut, maintenance free, and non-lubricated. Locking device
for valve should be available if needed.
All screws used in bonnet and gland must be, as a minimum, alloy steel SAE Grade 8.
Face-to-face and end-to-end dimensions of valve must be in accordance with ANSI
B16.10.
Flanged valve must conform to ANSI B16.5.
Weld end valves shall be machined per ANSI B16.25.
Valve stem and gate must be replaceable.
Valve shell and seat must be tested, by manufacturer, according to API 6D.
Marking
2.1
3.
Distribution and Transmission Line Valves, Regulator and Meter Station
Valves.
Detailed Specifications
1.1
2.
Material Specification: MS2.04
Valves
Grove
Kerotest Manufacturing
Notes
4.1
Date Issued:
Approved by:
Use ball or plug valve if possible.
06/03/05
Ed Ostrovich
Effective Date:
Written by:
06/03/05
P Tucker
Revision Date:
06/08/09
Revision: 3 Page:
1 of 1
ATMOS energy
Material Specification: MS2.05
Product Name: Needle Valves
Group Name: Valves
Description: Needle Valves
Approved Application:
For use in meter sets or Regulator stations, or any application which may
need a gauge or sample point.
1.
Specifications
1.1
1.2
O-ring style, carbon steel body, integral seat
Sizes
1.2.1
1.2.2
1.2.3
1.2.4
1.3
NPT threads, 3000 psig minimum rating @ 200° F.
1.3.1
1.4
1.5
1.6
2.
½” male x ¼” female
½” male x ½” female
¼” male x ¼” female
¼” female x ¼” female
For compressor application, consult engineering.
Valve must be equipped with a removable handle and/or a locking device that accepts a
barrel lock or padlock.
Material: 316SS, 304SS, ASTM A105, ASTM A108
Test standard: API 598 unless all the valves are 100% tested by manufacturer
Approved Manufacturers
2.1
2.2
2.3
2.4
Anderson
Kerotest Manufacturing
KF Industries
PGI
Date Issued:
Approved by:
06/03/05
Ed Ostrovich
Effective Date:
Written by:
02/25/03
P Tucker
Revision Date:
06/08/09
Revision: 3 Page:
1 of 1
ATMOS energy
Material Specification: MS4.06
Product Name: Weld Reinforcing Fittings
Group Name: Weld Fittings
Description: Weld Split Tees, Full Encirclement Saddles and Reinforcing Saddles
Approved Application:
1.
Detailed Specifications
1.1
Fitting Material
1.1.1
1.2
1.3
The saddles and split tees are not designed to contain internal pressure, but are to
be used as a reinforcement which is slipped over the welded joint of branch pipe and
header and then fillet welded all around. A vent hole prevents pressure build up
under the saddle.
Fitting Markings
1.3.1
1.3.2
Fittings will be stamped with the manufacturer's name, the nominal size and the
figure/catalog number.
All markings shall meet the requirements of MSS SP-25 or equivalent.
Approved Manufacturers
2.1
Company reserves the right to specify or reject fitting manufacturer. Fittings shall be of
domestic manufacture with country of origin legibly stamped on the fitting. The following
are approved manufacturers:
2.1.1
2.1.2
2.1.3
3.
Fittings shall be manufactured of material that meets A106 Grade B or ASTM A516
Grade 70 or equivalent specification.
Fitting Pressure-Temperature Ratings
1.2.1
2.
Reinforce Welded Connections on Headers and Branch Pipes
Steel Forgings, Inc.
Dresser
T.D. Williamson
Notes
3.1
Country of Origin
3.1.1
3.1.2
3.1.3
Date Issued:
Approved by:
All fittings will be manufactured in the United States of America where practical.
Manufacturer shall certify origin of fitting.
All fittings shall be approved for use prior to installation or returned to the
manufacturer.
03/01/05
Ed Ostrovich
Effective Date:
Written By:
03/01/05
P Tucker
Revision Date:
06/08/09
Revision: 1 Page:
1 of 2
ATMOS energy
Material Specification: MS4.06
Product Name: Weld Reinforcing Fittings
Group Name: Weld Fittings
Description: Weld Split Tees, Full Encirclement Saddles and Reinforcing Saddles
Approved Application:
3.1.4
3.1.5
3.2
Manufacturer to bear all expense including the cost to remove installed fittings not
meeting this requirement.
Fittings are required to be legibly stamped with the country of origin.
Shipping Provisions
3.2.1
3.3
Reinforce Welded Connections on Headers and Branch Pipes
Refer to material standard 7.01-11
Ordering Information
3.3.1
Include the following specification on the purchase requisition:
3.3.1.1
Date Issued:
Approved by:
Manufacturer, Description, Nominal Size, Figure /Catalog Number
03/01/05
Ed Ostrovich
Effective Date:
Written By:
03/01/05
P Tucker
Revision Date:
06/08/09
Revision: 1 Page:
2 of 2
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Detailed Specifications:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
1 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
2 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
3 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
4 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
5 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
6 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
7 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
8 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
9 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
10 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
11 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
12 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
13 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
14 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
15 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
16 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Date Issued:
Approved by:
Ernie Napier
11/20/05
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
17 of 18
ATMOS energy
Product Name: Induction Bend
Description: Induction Bend Weld Fittings
Approved Application:
Group Name:
Material Specification: MS4-07
Weld Fittings
Transmission & Distribution
Approved Manufacturers:
Houston Pipe Benders
Date Issued:
Approved by:
Ernie Napier
11/20/05
Effective Date:
11/20/05
Revision Date:
Revision:
Page:
18 of 18
ATMOS energy
Material Specification: MS6.01
Product Name: Butt Fusion
Group Name: Plastic Fittings
Description: PE Butt fusion fittings
Approved Application:
Underground mains and services operating at 80 psig or less
1.
Detailed Specifications
1.1
1.2
2.
Available Features
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3.
Molded Fittings are PE2406/2708 Butt fittings are manufactured and tested to the
requirements of ASTM D2513 and are manufactured for use with pipe conforming to ASTM
D2513 and with Butt fittings conforming to ASTM D3261. PE2406/2708 Butt fittings are
molded from a yellow medium density pre-blended virgin resin in accordance with the
material specifications listed in ASTM D3350 with a PPI designation of PE2406/2708. All
PE2406/2708 Butt Fittings are manufactured and tested to the requirements of ASTM
D3261 and are compatible for heat fusion with any pipe and or fitting manufactured from a
like or similar resin.
Molded PE3408/4710 Butt fittings are manufactured and tested to the requirements of
ASTM D2513, and ANSI/AWWA C906 for use with pipe conforming to ASTM D2513/3035,
F-714 and with Butt fittings conforming to ASTM D3261 as applicable. PE3408/4710 Butt
fittings are molded from an NSF listed pre-blended virgin resin in accordance with the
material specifications listed in ASTM D3350 with a PPI designation of PE3408/4710. All
PE3408/4710 Butt Fittings are manufactured and tested to the requirements of ASTM
D3261 and are compatible for heat fusion with any pipe and or fitting manufactured from a
like or similar resin.
PE2406/2708 fittings are engineered for use on MDPE Pipe
PE3408/4710 fittings are engineered for use on HDPE Pipe
Pressure rated for natural gas and potable water applications (based on fitting DR)
No de-rating of fitting required
IAPMO Approved
CSA Approved
PE3408/4710 fittings are tested to the requirements of AWWA C906
Can be joined by butt, socket or electrofusion
Can be used with all conventional fusion equipment
Manufactured in U.S.A.
Approved Manufacturers
3.1
3.2
3.3
Performance Pipe
Central Plastic Company
US Poly
Date Issued:
07/22/02
Approved by:
Ed Ostrovich
Effective Date:
Written by:
07/22/02
P Tucker
Revision Date:
Revision:
1
06/08/09
Page:
1 of 2
ATMOS energy
Material Specification: MS6.01
Product Name: Butt Fusion
Group Name: Plastic Fittings
Description: PE Butt fusion fittings
Approved Application:
Underground mains and services operating at 80 psig or less
4.
Notes
4.1
4.2
Fittings will be marked to ASTM D2513
The manufactory date must be marked.
Date Issued:
07/22/02
Approved by:
Ed Ostrovich
Effective Date:
Written by:
07/22/02
P Tucker
Revision Date:
Revision:
1
06/08/09
Page:
2 of 2
ATMOS Energy
Material Specification: MS6.03
Product Name: Electrofusion
Group Name: Plastic Fittings
Description: Electrofusion couplings for use with Polyethylene pipe
Approved Application:
1.
Detailed Specifications
1.1
1.2
1.3
Fittings covered under this standard shall include, but not be limited to: ells, tees, couplings,
reducers and caps.
Sizes ordered shall include from ½” thru 12” pipe size (IPS) as well as ½” copper tube size
(CTS). Other size requirements may be ordered as required to meet specific project
requirements.
Fittings shall conform for use with the following
1.3.1
1.3.2
1.4
2.
Underground mains and service lines
PE-2406/2708
PE-3408/4710
Polyethylene manufactured in accordance with current ASTM-D2513 specifications.
Approved Manufacturers
2.1
2.2
2.3
2.4
Central Plastics
Fritec
Innogaz (Kerotest)
MT Deason
Date Issued:
Approved by:
12/20/05
Ed Ostrovich
Effective Date:
Written by:
12/20/05
P Tucker
Revision Date:
06/08/09
Revision: 2 Page:
1 of 1
ATMOS Energy
Material Specification: MS6.04
Product Name: Plastic to Steel Couplings
Group Name: Plastic Fittings
Description: Bolt-on, pullout proof compression coupling
Approved Application:
Steel to steel, plastic to plastic, cast iron to steel, plastic to steel and plastic
to cast iron
1.
Detailed Specifications
1.1
1.2
1.3
1.4
2.
Maxi-grip EZ steel couplings, Dresser style 711 posi-hold steel couplings for sizes 1-1/4” to
8” and Permasert XL plastic anodeless couplings.
All materials contained in the steel coupling must conform to DOT 192.53 and the
manufacture and testing of the coupling must conform to DOT 192.53 and ASTM A-53. All
bolts must conform to ASTM A-242 with a minimum tensile strength of 70,000 PSI. All nuts
must conform to ASTM A-563 Grade A.
All materials contained in the plastic coupling must conform to DOT 192.53 and the
manufacture and testing of the coupling must conform to DOT 192.53, DOT 192.283(b),
ASTM D-2513 and ASTM D-1598. All bolts, nuts and washers must be 304 Stainless Steel.
Steel couplings must be epoxy coated. Bolts, nuts and washers must be corrosion
resistant. An anode is required to protect the nuts and bolts of these fittings.
Approved Manufacturers
2.1
2.2
2.3
Smith-Blair
Dresser Manufacturing
Perfection Corp.
Date Issued:
Approved by:
12/20/05
Ed Ostrovich
Effective Date:
Written By:
12/20/05
P Tucker
Revision Date:
06/08/09
Revision: 1 Page:
1 of 1
ATMOS Energy
Product Name: Transition Fittings
Group Name:
Description: Steel to Plastic fittings
Approved Application:
Steel to polyethylene transitions
1.
Detailed Specifications
1.1
1.2
1.3
2.
All Steel to Plastic Transition Fittings will be suitable for butt-welding to the steel portion and
for butt-fusion and mechanical coupling, or approved electrofusion to the plastic portion of
the fitting. The steel section shall conform to the requirements of API-5L for line pipe,
while the plastic portion shall conform to ASTM D2513. The plastic portion shall be either
PE 2406/2708 or PE 3408/4710. No substitutions or changes in resin will be allowed
without prior written permission from Atmos Energy.
The steel portion of the fitting shall be of the standard thickness and coated with heat fused
epoxy with a minimum of 14 mils thickness. The steel pipe section shall be beveled at a 30
degree angle with a 1/16" root face as shown in API 5L.
All transition fittings shall be tested to the requirements of plastic line pipe according to
ASTM D-2513. Any leakage shall be grounds for rejection. The fitting shall also be
designed to fail in the plastic portion (neck-down to 100% in length) without separation of
the two sections.
Approved Manufacturers
2.1
2.2
2.3
2.4
3.
Material Specification: MS6.05
Plastic Fittings
Central Plastics
Lyall
US Poly
Continental Industries
Notes
3.1
All transition fittings shall be marked with the following:
Manufacturer name or trademark.
Size and wall thickness (or SDR number) of each side.
Material Designation for each side.
Date (or lot number) of manufacture.
Date Issued:
Approved by:
03/31/05
Ed Ostrovich
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
06/08/09
Revision: 1 Page:
1 of 1
ATMOS Energy
Material Specification: MS6.06
Product Name: High Volume Tap Tees
Group Name: Plastic Fittings
Description: High Volume Applications for 1-1/4” and 2” Outlet High Volume Taps
Approved Application:
Polyethylene pipe
1.
Detailed Specifications
1.1
1.2
1.3
2.
Approved Manufacturers
2.1
2.2
2.3
2.4
3.
Electrofusion fittings must be manufactured in accordance with ASTM F1055 Electrofusion
Type Polyethylene Fittings for Outside Diameter Controlled polyethylene Pipe and Tubing.
Fittings must be manufactured from resin meeting ASTM Specifications for PE 2406/2708,
PE 3408/4710 or PE100 material.
Sidewall fusion fittings must be manufactured in accordance with ASTM D3261 for buttfusion fittings and to ASTM D2683 for socket fusing fittings or equivalent. Material shall
meet the requirements of ASTM D2513 for PE 2406/2708, PE 3408/4710 or PE100
material.
Mechanical fittings must be manufactured in accordance with ASTM D2513 and CFR 49
part 192.
US Poly
Central Plastics
Performance Pipe
Continental Industries
Notes
3.1
All fittings shall be marked with the following:
Manufacturer name or trademark.
Size.
Date (or lot number) of manufacture.
Date Issued:
Approved by:
03/31/05
Ernie Napier
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
06/08/09
Revision: 1 Page:
1 of 1
ATMOS energy
Product Name: Steel Pipe Coatings
Group Name:
Description: Specs for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
1.
General
1.1
1.2
1.3
2.
This specification for ATMOS Energy covers the minimum requirements for material,
application and testing of plant applied external fusion bond epoxy (FBE), both single and
multi-layer (abrasion-resistance overlayer), pipe coating.
The applicator will furnish all labor, materials, quality control, supervision, tools and
equipment, and provide for the performance of all operations and incidentials necessary for
the coating, handling, storing, and loading out of plant coated pipe. An ATMOS Energy
representative may make any investigation necessary to satisfy him/herself of compliance
by the applicator.
Specific coating material to be used will be specified on the purchase order. The coating
specified on the purchase order may only be changed by ATMOS Energy or their
representitive.
Definitions
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3.
Material Specification: MS7.01
Cathodic Protection
Applicator: The organization responsible to the purchaser for the coating application.
Coating: A liquid, liquefiable, or mastic composition that, after application to a surface is
converted into a solid protective, decorative, or functional adherent film.
Coating Material: Epoxy powder.
Holiday: A discontinuity in a protective coating that exposes unprotected surfaces to the
environment.
Inspector: The authorized agent for the purchaser.
Purchaser: The owner company or the authorized agency that purchases the coated
pipe.
Supplier: The manufacturer or distributor of the coating material and its authorized
technician.
Coating Material
3.1
Powders listed below has been approved for application of coated pipe. Other powders will
be added as they are tested and approved.
3.1.1
3.1.2
Date Issued:
Approved by:
3M
Scotchkote 206N
Scotchkote 6233
11/30/05
Ed Ostrovich
Scotchkote 6352*
Scotchkote 207R
Effective Date:
Written By:
11/30/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
1 of 6
ATMOS energy
Product Name: Steel Pipe Coatings
Group Name:
Description: Specs for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.1.10
Material Specification: MS7.01
Cathodic Protection
Dupont Nap-Guard Pipe Coatings
Napgard 7-2500
Napgard 7-2501
Napgard 7-2610*
Valspar (Lillyclad 2040)
Pipeclad 2000
Pipeclad 2040
Powercrete (ARO)
3.1.10.1 ARO (abrasion-resistant overlayer) coatings shall be applied over the FBE
coating within 7 days of the FBE coating being applied. ARO coatings shall be applied
to achieve a minimum film thickness of 30 mil.
3.2
All FBE coatings shall be:
3.2.1
3.2.2
3.2.3
3.3
3.4
4.
Coated as per manufacturer’s specifications.
Minimum thickness – 12 mil
Average thickness – 15 mil
Materials used in the coating process shall be within the guidelines of NACE RP039402, Section 3.
The applicator shall have Certification of Compliance from the powder manufacturer on
each batch (or lot) of material that meet the value limits for the properties listed in
NACE
Standard RP0394 Table 1. The applicator shall test all different batches of FBE
material to be used on the coating process as required under Table 2, for powder
quality.
Scheduling
4.1
The applicator will coat, furnish dunnage, and load out coated pipe on trucks, rail cars,
or other conveyances when notified and as required. The applicator shall give ATMOS
Energy a minimum of 48 hours notice before coating is to be applied. ATMOS Energy
reserves the right to have an inspector at the coating mill during the coating process.
4.2 No pipe shall be coated prior to fifteen (15) days after received from manufacturing to
prevent hydrogen build-up beneath the coating. The pipe shall be cleaned and prepared to
coating manufacturer's specification before coating is applied. All pipe coating material shall
be free of dust, debris, moisture or additives used to recondition the pipe coating material.
Coating shall be applied in such a way to prevent runs, sags, bare spaces, smears or
displacement of coating material.
Date Issued:
11/30/05
Effective Date: 11/30/05
Revision Date:
07/06/09
Approved by: Ed Ostrovich Written By:
P Tucker
Revision: 1 Page:
2 of 6
ATMOS energy
Product Name: Steel Pipe Coatings
Group Name:
Description: Specs for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
5.
Coating Performance
5.1
6.
Applied external coatings shall meet the characteristics as outlined in NACE Standard
RP0169 and NACE Standard RP0394, Section 4.
Surface Preparation of Pipe
6.1
6.2
6.3
7.
Material Specification: MS7.01
Cathodic Protection
Prior to the coating of bare pipe, surface preparation shall be acceptable if prepared under
the guidelines of NACE RP0394, Section 5, and/or NACE No.2/SSPC-SP10.
After abrasive cleaning, blasted surfaces shall be monitored to determine if an anchor
pattern profile of not less than 1.5 mil nor more than 3.0 mil is achieved.
Cleaned pipe not coated within two (2) hours shall be re-blast cleaned prior to coating.
Coating Application
7.1
Application shall be within the guidlines of NACE Standard RP0394 and the following:
7.1.1
Pipe will not be heated to a temperature in excess of 525 degrees F during any stage
of the coating operation. Temperature will be monitored with 450, 463, and 475 degree
tempil sticks.
7.1.2 Pipe heated in excess of 525 degrees F must be tested in accordance with the original
pipe manufacturing specification and any other requirements of ATMOS Energy to
determine whether the physical properties of the pipe have been altered. If it is
determined that the pipe no longer meets original specification, coating contractor shall
be responsible for the total value of such pipe in addition to the cost incurred in testing
each overheated joint of pipe.
7.1.3 The finish coat will have a maximum cutback of 2-1/2 inches and a minimum cutback of
1-1/2 inches. Cutback is measured from the bevel shoulder. Taping of the ends will
not be an accepted method to achieve the cutback in plants where the tape would be
subsequently exposed to flames.
7.1.4 Oxidation of the steel pipe in any apparent form is not acceptable. The pipe shall be
cooled to a temperature acceptable by the blast cleaning operations and re-cleaned as
described under Section 6 at no additional cost to ATMOS Energy.
7.1.5 The coating shall be applied to pipe in a uniform film thickness of fifteen (15) mils with a
minimum of twelve (12) mils and maximum of twenty-five (25) mils. Pipe having film
thickness exceeding twenty-five (25) mils and re-coated pipe shall be stenciled "DO
NOT BEND" in letters at least two (2) inches high, one (1) foot from both ends of pipe.
7.1.6 "Fusion Bonded Epoxy" coating systems requirements will be governed strictly by the
coating manufacturer recommendation and approval of ATMOS Energy.
Date Issued:
11/30/05
Effective Date: 11/30/05
Revision Date:
07/06/09
Approved by: Ed Ostrovich Written By:
P Tucker
Revision: 1 Page:
3 of 6
ATMOS energy
Product Name: Steel Pipe Coatings
Group Name:
Description: Specs for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
7.1.7
7.1.8
7.1.9
Material Specification: MS7.01
Cathodic Protection
While curing, pipe shall be handled so as to avoid damage to coating and after the pipe
is cured shall be cooled with air or running water to under 200 degrees F. for inspection
and handling.
Before handling, protective separators are to be attached to each joint.
It will be the responsibility of the coating applicator to take immediate corrective
measures when conditions exist which adversely affect the external coating operation
with respect to cleaning, application, or material performance.
7.1.9.1 NOTE: Pipe temperature at the entrance to the coating station and post
application curing time shall be closely monitored to comply with the limits set
by the coating manufacturer. A "best" temperature and cure time can usually
be determined after the first few joints are coated. Ring test results shall be used
to make the final determination. The objectives in controlling these conditions are:
7.1.10 Application temperature shall be high enough to assure complete powder melt,
flowout, wetting of the pipe surface and fusion.
7.1.11 Application temperature shall not be higher than that at which optimum polymerization
occurs without premature gelatin before completion of flowout, wetting, and fusion.
7.1.12 Post application cure temperature and time shall not be less than that required for
sufficient cure of the applied coating.
8.
Marking
8.1
8.2
8.3
Pipe shall be marked in accordance with NACE RP0394-02, Section 10.
Each joint of coated pipe shall be marked by the coating contractor on the outside surface of
the coating starting approximately twelve (12) inches from the end of the pipe. Marking
shall be stenciled utilizing a waterproof permanent type paint or ink. Marking shall be
legible from a distance of five (5) to six (6) feet with letters not less than one quarter (1/4)
inches in height.
Marking shall be in the following sequence without regard to any marking that may have
been on the inside or outside surface of the bare pipe:
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
Pipe manufacturer’s name or mark
API
Outside diameter in inches
Wall thickness in inches
Grade of pipe
Process of manufacture (seamless – “SMLS”, electric resistance welded – “ERW”,
submerged arc welded – “SAW”)
Date Issued:
11/30/05
Effective Date: 11/30/05
Revision Date:
07/06/09
Approved by: Ed Ostrovich Written By:
P Tucker
Revision: 1 Page:
4 of 6
ATMOS energy
Product Name: Steel Pipe Coatings
Group Name:
Description: Specs for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
8.3.7
8.3.8
9.
Material Specification: MS7.01
Cathodic Protection
Applicator’s initials and coating material
Date (date pipe coated)
Inspection and Testing
9.1
9.2
9.3
9.4
Each joint of pipe shall be numbered and equivalently numbered inspection records
maintained and a copy made available to ATMOS Energy’s authorized representative.
All coated pipes shall be inspected and electrically tested with a holiday detector operating
at the coating manufacturer's recommended voltage. All holidays shall be repaired in
accordance with the coating manufacturers recommended repair procedures.
Patching repair limits will be generally based on one (1) holiday per each three (3) feet of
length for all pipe diameters up to twenty (20) inch with a maximum of ten (10) holidays for
an average forty (40) foot joint and thirteen (13) holidays for an average sixty (60) foot joint.
Repair limits for all pipe diameters over twenty (20) inch will be based on one (1) holiday for
each twenty-five (25) square feet of coated surface. For other joint lengths interpolation
may be used to determine the permissible number of holidays. Repetitious holiday counts
near maximum shall be cause for rejection. In all cases, ATMOS Energy’s authorized
representative shall make the final determination as to whether a joint of pipe will be reblasted and re-coated as bare pipe.
The applicator shall perform the following Test Requirements as outlined in NACE Standard
RP0394 and Appendix’s:
9.4.1
9.4.2
9.4.3
9.4.4
9.4.5
9.4.6
9.4.7
Gel Time Determination (Appendix C)
Cathodic Disbondment Test (Appendix F)
Flexibility (Appendix H)
Moisture Permeation (Appendix J)
Interface Contamination (Appendix K)
Cross-Section Porosity (Appendix G)
Impact Resistance (Appendix I)
10. Repair
10.1 All coating defects, shall be repaired under the guidelines of NACE RP0394, Section 8
using materials that are compatible with, have the same or better performance at the
expected service temperature, adhere well to the FBE coating and are approved by the
purchaser.
10.2 A relatively large area requiring repair shall have a minimum one (1) inch overlap of the
undamaged coating by the added repair coating.
Date Issued:
Approved by:
11/30/05
Ed Ostrovich
Effective Date:
Written By:
11/30/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
5 of 6
ATMOS energy
Product Name: Steel Pipe Coatings
Group Name:
Description: Specs for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
Material Specification: MS7.01
Cathodic Protection
11. Handling, Storage, and Shipping
11.1 Due care shall be exercised in the unloading, loading, handling of materials or
products belonging to ATMOS Energy. Manufacturer shall satisfactorily repair or
replace, if ATMOS Energy shall deem it necessary, any damaged materials caused by
improper handling or neglect on the manufacturer or shipping/carrier company.
11.2 Company reserves the right to reject shipment if there is obvious damage or defects, or if
the shipment is not properly protected.
11.3 Materials shall be protected from physical damage during shipment. No chains or metallic
slings shall come in direct contact with materials or products.
11.4 All hooks, forks, and slings shall be padded or of a material that will not damage materials or
products being handled.
11.5 Nylon straps shall be used to secure loads on trucks.
11.6 Manufacturer shall give ATMOS Energy’s receiving location 48 hours notice before
shipping.
11.7 Materials shall be positioned in such a manner as to be clearly identifiable at all times.
Material or products that cannot be identified as being purchased by ATMOS Energy, will
not be accepted.
11.8 A detailed loading procedure shall be furnished by the material or product manufacturer to
ATMOS Energy’s authorized representative on request.
Date Issued:
Approved by:
11/30/05
Ed Ostrovich
Effective Date:
Written By:
11/30/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
6 of 6
ATMOS energy
Material Specification: MS7.02
Product Name: Anodes
Group Name: Cathodic Protection
Description: Pre-Packaged and Drive-In Sacrificial Anodes
Approved Application:
For sacrificial cathodic protection systems in steel transmission and
distribution systems.
1.
Types
1.1
The types of magnesium anodes to be used are the 1/2 pound driveable, 1 pound, 5 pound,
17 pound and 32 pound prepackaged in low resistance backfill anodes, and the ribbon type
anode.
1.1.1 One-half Pound Driveable Anode
1.1.1.1 One-half pound driveable anodes are to be used only on existing risers, when
required. No test stations are required on this type of installation.
1.1.2 One Pound Anode
1.1.2.1 One pound anodes are to be used only on well-coated and insulated service lines
at the time of installation or when an open ditch is available. No test stations are
required on this type of installation.
1.1.3 Five Pound Anode
1.1.3.1 Five pound anodes are to be used only on well-coated and insulated service lines
at the time of installation or when an open ditch is available. No test stations are
required on this type of installation.
1.1.4
Seventeen Pound Anodes
1.1.4.1 Seventeen pound anodes have an approximate useful life of 20 years at a 50
milliampere drain, and are generally used in soils having a resistivity of 2,000
to 4,500 ohm-cm.
1.1.5
Thirty-two Pound Anodes
1.1.5.1 Thirty-two pound anodes have an approximate useful life of 20 years at a 100
milliampere drain, and are generally used in soils having a resistivity of 1,000
to 2,000 ohm-cm.
Date Issued:
Approved by:
03/31/05
Ed Ostrovich
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
1 of 2
ATMOS energy
Material Specification: MS7.02
Product Name: Anodes
Group Name: Cathodic Protection
Description: Pre-Packaged and Drive-In Sacrificial Anodes
Approved Application:
For sacrificial cathodic protection systems in steel transmission and
distribution systems.
1.1.6
Ribbon type
1.1.6.1 Ribbon type is an extruded magnesium ribbon having a rectangular cross
section of 3/8" X 3/4". This type of anode is to be used only when specified by the
operating company Corrosion Department.
2.
Approved Manufacturers
2.1
2.2
2.3
2.4
MESA
CORRPRO
HARCO
ALLIED
Date Issued:
Approved by:
03/31/05
Ed Ostrovich
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
2 of 2
ATMOS energy
Material Specification: MS7.03
Product Name: Weld-In Insulators
Group Name: Cathodic Protection
Description: Weld-In Insulators for electrical insulation of steel piping systems.
Approved Application:
Electrical Isolation of buried steel piping for transmission and distribution
systems.
1.
Detailed Specification
1.1
1.2
1.3
2.
Weld-in insulators shall conform to API-5L for line pipe or the equivalent. All components of
the insulator shall be capable of meeting the maximum pressures allowed by the specified
ANSI class. Pipe ends shall be beveled to API-5L specifications and shall be shipped with
protective end caps.
Dielectric Testing – The fitting should be dry tested for insulating integrity at 2,500 AC volts
with no current leakage. This test shall be performed subsequent to any pressure or
strength test.
The steel portion of all insulators shall be epoxy coated and shall be free of dents, gouges,
arc burns or other surface defects. All insulators shall be marked to show the size, ANSI
class, API designation and the manufacturer.
Approved Manufacturers
2.1
2.2
2.3
Kerotest
P.S.I. Electrostop
Advanced Products & Systems
Date Issued:
Approved by:
03/31/05
Ed Ostrovich
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
07/06/09
Revision: 2 Page:
1 of 1
ATMOS energy
Material Specification: MS7.04
Product Name: Insulators – Flange
Group Name: Cathodic Protection
Description: Insulating Flange Gaskets
Approved Application:
Insulating flange gaskets for electrical isolation of steel distribution and
transmission systems.
1.
Detailed Specification
1.1
1.2
Flange gaskets shall be manufactured in accordance with ANSI B16.5, MSS standard
practice SP-44 or equivalent. The dimensions of the gaskets shall conform to ANSI 16.21
and shall be able to withstand the maximum pressure allowed under the appropriate ANSI
class rating.
Type "E" full face.
1.2.1
2.
Neoprene faced phenolic gasket or optional o-ring gasket. Double integral washer kit
with polyethylene sleeves.
Approved Manufacturers
2.1
2.2
2.3
2.4
Central Plastics
Maloney
Advance Products & Systems Inc.
PSI
Date Issued:
Approved by:
03/31/05
Ed Ostrovich
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
07/06/09
Revision: 2 Page:
1 of 1
ATMOS energy
Material Specification: MS7.06
Product Name: Casing Seals
Group Name: Cathodic Protection
Description: Seals the annular space between carrier pipe and casing.
Approved Application:
Steel Casing-Steel Carrier; Steel Casing-Plastic Carrier
1.
Detailed Specifications
1.1
1.2
2.
Approved Manufacturers
2.1
2.2
3.
Seals must be able to withstand a temperature range of -40ºF to +250ºF (-40ºC to +121ºC)
All fasteners should be constructed of Stainless Steel.
PSI
Maloney
Notes
3.1
3.2
Casing pipe to be used only as a last resort. Engineering approval is required.
Not to be used on carrier pipe larger than 24”.
Date Issued:
Approved by:
03/31/05
Ed Ostrovich
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
07/06/09
Revision: 2 Page:
1 of 1
ATMOS energy
Material Specification: MS7.07
Product Name: Test Stations
Group Name: Cathodic Protection
Description: Post utilized to bring CP test point above ground.
Approved Application:
CP Test Points, Tracer Wire Access Points
1.
Detailed Specifications
1.1
2.
Tri-View Flex Test Station – Trangular in shape. Each side is 3 ½” in width. Post is 5 ½
feet in length. Can accomodate up to 5 test wires. Must be high visibility yellow with
approved company pipeline warning sticker.
Approved Manufacturers
2.1
Repnet, Inc.
Date Issued:
Approved by:
03/31/05
Mike C.
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
1 of 1
ATMOS energy
Material Specification: MS7.08
Product Name: Rock Shield
Group Name: Cathodic Protection
Description: Shields steel pipe coating from debris during and after backfill.
Approved Application:
To protect coated steel pipe.
1.
General
1.1 The purpose of this is to specify the requirements for ordering and installing a rockshield
protector for pipe.
1.2 The Rock Shield is a plastic pad wrap that is used to wrap around the pipe (steel or poly) to
protect it during construction.
1.3 The main purpose of the Rock Shield is to protect the pipe coating surface form damage
during and after backfill.
1.4 Rock Shield is a non-metallic wrap made from flexible P.V.C. material that can accomadate
for normal pipe movement that may occur.
2.
Specifications
2.1 The Rock Shield is an 11 mm (0.433 in) thick P.V.C. strand extruded pipe protection pad for
both steel and/or plastic pipe.
2.2 P.V.C. Material temperature range -50 C to 120 C (-58 F to 248 F).
2.3 The impact resistance of the rock shield is for loads up to 150 lbs.
2.4 The color of the rock shield wrap shall be yellow to identify in ground pipe to third party
companies and contractors.
2.5 The Rock Shield must be bi-directional. This means that the Rock Shield should sufficiently
protect the pipe regardless which side of the Rock Shield faces the pipe. This will reduce the
risk of quality issues due to improper installation.
3.
Storage
3.1 Check the Rock Shield upon arrival.
3.1.1 It shall be extruded from an elastomeric plastic material of which the basic resin is
prime virgin polyvinyl chloride.
3.1.2 The PVC compound shall not contain any scrapped, reclaimed or recycled material
whatsoever.
Date Issued:
03/31/05
Approved by:
Ed Ostrovich
Effective
Date:
Written By:
03/31/05
Revision Date:
T. COOPER
Revision:
3
3/24/10
Page:
1 of 2
ATMOS energy
Material Specification: MS7.08
Product Name: Rock Shield
Group Name: Cathodic Protection
Description: Shields steel pipe coating from debris during and after backfill.
Approved Application:
To protect coated steel pipe.
3.2 Store Rock Shield underneath tarps to protect from oil, dirt, and sunlight.
4.
Installation Instructions
4.1 Rock shield pads shall be affixed to pipe utilizing non-metallic bands of filament tape.
4.2 Spacing of non-metallic banding shall not exceed 80 cm (2.62 feet) on center.
4.3 Rock shield shall completely encircle the pipe with a minimum overlap of 10 cm (3.94
inches). Overlap shall be located at the bottom radius (6 o’clock position).
4.4 Back-fill should be “shaded” into the trench during back-fill procedure. Do not dump back-fill
directly on protected pipe.
4.5 Follow manufacturer’s recommendations.
5.
Approved Manufacturers
5.1
5.2
Tapecoat
Tuff-N-Nuff
Date Issued:
03/31/05
Approved by:
Ed Ostrovich
Effective
Date:
Written By:
03/31/05
Revision Date:
T. COOPER
Revision:
3
3/24/10
Page:
2 of 2
ATMOS energy
Material Specification: MS7.09
Product Name: Wax Tape and Primer
Group Name: Cathodic Protection
Description: Field Applied coating for steel valves, fittings and pipe
Approved Application:
For above and below ground applications.
1.
Tape
1.1
1.2
1.3
1.4
1.5
2.
Primer (If Required):
2.1
2.2
2.3
3.
Filler Putty should be used on irregular shaped fittings and valves
Filler Putty shall be compatible with the wax tape being used.
Filler Putty shall be cold applied.
Outer Wrap (If Required):
4.1
5.
Primer shall be compatible with the wax tape being used.
Primer shall be cold applied.
Primer pour points shall not be greater than 100°F.
Filler Putty (If Required):
3.1
3.2
3.3
4.
Wax tape shall be a cold applied pipe and fitting coating.
Tape shall have a minimum dielectric strength of 100 V/mil, a minimum tensile strength of
40 lbs./ linear inch and an application temperature from 0 - 100°F.
Tape shall be non-toxic, non-hazardous, non-carcinogenic and enviromentally safe.
Tape shall be a non-stitched, non-woven, synthetic fiber tape saturated with a mixture of
petroleum wax.
Tape shall be paintable and UV stable.
To be used for direct-bury applications.
Approved Manufacturers:
5.1
5.2
5.3
5.4
Central
Trenton
Denso
Royston
Date Issued:
Approved by:
03/31/05
Ed Ostrovich
Effective Date:
Written By:
03/31/05
P Tucker
Revision Date:
07/06/09
Revision: 2 Page:
1 of 1
ATMOS energy
Product Name:
Material Specification: MS7.11
Cathodic Protection
Steel Pipe Field Applied
Group Name:
Coatings
Description: Specifications for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
1.
General
1.1
1.2
2.
Definitions
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3.
This specification for ATMOS energy covers the minimum requirements for material,
application and testing of field applied external fusion bond epoxy (FBE), abrasionresistance overlayer (ARO) and pipe coating.
Coating will be specified on the stenciling of the pipe. The coating specified on the
purchase order may only be changed by ATMOS energy or their representitive.
Applicator: The organization responsible for the coating application.
Coating: A liquid, or liquifiable composition that, after application to a surface is
converted into a solid protective, decorative, or functional adherent film.
Coating Material: Epoxy powder.
Holiday: A discontinuity in a protective coating that exposes unprotected surfaces to the
environment.
Inspector: The authorized agent for the purchaser.
Purchaser: The owner, company or the authorized agency that purchases the coated pipe.
Supplier: The manufacturer or distributor of the coating material and its authorized
technician.
Coating Material
3.1
Powders listed below have been approved by the purchaser for application of coated pipe.
Other powders will be added as they are tested and approved.
3.1.1 3M
3.1.1.1 Scotchkote 323
3.1.2 Denso
3.1.2.1 Protal 7000
3.1.3 Powercrete *
3.1.3.1 R95*
3.1.3.2 R120*
3.1.3.3 Powercrete J* +
Scotchkote326
Protal 7200*
* ARO (abrasion-resistant overlayer) coatings shall be applied over the FBE coating
where possible. ARO shall be applied within 7 days of the FBE coating being applied.
Date Issued:
Approved by:
11/30/05
Ed Ostrovich
Effective Date:
Written By:
11/30/05
P Tucker
Revision Date:
04/27/10
Revision: 3 Page:
1 of 3
ATMOS energy
Product Name:
Material Specification: MS7.11
Cathodic Protection
Steel Pipe Field Applied
Group Name:
Coatings
Description: Specifications for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
ARO coatings shall be applied to achieve a total film thickness of 30 mil minimum.
+
May be applied using alternate surface preparation, see section 5
3.1.4 All coating shall be:
3.1.4.1 Coated as per manufacturer’s specifications.
3.1.4.2 Minimum thickness – 12 mil
3.1.4.3 Average thickness – 15 mil
3.1.5
3.1.6
4.
Coating Performance
4.1
5.
Materials used in the coating process shall be within the guidelines of NACE RP039402, Section 3.
The applicator shall have Certification of Compliance from the powder manufacturer on
each batch (or lot) of material that meet the value limits for the properties listed in
NACE Standard RP0394 Table 1. The applicator shall test all different batches of FBE
material to be used on the coating process as required under Table 2, for powder
quality.
Applied external coatings shall meet the characteristics as outlined in NACE Standard
RP0169 and NACE Standard RP0394, Section 4.
Surface Preparation of Pipe
5.1
5.2
Prior to the coating of bare pipe, surface preperation shall be acceptable if prepared under
the guidelines of NACE RP0394, Section 5, and/or NACE No.2/SSPC-SP10. After abrasive
cleaning, blasted surfaces shall be monitored to determine if an anchor pattern profile of
not less than 1.5 mil nor more than 3.0 mil is achieved. Cleaned pipe not coated within two
(2) hours shall be re-blast cleaned prior to coating or per manufacturer’s specification.
Alternate surface preparation for Powercrete J.
5.2.1
Date Issued:
Approved by:
The surface to be coated shall be cleaned of all coatings and free of all contaminates.
Following cleaning, the surface of the steel can roughened or abraded with suitable
hand or power tools. A power sander using 50 grit or coarser paper can be used in a
cross direction pattern for acceptable surface pattern. Avoid surface preparation that
polishes and/or smoothes the pipe surface. The pipe surface shall not be burnished.
Steel surface to be coated shall be cleaned to the grade of SSPC-SP-6 Commercial
Blast minimum or better.
11/30/05
Ed Ostrovich
Effective Date:
Written By:
11/30/05
P Tucker
Revision Date:
04/27/10
Revision: 3 Page:
2 of 3
ATMOS energy
Product Name:
Material Specification: MS7.11
Cathodic Protection
Steel Pipe Field Applied
Group Name:
Coatings
Description: Specifications for fusion bond epoxy coatings for steel pipe
Approved Application:
Steel distribution and transmission pipe.
5.2.2
5.2.3
6.
Coating Application
6.1
Application shall be within the guidelines of NACE Standard RP0394 and the following.
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
7.
Pipe will not be heated to a temperature in excess of 100 degrees F.
Oxidation of the steel pipe in any apparent form is not acceptable. The pipe shall be
cooled to a temperature acceptable by the blast cleaning operations and re-cleaned as
described under Section 6 at no additional cost to ATMOS Energy.
The coating shall be applied to pipe in a uniform film thickness of fifteen (15) mils with a
minimum of twelve (12) mils and maximum of twenty-five (25) mils.
"Fusion Bonded Epoxy" coating systems requirements will be governed strictly by the
coating manufacturer recommendation and approval of ATMOS Energy.
While curing, pipe shall be handled so as to avoid damage to coating.
It will be the responsibility of the coating applicator to take immediate corrective
measures when conditions exist which adversely affect the external coating operation
with respect to cleaning, application, or material performance.
Post application cure temperature and time shall not be less than that required for
sufficient cure of the applied coating.
Inspection and Testing
7.1
8.
Before applying the Powercrete J coating, the pipe shall be subject to inspection for
appropriate surface preparation.
The surface of the existing coating that will be overlapped, if present, shall be tapered,
cleaned, and abraded.
All field applied coating of pipes shall be inspected and electrically tested with a holiday
detector operating at the coating manufacturer's recommended voltage. All holidays shall
be repaired in accordance with the coating manufacturer’s recommended repair procedures
and Material Specification MS 07-01.
Repair
8.1
All coating defects, shall be repaired under the guidelines of NACE RP0394, Section 8
using materials that are compatible with, have the same or better performance at the
expected service temperature, adhere well to the FBE coating and are approved by the
purchaser. A relatively large area requiring repair shall have a minimum one (1) inch
overlap of the undamaged coating by the added repair coating.
Date Issued:
Approved by:
11/30/05
Ed Ostrovich
Effective Date:
Written By:
11/30/05
P Tucker
Revision Date:
04/27/10
Revision: 3 Page:
3 of 3
ATMOS energy
Product Name: Service Tee – Steel to Steel
Group Name:
Description: Service Tee – Steel to Steel
Approved Application:
For use in service applications.
1.
Standards
1.1
All service tees, also known as service taps, must meet the following minimum
specifications.
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
2.
Material Specification: MS8.01
Service Line Fittings
ASTM A-105
ASTM A-181
ASTM A-234
ASTM A-420
ASTM A-694
ASTM A-758
Approved Manufacturers
2.1
2.2
2.3
Mueller
TD Williamson
Continental
Date Issued:
Approved by:
07/22/03
Ed Ostrovich
Effective Date:
Written By:
04/11/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
1 of 1
ATMOS energy
Product Name:
Service Tee – Steel to
Group Name:
Polyethylene
Description: Service Tee – Steel to Polyethylene
Approved Application:
For use in service applications.
1.
Standards
1.1
All service tees, also known as service taps, must meet the following minimum
specifications.
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
ASTM A-105
ASTM A-181
ASTM A-234
ASTM A-420
ASTM A-694
ASTM A-758
The polyethylene side of the fitting shall be manufactured to the specifications and
requirements of:
1.1.7.1
1.1.7.2
1.1.7.3
1.1.7.4
1.1.8
2.
Material Specification: MS8.02
Service Line Fittings
ASTM D-2683 for socket fittings,
ASTM D-3261 for butt fittings
ASTM F-1055 for electrofusion fittings and
ASTM F-1924 Section 3.1.6.1 for Mechanical fittings.
The material used in fitting manufacture shall be the same approved base resin
material as the connecting pipe (PE 2406 or PE 3408).
Approved Manufacturers
2.1
2.2
2.3
Mueller
TD Williamson
Continental
Date Issued:
Approved by:
07/22/03
Ed Ostrovich
Effective Date:
Written By:
04/11/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
1 of 1
ATMOS energy
Product Name: Anodeless Risers
Group Name:
Description: Anodeless Riser, Flexible and Rigid
Approved Application:
For use in service line applications
1.
Standards:
1.1
Anodeless Risers, both flexible and rigid must meet or exceeds the following requirements.
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.2
1.3
1.4
2.
Material Specification: MS8.03
Service Line Fittings
ASTM D-2513 category 1
ANSI B 1.20
ANSI B 31.8
US DOT Part 192
NFPA-58 and CSA B137.4
All gas carrying welds to be leak tested @ 100 PSI for a minimum of 10 seconds. Epoxy
coat all steel with the exception of the raised portion of the flange or threads.
Atmos must approve manufacturer drawings and specifications.
The risers shall be tested according to approved manufacturer specifications to a minimum
of 1.5 times the design factor.
Approved Vendors
2.1
Central
Date Issued:
Approved by:
11/15/05
Ed Ostrovich
Effective Date:
Written By:
11/15/05
P Tucker
Revision Date:
07/06/09
Revision: 1 Page:
1 of 1
ATMOS energy
Product Name:
Material Specification: MS8.05
Service Line Fittings
Tap Tee – Polyethylene to
Group Name:
Polyethylene
Description: Mechanical Fittings
Approved Application:
For use in service applications for new installation and repair 2” and smaller
1.
Detailed Specifications
1.1
2.
Mechanical fittings for joining polyethylene pipe to be utilized for new service installation,
service line repair and main repair on sizes 2” and smaller. All fittings must comply with
ASTM D2513 and CFR 49 part 192.
Standards
2.1
2.2
2.3
2.4
Meets or exceeds all requirements for the Categorization of Mechanical Fittings within
ASTM D2513-90c Category 1, and requirements from the Code of Federal Regulations,
Title 49 part 192.281 and 192.283.
Meets or exceeds NFPA-58-1992, DOT and ISO requirements.
Listed with IAPMO/UPC and CSA.
Exceeds all testing methods described under:
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.4.6
2.5
Material Properties include:
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
2.5.6
2.5.7
3.
Tensile Strength Test ASTM D638-86
Hydrostatic Quick Burst ASTM D1599-88
Sustained Pressure Test ASTM D1598-86
Elevated Temperature Stress Rupture ASTM D1598
Thermal Cycle Test (-25°F through 176°F)
Constant Tensile Load Joint Test
Melting Point (ASTM D789)
Water Absorption (ASTM D570)
Tensile Strength (ASTM (D638)
8700 psi @ 176°F (80°C) thru 9400 psi @ -40°F (-40°C)
Impact Strength (ASTM D256)
Long-Term Hydrostatic Strength (ASTM D2837)
2500 psi (17.2 Mpa) @ 68°F (20°C) thru 1250 psi (8.6 Mpa) @ 176°F (80°lC)
Approved Manufacturers
3.1
3.2
3.3
3.4
Continental Industries – Constab
Perfection Corporation – Permasert
US Poly – Metfit
RW Lyall – LycoFit
Date Issued:
Approved by:
07/22/03
Ed Ostrovich
Effective Date:
Written By:
04/11/05
P Tucker
Revision Date:
08/17/09
Revision: 1 Page:
1 of 1
ATMOS energy
Material Specification: MS12-01
Product Name: Thread Seal Compound
Group Name: General
Description: Sealing Compound For Threaded Connections
Approved Application:
For use on threaded connections on steel, galvanized steel, aluminum, iron
and brass.
1. Specifications
1.1. Compound shall be non-toxic.
1.2. Compound must meet AGA Requirement 4-90.
1.3. Certified to ANSI/NSF Standard 61.
1.4. Compound shall have a built-in brush.
1.5. Gas pressure rating, 2000 psig minimum.
2. Approved Manufacturers
2.1. Cameron
2.1.1. Key Tite
2.2. Hercules Real
2.2.1. Tuff (not approved for Mid-Tex)
2.3. JC Whitlam
2.3.1. Blue Magic
2.4. Jomar
2.4.1. Gimme the Green Stuff
2.5. Rectorseal
2.5.1. T Plus 2
2.5.2. No. 5
2.5.3. True Blue
2.6. LA-CO
2.6.1. SLIC-TITE (not approved for Mid-Tex)
Date Issued:
Approved By
05/12/2005
Ed Ostrovich
Effective Date:
Written By
05/12/2005
P Tucker
Revision Date:
03/01/2010
Revision: 1 Page:
1 of 1
ATMOS energy
Material Specification: 12-02
Product Name: Tracer Wire & Connectors
Group Name: General
Description: For installation with all buried plastic mains and services.
Approved Application:
For installation with all buried plastic mains and services.
1. SPECIFICATIONS - WIRE
1.1. Must meet the following specifications.
1.1.1. UL 83
1.1.2. UL 758
1.1.3. UL 1063
1.1.4. ASTM B3
1.1.5. ASTM B787
1.1.6. ASTM D1248
1.1.7. ANSI C-8.35
1.1.8. ANSI/ICEA S-70-547-2000
1.2. Wire must be 12 gauge solid, soft or annealed copper or 10 gauge for long directional bores.
1.3. Wire must be UL listed for 600 V (minimum) Gas Line Tracer Wire.
1.4. Insulation must be 30 mils yellow polyethylene HMW.
1.5. Wire shall be packaged on spools in quantities of 500 feet minimum.
2. APPROVED MANUFACTURERS – WIRE
2.1. BICC
2.2. Kalas Manufacturing
2.3. General Cable
2.4. Kris Tech
2.5. Republic Wire
2.6. Southwire
3. SPECIFICATIONS – CONNECTORS
3.1. Must meet the following specifications.
3.1.1. UL 4866D
Date Issued:
Approved by:
06/03/05
Ed Ostrovich
Effective Date:
Written by:
06/03/05
P Tucker
Revision Date:
12/20/2010
Revision: 3 Page:
1 of 2
ATMOS energy
Material Specification: 12-02
Product Name: Tracer Wire & Connectors
Group Name: General
Description: For installation with all buried plastic mains and services.
Approved Application:
For installation with all buried plastic mains and services.
4. APPROVED MANUFACTURERS - CONNECTORS
4.1. 3M
4.1.1. DBR-6
4.1.2. DBY-6
4.2. King Innovation
4.2.1. Direct Bury Dry Conn Waterproof Connectors
Date Issued:
Approved by:
06/03/05
Ed Ostrovich
Effective Date:
Written by:
06/03/05
P Tucker
Revision Date:
12/20/2010
Revision: 3 Page:
2 of 2
ATMOS energy
Product Name: Paint
Description: Paint
Approved Application:
1.
Group Name:
Material Specification: 12-06
General
District Regulator Stations, Measuring Stations, Above Ground Piping and
Compressor Station Piping
APPLICATION
1.1. This specification applies to all new installations and complete refurbishment of District
Regulator Stations, Measuring Stations and Above Ground Pipelines.
1.2. This specification does NOT apply to touch ups and residential meter sets.
2.
SURFACE PREPARATION - CARBON STEEL
2.1. All vessel nameplates, valve and regulator tags shall be taped over with two (2) layers of
painters masking tape prior to cleaning and painting. Protective tape shall be preserved
throughout the work required to complete the painting. Tape shall be removed after
painting is complete.
2.2. Carbon steel surfaces which are to be painted shall be sandblasted clean to gray metal.
Those surfaces which are inaccessible to sandblasting shall be power brushed or hand
brushed.
2.3. Sandblasting or cleaning shall be scheduled so that all surfaces prepared in this manner
can be coated with the appropriate primer prior to rusting or the onset of other corrosion.
Contractor shall be responsible for verifying that sufficient primer is on site and available
for use prior to sandblasting.
2.4. Surface preparation shall be accomplished by sand or shot blasting to conform with
SSPC-SP #6 or N.A.C.E. #3 surface preparation standards described below.
2.5. Such finish shall be defined as surface from which all oil, grease, dirt, rust, scale and
foreign matter have been completely removed and all rust, scale and old paint have been
removed except for slight shadows, streaks, or discolorations cause by rust stain or scale
oxide binder. No more than two-thirds (2/3) of the surface area shall have light
discoloration, slight staining, or light residues as mentioned above.
2.6. Prior to sandblasting Contractor shall:
2.6.1. Round off all sharp edges and remove weld splatter with power or hand tools.
Date Issued:
Approved by:
09/20/2005
Ed Ostrovich
Effective Date:
Written by:
09/20/2005
P Tucker
Revision Date:
04/01/10
Revision: 3 Page:
1 of 3
ATMOS energy
Product Name: Paint
Description: Paint
Approved Application:
Group Name:
Material Specification: 12-06
General
District Regulator Stations, Measuring Stations, Above Ground Piping and
Compressor Station Piping
2.6.2. Remove oil, grease and other surface contaminants with suitable solvent or
detergent wash.
2.6.3. Following sandblasting and prior to priming, Contractor shall remove all sand and
other residue from surface with high pressure air, vacuum or lint-free rags.
2.6.4. The sandblasted surface shall not exhibit effects of oxidation or contaminants prior
to primer application.
3.
PAINT APPLICATION SCHEDULE
3.1. The following surfaces shall be primed and painted in accordance with this Paint
Application Schedule.
3.1.1. All new, existing and relocated above grade piping, valves, fittings, flanges, vessels,
steel tanks and associated equipment.
3.1.1.1.
One (1) coat suitable primer.
3.1.1.2.
One (1) intermediate coat two component cross link epoxy.
3.1.1.3.
One (1) coat acrylic aliphatic polyurethane.
3.2. All flange rings and valve hand wheels shall be painted with the color designated by the
Company.
3.3. Aluminum conduit or stainless steel tubing will not be painted. Galvanized metal will not
be painted unless authorized by Company.
Date Issued:
Approved by:
09/20/2005
Ed Ostrovich
Effective Date:
Written by:
09/20/2005
P Tucker
Revision Date:
04/01/10
Revision: 3 Page:
2 of 3
ATMOS energy
Product Name: Paint
Description: Paint
Approved Application:
4.
Group Name:
Material Specification: 12-06
General
District Regulator Stations, Measuring Stations, Above Ground Piping and
Compressor Station Piping
COATING SPECIFICATIONS - GENERAL
4.1. Apply per manufacturer’s specified application procedures.
5.
COLORS
5.1.
Approved colors for ATMOS
5.1.1. S800 White
5.1.2. S150 Blue
5.1.3. PMS 285C Blue (Atmos Blue)
5.1.4. ASA 49 Gray
5.1.5. Color Matching as specified by Company.
6.
CLEAN UP
6.1. As work proceeds, all spills, splashes, splatters, and over sprays shall be immediately
removed.
6.2. As work proceeds, the immediate premises shall remain clear of unnecessary tools,
equipment, surplus material, and debris.
6.3. All waste, which may constitute a fire hazard, shall be placed in closed metal containers
and removed from the premises daily.
7.
APPROVED MANUFACTURERS
7.1.
Carboline
7.2.
Duron Coatings Group
7.3.
Sherwin Williams
7.4.
Wilson
Date Issued:
Approved by:
09/20/2005
Ed Ostrovich
Effective Date:
Written by:
09/20/2005
P Tucker
Revision Date:
04/01/10
Revision: 3 Page:
3 of 3
PROJECT 29151.01
101012
SECTION 00 01 10
TABLE OF CONTENTS
PROCUREMENT AND CONTRACTING REQUIREMENTS GROUP
DIVISION 00
PROCUREMENT AND CONTRACTING REQUIREMENTS
00 01 10
TABLE OF CONTENTS
00 01 15
LIST OF DRAWINGS SHEETS
00 45 13
CONTRACTOR QUALIFICATION REQUIREMENTS
SPECIFICATIONS GROUP
DIVISION 01
GENERAL REQUIREMENTS
01 11 13
SUMMARY OF WORK
01 22 00
MEASUREMENT AND PAYMENT
01 31 13
PROJECT COORDINATION
01 32 19
SUBMITTALS
01 33 23
SHOP DRAWINGS
01 33 26
QUALITY CONTROL
01 42 19
REFERENCE STANDARDS
01 50 00
TEMPORARY FACILITIES AND CONTROLS
01 66 00
DELIVERY, STORAGE AND HANDLING
01 78 39
PROJECT RECORD DOCUMENTS
DIVISION 31
EARTHWORK
31 11 00
CLEARING AND GRUBBING
DIVISION 33
UTILITIES
33 71 00
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 16
ELECTRICAL UTILITY POLES
33 71 26
OVERHEAD ELECTRICAL LINE MATERIALS
REVISION
REVISION
END OF SECTION
TABLE OF CONTENTS
00 01 10-1
PROJECT 29151.01
101012
SECTION 00 01 15
LIST OF DRAWING SHEETS
The following is a list of Construction Drawings in which this contract is to be based. These
drawings are entitled “SIA Road serving Newell Rubbermaid” and dated October 10, 2012 as
noted.
DRAWING NO.
DRAWING DESCRIPTION
U3-1
ESTIMATED QUANTITIES AND DRAWING INDEX
U3-2
COVER SHEET, LEGEND AND GENERAL NOTES
U3-3
ELECTRIC UTILITY RELOCATION BEGIN PROJECT TO STA.
109+00
U3-4
ELECTRIC UTILITY RELOCATION STA. 109+00 TO STA.
122+00
U3-5
ELECTRIC UTILITY RELOCATION STA. 122+00 TO STA.
134+00
U3-6
ELECTRIC UTILITY RELOCATION STA. 134+00 TO END
OF PROJECT
U3-7
POLE LOCATIONS AND CONDUCTOR NOTES
U3-8
CONSTRUCTION DETAILS
U3-9
CONSTRUCTION DETAILS
REVISION
END OF SECTION
LIST OF DRAWING SHEETS
00 01 15-1
PROJECT 29151.01
101012
SECTION 00 45 13
CONTRACTOR QUALIFICATION REQUIREMENTS
1) The purpose of this document is to list the qualification requirements for the Electrical
Utility Contractor (or Subcontractor) proposed for the Overhead and/or Underground
Utility work required for the completion of the Project as established in the Drawings and
Specifications.
This document also lists Electrical Utility Contractors that have been Pre-Qualified by the
Utility Owner for work required by this Project. Work on this Project is NOT in any
way restricted to the listed Pre-Qualified Electrical Utility Contractors.
Contractors that have not been Pre-Qualified shall submit the required qualifications and
information listed for the Utility Owner’s inspection. The Tennessee Department of
Transportation shall be notified as to acceptance or non-acceptance in a timely manner
prior to the start of the Project.
2) Qualification Requirements:
a) Tennessee State Contractor’s License Classification(s): CE, E or E-A
b) Five years of experience in the construction of electrical utility projects of the type
depicted in the Project Drawing and Specifications.
c) Minimum of $5 Million total value of electrical utility projects completed in the
previous calendar year.
d) Fifty (50%) percent of contractors’ overall project value shall be in the electric utility
field.
e) Minimum Bonding capacity of $5 Million.
f)
Minimum Liability Insurance Aggregate of $3,000,000.
g) Shall demonstrate availability of suitable equipment, qualified supervisory and field
crews for the type of work (including energized line work) required by the Project,
and workload to meet the Project Schedule.
3) Electrical Utility Contractors proposed by the State Contractor that are NOT listed as
“Pre-Qualified”, shall submit the following information to the Utility Owner 30
days prior to the start of the Project Construction (as listed by TDOT). The Utility
Owner will notify TDOT as to acceptance or rejection of the proposed Electrical Utility
Contractor.
a) Evidence of meeting the requirements listed in Paragraph 2, a) thru g), above.
b) References for three (3) contracts (different Utility Owners) within the past two (2)
years for similar Overhead and/or Underground Electric Line work performed by the
proposed Contractor. References shall include the names and telephone numbers of
the Utility Owner’s personnel with whom the Contractor had primary contact.
c) Detailed information of supervisory/field personnel including experience,
qualifications, and training for performing Overhead and/or Underground Electric Line
work.
CONTRACTOR QUALIFICATION REQUIREMENTS
00 45 13-1
PROJECT 29151.01
101012
d) Detailed information on any contractual penalties, OHSA violations, legal
proceedings, lawsuits or claims levied against the proposed Contractor within the
past two (2) years, contending breach of or noncompliance with contract
requirements or specifications.
4) Pre-Qualified Electrical Utility Contractors. The following Electrical Utility
Contractors have been Pre-Qualified by the Utility Owner for the Work required by this
Project:
Davis H. Elliot Co. Inc.
Attn: Keith Simpson
673 Blue Sky Parkway
Lexington, KY 40509-9459
Phone: 859-263-5148
Fax: 859-263-5468
Pike Electric
Attn: David McDuffie
100 Pike Way
Mount Airy, NC 27030
Phone: 336-789-2171
Fax: 336-719-4582
New River Electrical Corp.
Attn: Johnny Lanning
Fifteen Cloverdale Place
Cloverdale, VA 24077
Phone: 540-966-1650
Fax: 540-966-1699
Service Electric Company
Attn: Jody Shea
1631 East 25th Street
Chattanooga, TN 37404
Phone: 423-265-3161
Fax: 423-265-3960
END OF SECTION
CONTRACTOR QUALIFICATION REQUIREMENTS
00 45 13-2
PROJECT 29151.01
101012
SECTION 01 11 13
SUMMARY OF WORK
PART 1. GENERAL
1.01
SUMMARY
A.
The "Project," of which the "Work" of this Contract is a part, is titled “SIA Road
serving Newell Rubbermaid”.
B.
The "Work" of this Contract is defined in the Contract Documents to include
furnishing and paying for all necessary materials, labor, tools, equipment, and
other items, and constructing complete in every detail and ready for Utility
Owner’s beneficial use, as specified herein, and/or indicated on the Contract
Drawings listed elsewhere in these specifications. This project shall consist
generally of but not be limited to the following items:
Overhead Electrical Distribution System
1. Metal Poles.
2. Overhead Assemblies.
3. Stringing/Sagging Conductors.
4. Switches.
5. Distribution Systems.
6. Easement Clearing.
7. Transformers and Service Equipment.
8. Temporary Construction Facilities.
C.
1.02
Contractor shall correct all deficiencies in “Work” by the Contractor as may be
indicated by testing and as directed by the Engineer.
RELATED SECTIONS
A.
Documents affecting work of this Section include, but are not necessarily limited
to Sections in DIVISION 1 of these Specifications and other Sections as listed
below:
B.
Section 01 22 00 – MEASUREMENT AND PAYMENT
C.
Section 01 50 00 – TEMPORARY FACILITIES AND CONTROLS
D.
Section 33 71 00 – OVERHEAD ELECTRICAL LINE CONSTRUCTION
E.
Section 33 71 26 – OVERHEAD ELECTRICAL LINE MATERIALS
1.03
WORK CONDITIONS
A.
All of the work will be done with existing facilities energized.
B.
The Contractor shall take all necessary precautions and use the appropriate safety
work methods for working on energized facilities as may be specified by Federal,
State, Local, or other appropriate regulatory authority.
SUMMARY OF WORK
01 11 13-1
PROJECT 29151.01
1.04
101012
TEMPORARY CONSTRUCTION FACILITIES
A.
See Section 01 50 00 – TEMPORARY FACILITIES AND CONTROLS for requirements
for temporary construction facilities.
1.05
SERVICE OUTAGES
A.
All Contractor requested outages shall be coordinated with the Utility Owner. A
representative of the Contractor shall be on-site during outages. Exact details of
the outages, including date, time, duration and facilities involved, shall be
presented to the Utility Owner at least two working days prior to proposed outage.
1.06
UTILITY OWNER FURNISHED MATERIALS
A.
The Table below is a tabulation of the equipment to be furnished by the Utility
Owner and/or others. Updated equipment delivery information will be provided to
the Contractor when it is available.
ITEM
QUANTITY
DESCRIPTION
VALUE
1
3
Pole-Mounted Transformers
See 1.08
1.07
A.
UTILITY OWNER FURNISHED WORK
The Utility Owner will furnish:
1.
1.08
A.
Labor for coordination and operations of the electric system that is required
by construction activities. This includes activities such as power system
switching operations and controls. This does not include items such as project
construction activities or temporary facilities not specifically listed as Utility
Owner Furnished Work.
UTILITY OWNER’S SALVAGE MATERIALS
The salvage materials listed below are to be removed by the Contractor and
returned to the Utility Owner at the location designated.
1.
The following items shall be returned to the Utility Owner’s warehouse:
a.
Pole-mounted Transformers
SUMMARY OF WORK
01 11 13-2
PROJECT 29151.01
1.9
101012
ENERGIZING FACILITIES
A.
The Engineer will review Project related Test Reports and the Work. After review
and acceptance of the Test Reports and Work, the Engineer and Utility Owner will
determine the suitability of the facility to be energized.
B.
The facilities will not be accepted for energizing without the appropriate safe
guards in place as required by Utility Owner, Federal, State, Local, or other
appropriate regulatory authority.
C.
The Contractor shall be on site during the energizing of all facilities.
1.10
QUALITY ASSURANCE
A.
Perform all work in accordance with applicable codes and standards.
B.
Maintain at least one copy of Contract Drawings and Manufacturers’ recommended
installation methods on site at all times.
END OF SECTION
SUMMARY OF WORK
01 11 13-3
PROJECT 29151.01
101012
SECTION 00 12 00
MEASUREMENT AND PAYMENT
PART 1.
1.01
A.
1.02
A.
1.03
A.
1.04
GENERAL
SECTION INCLUDES
Description of basic units and assemblies used in the Work.
RELATED SECTIONS
Documents affecting work of this Section include, but are not necessarily limited to,
General Conditions, Supplementary Conditions, and Sections in DIVISION 1 of these
Specifications.
SUBMITTALS
As required by and described in the General Conditions, Contractor shall prepare and
submit a Schedule of Values to be compatible with the Application for Payment.
ASSEMBLY UNIT BASIS
A.
The construction assemblies are on a unit basis or as otherwise indicated below so
that the Utility Owner may authorize any combination, addition, or deletion of
construction units desired.
B.
The descriptions apply to those assemblies on the project drawings and assembly
guide drawings and includes all necessary labor and material required to make the
assemblies complete.
1.05
ASSEMBLY GUIDE DRAWINGS AND PROJECT CONSTRUCTION DRAWINGS
A.
The assembly and guide drawings are diagrammatic indicating major items of
materials and general arrangement of assemblies to establish a standard of
construction.
B.
Conditions encountered in the field
assembly guide drawings, and the
accommodate the field conditions
determine the most suitable method
1.06
A.
may vary materially from those shown on the
construction shall be modified as required to
involved. In special cases the Engineer will
of framing to be used.
UNIT PRICE METHOD OF MEASUREMENT
The Unit Prices, as stated in the Contract Documents, shall include all necessary
labor, material, equipment, basic supplies, overhead, profit and applicable taxes to
provide a complete Unit ready for the Utility Owners use. The Unit shall include all
items and shall be measured as described below and in the appropriate detail/guide
drawings.
MEASUREMENT AND PAYMENT
01 22 00-1
PROJECT 29151.01
B.
101012
Installation Assemblies
1.
Pole unit shall consist of one pole in place and shall be measured on a per unit
basis. The first two digits of the unit description indicate length; the third shows
ASA classification. Thus 35-4 signifies a 35 foot class 4 pole.
Unit consists of
necessary means of excavation required by the types of soils and interferences
encountered, and specified backfilling around pole. Unit price shall include any
necessary repair or replacement of existing concrete, asphalt, or other
manmade surfaces disturbed by excavation.
2.
Pole Top Assemblies shall consist of the hardware, crossarms and their
appurtenances, insulators, and connectors installed as required to support the
conductors and measured on a per unit basis. Unit does include all required field
drilling for installation of assembly.
3.
Conductor units shall consist of 1 Linear Foot of single conductor, and shall be
measured by the horizontal distance between conductor supports. The unit
includes proper stringing and sagging, tie wires, sleeves for splicing, connectors,
and armor rods; jumpers and connections at deadends, junctions and taps.
Designation of each conductor shall be by the Manufacturer's industry standard
designations.
4.
Guy units shall consist of the necessary length of guy wire, pole attachment
fittings bolts, lag screws, guy bonding bolt, guy strain insulators, guy grips,
clamps, etc., and all grounding jumpers and connectors. Unit shall include the
wire length between pole attachment and anchor attachment, or in the case of
overhead guys, to pole attachments. Unit description is applicable to both
overhead and down guys. Guy markers are not included with the guy unit,
unless otherwise indicated.
5.
Each anchor unit shall consist of the anchor, rod, and eye nut installed complete
and ready for attaching the guy wire, and shall be measured on a per unit basis.
Includes all shear pins as required for power anchor installation when specified.
6.
Secondary and Service Assemblies shall consist of the hardware, insulators, tie
wire, armor tape, armor rods, all appropriate size and type connectors, tying,
sagging and re-sagging, handling, holding and splicing of all cables whether
new, or existing, and those transferred from an existing position to a new
position on the same pole, or to a new pole. Unit shall be measured on a per
unit basis.
7.
The following are descriptions of assemblies that are not explicit or shown on
the Contract Drawings.
a.
Grounding units consist of the pole ground wire, staples, plates, wraps, or
rods, all connector, clamps and associated hardware and jumper leads
required to interconnect conductors and equipment that are to be
grounded.
b.
Transformers
1) Consists of the transformer, primary and secondary jumpers and
leads, length and size as required, hot line clamps, connectors and
mounting hardware.
MEASUREMENT AND PAYMENT
01 22 00-2
PROJECT 29151.01
101012
2)
Protective equipment, crossarms, insulator, and steel pins are called
for separately, unless designated on the assembly guide drawings.
3)
Transformers that are transferred shall be reconnected like the
existing wiring scheme using the existing size jumpers and leads as a
minimum size for the new installation.
c.
C.
Line Protection Equipment
1) Consists of the hardware, appropriate size and type of jumpers, leads
and all connectors, and clamps, mounting brackets, fuse links, etc.,
required to install fused cutouts, lightning arresters, switches, etc.
Removal Assemblies
1.
Removal assembly units cover the furnishing of all labor for removal of existing
units of construction from existing lines, disassembling into material items, and
all labor and transportation for the returning of all materials in groups of like
items to the warehouse of the Utility Owner or other location as specified in the
Contract Documents.
2.
Contractor shall reinstall at his own expense any other units removed by him for
his own convenience.
3.
Existing materials turned in to the Utility Owner shall be verified with the
inventory of unit assemblies removed. Material items not turned in will be
charged to the Contractor at the Utility Owner's present stock value. Keep
accurate records of the material item breakdown turned in and have the Utility
Owner's representative verify accuracy of this inventory. A summary of this
inventory, verified by the Utility Owner, shall be given to the Engineer at the
completion of the project.
4.
The unit of removal shall include any holding or handling of conductors where
such is involved, and re-installing as required.
5.
Materials damaged due to negligence and/or improper handling will be charged
to the Contractor at the Utility Owner's present stock value. No charge will be
made for material items returned to the Utility Owner which, in the opinion of
the Utility Owner or the Engineer, were not damaged in removal and handling
even though the materials may not be reusable for reasons of obsolescence or
deterioration.
a.
Poles - All poles of the same height, regardless of pole class, are
designated by the same unit. Do not remove ground wire or pole numbers
from the pole. Where concrete, asphalt, or other man-made surfaces are
encountered the replacement surface shall be that of the surrounding
surface and shall be included in the bid price.
b.
Pole-top Assemblies - The unit of removal of pole-top assemblies includes
all hardware, crossarms and their appurtenances, insulators, and
connectors.
MEASUREMENT AND PAYMENT
01 22 00-3
PROJECT 29151.01
D.
E.
101012
c.
Conductors - Removal unit for each size of conductor or cable is shown by
the conductor or cable type, and consists of 1 Linear Foot of single
conductor and is the measured horizontal distance between conductor
supports. If unit is to be completely removed from Project and stored,
remove in the longest practical length, preferably between deadends,
without unnecessary kinking or nicking. Coil or reel all conductors for
delivery to the Utility Owner. Remove and retain possession of all tie wire,
armor rods, jumpers, and miscellaneous connectors. The Utility Owner will
furnish reels if the conductor is to be returned to the Utility Owner’s
warehouse on reels. The Utility Owner will charge $150.00 for each reel
that is not returned or returned in a damaged condition.
d.
Guys - Remove and coil guy strand in the longest practical length.
Dismantle all three-bolt clamps, guy attachments, bonding bolts and guy
markers.
e.
Anchors - Only anchor rods are to be removed in the anchor removal units.
If the rod cannot be unscrewed, the end of the rod shall either be cut off or
bent down so that the rod will be at least 18 inches below the ground line.
f.
All other units designed for removal shall include hardware, convection,
insulators, or other items of our existing assembly: and include all
necessary handling or holding, untying, re-sagging, retiring, or re-installing
conductors to remain.
Transferred Assemblies
1.
For all transferred units, unit price measurement shall include any necessary
labor and equipment to transport the unit from one site to another, or to handle
the unit in place while it is detached and then reattached. If conductor is shown
on Contract Drawings as transferred, unit will include moving the conductor
from the aerial suspension and connection to the pole-top assembly. Unit would
not include stringing, but would include sagging.
2.
Consists of furnishing of all labor for removing and re-installing the unit
specified from one location to another on the same or a new pole. Includes
materials such as bolts, armor rods, connectors, clamps, splices, leads and
jumpers, insulators, and all mounting hardware and supports the handling or
holding of conductors, and untying, re-sagging, and retiring, all as required to
re-install the unit in the new locations. Material in the transfer unit such as
bolts of proper length and size, brackets, and other items may be reused if in
satisfactory condition. All other items required to re-install the unit shall be
included in the Bid Price.
3.
Also includes the removal and reattachment of any or all conductors associated
with the unit, any sagging or re-sagging, tying, untying and re-tying, armor
rodding or re-armor rodding, all splices, connectors, etc., and any other labor
and hardware required to make a complete assembly.
Easement Clearing
1.
Line Easement Clearing unit shall consist of clearing an easement corridor with a
lump sum unit as indicated on the Contract Drawings. Payment shall be on a
MEASUREMENT AND PAYMENT
01 22 00-4
PROJECT 29151.01
101012
lump sum basis and shall include clearing of all foliage, underbrush, tree
removal, and such tree trimming as indicated on the Contract Documents. This
unit shall not include removal of any danger trees.
2.
F.
1.07
Danger trees shall be included in the line easement lump sum bid price and shall
include clearing and removal of such units as indicated by the Utility Owner.
Existing Assemblies and Conditions
1.
When existing assemblies are encountered include attention and maintenance
work such as re-stapling pole grounds, inspecting and tightening nuts/locknuts
and grounding bonds, securing the wires, backfilling existing poles, and other
work to miscellaneous item such that the integrity of the existing assembly is
assured.
2.
Include such work in the Bid Price. Any change or replacement to an existing
assembly shall be approved prior to commencement of work on an assembly.
QUALITY ASSURANCE
A.
Use required means to assure arithmetical accuracy of the sums described.
B.
When so required by the Engineer, provide copies of the subcontracts or other data
acceptable to the Engineer, substantiating the sums described.
END OF SECTION
MEASUREMENT AND PAYMENT
01 22 00-5
PROJECT 29151.01
101012
SECTION 01 31 13
PROJECT COORDINATION
PART 1.
1.01
GENERAL
SECTION INCLUDES
A.
Coordination
B.
Project Representatives and Addresses
1.02
A.
1.03
A.
B.
COORDINATION
All work, submittals, and testing shall be coordinated with the Work listed in the
Contract Documents to assure efficient progress of the Project Construction.
PROJECT REPRESENTATIVES AND ADDRESS
Owner:
Shelbyville Power, Water & Sewerage
Address:
308 South Main Street
Shelbyville, Tennessee 37160
Phone:
Fax:
(931) 684-7171
(931) 685-0113
Primary Contact:
Pruitt Marshall
Engineer:
Gresham, Smith and Partners
Address:
1111 N. Northshore Drive, Suite S-400
Knoxville, Tennessee 37919
Phone:
Fax:
(865) 521-6777
(865) 539-7192
Primary Contact:
Richard Yeager
Alternate Contact:
Mark Washing, P.E.
C.
All correspondence, submittals and shop drawings shall be submitted to the
Tennessee Department of Transportation (TDOT) Project Supervisor.
D.
Forward a copy of all correspondence addressed to the TDOT Project Supervisor to
the Utility Owner.
E.
All correspondence, submittals or other items associated with the Contract shall be
identified by the Utility Owner and Project name as listed in the Contract Documents.
END OF SECTION
PROJECT COORDINATION
01 31 13-1
PROJECT 29151.01
101012
SECTION 01 32 19
SUBMITTALS
PART 1.
1.01
GENERAL
SECTION INCLUDES
A.
Submittal Procedures
B.
Construction and Progress Schedules
1.02
RELATED SECTIONS
A.
DIVISIONS 0 and 1 - CONTRACT DOCUMENTS, and GENERAL REQUIREMENTS:
These shall apply to all work included in this section.
B.
Section 01 22 00 – MEASUREMENT AND PAYMENT
C.
Section 01 31 13 – PROJECT COORDINATION
D.
Section 01 33 23 – SHOP DRAWINGS
E.
Section 01 33 26 – QUALITY CONTROL
F.
Section 01 78 39 – PROJECT RECORD DOCUMENTS
1.03
SUBMITTAL PROCEDURES
A.
Transmit each submittal with transmittal letter or Engineer accepted form.
Sequentially number the transmittal forms.
Re-submittals to have original
number with an alphabetic suffix.
B.
Submit shop drawings as specified in Section 01 33 23 - SHOP DRAWINGS.
C.
Identify project, Contractor, subcontractor or supplier; pertinent drawing sheet
and detail number(s), and specification section number, as appropriate.
D.
Schedule submittals to expedite the project, and deliver to Engineer with copy of
transmittal letter to Utility Owner's representative as identified in Section 01 31
13 - PROJECT COORDINATION.
E.
Identify variations from Contract Documents and product or system limitations
which may be detrimental to successful performance of the completed Work.
F.
Provide space for Contractor and Engineer review stamps.
G.
Revise and re-submit submittals as required, identify all changes made since
previous submittal.
H.
Distribute copies of reviewed submittals to concerned parties. Instruct parties to
promptly report any inability to comply with provisions.
SUBMITTALS
01 32 19-1
PROJECT 29151.01
1.04
A.
101012
SUBMITTAL SCHEDULE
Provide schedule for project submittals in accordance with the specifications and
as agreed to by the Utility Owner and the Tennessee Department of
Transportation (TDOT) Project Supervisor.
END OF SECTION
SUBMITTALS
01 32 19-2
PROJECT 29151.01
101012
SECTION 01 33 23
SHOP DRAWINGS
PART 1. GENERAL
1.01
A.
1.02
SECTION INCLUDES
Submit Shop Drawings and product data required by contract documents.
RELATED SECTIONS
A.
DIVISIONS 0 and 1 - CONTRACT DOCUMENTS, and GENERAL REQUIREMENTS:
These shall apply to all work included in this section.
B.
Section 01 31 29 – SUBMITTALS
C.
Section 01 78 39 – PROJECT RECORD DOCUMENTS
1.03
SHOP DRAWINGS
A.
Shop drawings shall include: fabrication information; material lists; manufacturer's
catalog sheets and/or descriptive data, showing dimensions, performance
characteristics, and capacities; electrical characteristics, and capacities; and other
pertinent information as required to obtain approval of the items involved.
B.
Drawings shall be presented in a clear and thorough manner.
1.
1.04
A.
B.
1.05
A.
Details shall be identified by reference to sheet and detail numbers shown on
Contract Drawings and Specification Sections.
PRODUCT DATA
Preparation:
1.
Clearly mark each copy to identify pertinent products or models.
2.
Show dimensions and clearances required.
Manufacturer's standard drawings and diagrams:
1.
Modify drawings and diagrams to delete information which is not applicable to
the Work.
2.
Supplement standard information to provide information specifically applicable
to the Work.
CONTRACTOR RESPONSIBILITIES
Designate in the construction schedule, or in a separate coordinated schedule, the
dates for submission and the dates that reviewed Shop Drawings and product data
will be required to maintain construction schedule.
SHOP DRAWINGS
01 33 23-1
PROJECT 29151.01
101012
B.
Review Shop Drawings and Product Data prior to submission.
C.
Contractor is responsible for review of all Subcontractor and supplier submittals.
D.
Determine and verify:
1.
Field measurements
2.
Field construction criteria
3.
Catalog numbers and similar data
4.
Conformance with specifications
E.
Coordinate each submittal with requirements of the Work and of Contract
Documents.
F.
Notify the Utility Owner/Engineer in writing, at time of submission, of any deviations
in the submittals from requirements of the Contract Documents.
G.
Begin no fabrication or work which required submittals until return of submittals with
satisfactory review.
1.06
SUBMISSION REQUIREMENTS
A.
Make submittals promptly in accordance with approved schedule, and in such
sequence as to cause no delay in the work or in the work of any other contractor.
B.
Number of submittals required:
C.
1.
Shop Drawings: Submit three (3) paper copies of shop drawings of all items for
which shop drawings are specified in other sections, and for all major equipment
items.
2.
Product Data: Submit three (3) copies of product data of all items for which
product data is specified in other sections and for all major items.
3.
One (1) copy of electronic data files of all drawings prepared for the project.
Format shall be either CAD format (.DGN or .DWG), or PDF format. Media shall
be CD-ROM.
Submittals shall contain:
1.
Submittal identification number. Submittals shall be numbered consecutively.
Re-submittals shall use the same submittal number with an alphabetic suffix
added.
2.
The date of submission and the dates of any previous submissions.
3.
The project title and number.
SHOP DRAWINGS
01 33 23-2
PROJECT 29151.01
101012
4.
The
a.
b.
c.
d.
names of:
Contractor
Subcontractor
Supplier
Manufacturer
5.
Identification of the project, with the specification section number.
6.
Field dimensions, clearly identified as such.
7.
Relation to adjacent or critical features of the work or materials.
8.
Applicable standards, such as ASTM or Federal Specification numbers.
9.
Identification of deviations from Contract Documents.
10. Identification of revisions on resubmittals.
11. An 8"x3" blank space for Contractor and Engineer stamps.
12. Contractor's stamp, initialed or signed, certifying to review of submittal,
verification of products, field measurements and field construction criteria, and
coordination of the information within the submittal with requirements of the
Work of Contract Documents.
1.07
A.
1.08
RETURN FOR RE-SUBMISSION
The Engineer will return for resubmission all shop drawings submitted without the
above specified approval and certification which in the Engineers opinion contain
numerous discrepancies, have not been checked, or do not meet the requirements
for submission.
REVIEW OF SUBMITTALS
A.
The Engineer will review, mark and date all submitted shop drawings. Two (2) sets
will be returned to the Contractor and remaining sets will be retained by the
Engineer. Contractor shall make corrections and changes as indicated.
B.
Resubmit shop drawings as specified above, until satisfactory review has been
obtained. Corrections and/or changes indicated on shop drawings by Engineer/Utility
Owner shall not be considered as an extra work order.
C.
After satisfactory "Review" or "Furnish as Corrected" has been obtained for all shop
drawings, three (3) copies of shop drawings marked "FOR CONSTRUCTION" shall be
furnished to the Utility Owner/Engineer within 21 days of receipt of approval
drawings by Contractor. Format of electronic data files shall be as specified in Article
1.06, above.
D.
Review of shop drawings by the Utility Owner/Engineer will be general only, and such
review will not relieve the Contractor of responsibility for accuracy of such shop
drawings, proper fitting, coordination, construction of work, and furnishing materials
required by the Specifications but not indicated on shop drawings. Review of shop
drawings shall not be construed as approving departures from the Specifications.
SHOP DRAWINGS
01 33 23-3
PROJECT 29151.01
1.09
A.
1.10
101012
DISTRIBUTION
Distribute copies of Shop Drawings and copies of Product Data which carry the
Engineer stamp of approval to:
1.
Job site file
2.
Record Documents File
3.
Other affected contractors
4.
Subcontractors
5.
Supplier or fabricator
UTILITY OWNER / ENGINEER DUTIES
A.
Review submittals with reasonable promptness and in accordance with schedule.
B.
Affix stamp and initials or signature, and indicate requirements for resubmittal, or
satisfactory review of submittal.
C.
Return submittals to Contractor for distribution, or for re-submission.
END OF DOCUMENT
SHOP DRAWINGS
01 33 23-4
PROJECT 29151.01
101012
SECTION 01 33 26
QUALITY CONTROL
PART 1.
1.01
A.
1.02
A.
1.03
GENERAL
SECTION INCLUDES
Required inspection and testing services are intended to assist in the determination
of compliance of the work with the quality standards specified or indicated.
RELATED SECTIONS
DIVISIONS 0 and 1 - CONTRACT DOCUMENTS, and GENERAL REQUIREMENTS:
These shall apply to all work included in this section.
QUALITY OF WORK
A.
Perform all work in the most workmanlike manner and according to the best
standard practices. All work shall be free from faults and defects in workmanship.
B.
Contractor shall be solely responsible for quality control of the work and shall
maintain quality control over suppliers, manufacturers, products, services, site
conditions and workmanship, to produce work of specified quality.
C.
Required testing and inspection are intended to assist in determination of probable
compliance of the Work with the Contract Documents, but do not relieve Contractor
of responsibility for this compliance.
Specified testing and inspection are not
intended to limit Contractor's quality control program.
D.
Contractor shall submit a Project Quality Control Plan.
END OF DOCUMENT
QUALITY CONTROL
01 33 26-1
PROJECT 29151.01
101012
SECTION 01 42 19
REFERENCE STANDARDS
PART 1.
1.01
GENERAL
SECTION INCLUDES
A.
Quality Assurance
B.
Schedule of References
1.02
QUALITY ASSURANCE
A.
Comply with latest revision of the standard for all equipment, materials and
labor, except when more rigid requirements are specified or are required by
applicable codes.
B.
Request clarification from Engineer before proceeding, should specified reference
standards conflict with Contract Documents.
1.03
A.
SCHEDULE OF REFERENCE
Documents and/or Standards from the following agencies may be referenced in
the Contract Documents:
AA
Aluminum Association
AASHTO
American Association of State Highway and Transportation Officials
ACI
American Concrete Institute
AISC
American Institute of Steel Construction
ANSI
American National Standards Institute
ASCE
American Society of Civil Engineers
ASME
American Society of Mechanical Engineers
ASTM
American Society for Testing and Materials
AWS
American Welding Society
CRSI
Concrete Reinforcing Steel Institute
CSI
Construction Specifications Institute
EEI
Edison Electric Institute
EPA
Environmental Protection Agency
REFERENCE STANDARDS
01 42 19-1
PROJECT 29151.01
101012
ICEA
Insulated Cable Engineers' Association
IEEE
Institute of Electrical and Electronics Engineers
NEC
National Electrical Code
NECA
National Electrical Contractors Association
NEMA
National Electrical Manufacturers' Association
NESC
National Electrical Safety Code
NFPA
National Fire Protection Association
OSHA
Occupational Safety and Health Administration
SSPC
Steel Structures Painting Council
RUS
Rural Utilities Service
UL
Underwriters' Laboratories, Inc.
END OF SECTION
REFERENCE STANDARDS
01 42 19-2
PROJECT 29151.01
101012
SECTION 01 50 00
TEMPORARY FACILITIES AND CONTROLS
PART 1.
1.01
A.
1.02
A.
1.03
A.
SECTION INCLUDES
Summary of temporary facilities and controls that are required for the Work, such
as:
1.
Overhead line construction guard structures
2.
Construction Cleaning
RELATED SECTIONS
DIVISIONS 0 and 1 - PROPOSAL DOCUMENTS, MATERIALS CONTRACT AND
GENERAL REQUIREMENTS: These shall apply to all work included in this section.
REFERENCES
Published Specifications, standards, tests, or recommended methods of trade,
industry, or governmental organizations apply to work in this section where cited in
Section 01 42 19 - REFERENCE STANDARDS.
PART 2.
2.01
A.
EXECUTION
TEMPORARY GUARD STRUCTURES
Utility and Road Crossings.
1.
B.
GENERAL
The contractor shall furnish and install all guard structures required for all
crossings over electric supply lines, communication lines, railroads, roads,
highways, and other obstructions, and for the protection of the conductors. The
Utility Owner shall obtain the necessary permissions or permits for stringing
conductors over utilities, railroads, and other obstructions. The Contractor shall
make adequate preparations to safely cross all facilities with a minimum of
inconvenience and delay to the public.
Project Clean Up
1.
The site shall be maintained and kept clean and free from rubbish, unused
materials, and equipment during the construction period. Materials known to
belong to others shall not be removed from the site without duly notifying the
Owner thereof.
2.
Upon completion of the work the Contractor shall remove all construction
equipment and unused materials provided for the Work.
END OF SECTION
TEMPORARY FACILITIES AND CONTROLS
01 50 00-1
PROJECT 29151.01
101012
SECTION 01 66 00
DELIVERY, STORAGE AND HANDLING
PART 1.
1.01
GENERAL
SUMMARY
A.
Protect products scheduled for use in the Work by means including, but not
necessarily limited to, those described in this Section.
B.
Related Work:
1.02
A.
1.03
A.
1.04
A.
B.
1.05
1.
Documents affecting work of this Section include, but are not necessarily limited
to Sections in Division 1 of these Specifications.
2.
Additional procedures also may be prescribed in other Sections of these
Specifications.
QUALITY ASSURANCE
Include within the Contractor's quality assurance program such procedures as are
required to assure full protection of work and materials.
MANUFACTURERS' RECOMMENDATIONS
Except as otherwise approved by the Utility Owner, determine and comply with
manufacturers' recommendations on product handling, storage, and protection.
PACKAGING
Deliver products to the job site in their manufacturer's original container, with labels
intact and legible.
1.
Maintain packaged materials with seals unbroken and labels intact until time of
use.
2.
Promptly remove damaged material and unsuitable items from the job site, and
promptly replace with material meeting the specified requirements, at no
additional cost to the Utility Owner.
The Utility Owner may reject as non-complying such material and products that do
not bear identification satisfactory to the Utility Owner as to manufacturer, grade,
quality, and other pertinent information.
PROTECTION AND HANDLING
A.
Protect finished surfaces, including jambs and soffits of openings used as
passageways, through which equipment and materials are handled.
B.
Provide protection for finished floor surfaces in traffic areas prior to allowing
equipment or materials to be moved over such surfaces.
DELIVERY, STORAGE AND HANDLING
01 66 00-1
PROJECT 29151.01
C.
1.06
101012
Maintain finished surfaces clean, unmarred, and suitably protected until accepted by
the Utility Owner.
REPAIRS AND REPLACEMENTS
A.
In event of damage, promptly make replacements and repairs to the approval of the
Utility Owner and at no additional cost to the Utility Owner or the Tennessee
Department of Transportation (TDOT).
B.
Additional time required to secure replacements and to make repairs will not be
considered by the Utility Owner to justify an extension in the Contract Time of
Completion.
END OF SECTION
DELIVERY, STORAGE AND HANDLING
01 66 00-2
PROJECT 29151.01
101012
SECTION 01 78 39
PROJECT RECORD DOCUMENTS
PART 1.
1.01
GENERAL
SECTION INCLUDES
A.
Record of changes
B.
Final “As-Built” drawings
C.
Operation and maintenance manuals
1.02
RELATED SECTIONS
A.
DIVISIONS 0 and 1 - CONTRACT DOCUMENTS, and GENERAL REQUIREMENTS:
These shall apply to all work included in this section.
B.
Other requirements affecting Project Record Documents may appear in pertinent
other Sections of these Specifications.
1.03
A.
1.04
SUBMITTALS
Comply with pertinent provisions of Section 01 32 19 - SUBMITTALS
QUALITY ASSURANCE
A.
Delegate the responsibility for maintenance of Record Documents to one person on
the Contractor's staff as approved by the Engineer.
B.
Accuracy of records:
C.
1.05
1.
Thoroughly coordinate changes within the Record Documents, making adequate
and proper entries on each page of Specifications and each sheet of Drawings
and other Documents where such entry is required to show the change properly.
2.
Accuracy of records shall be such that future search for items shown in the
Contract Documents may rely reasonably on information obtained from the
approved Project Record Documents.
Make entries within 24 hours after receipt of information that the change has
occurred.
DELIVERY, STORAGE, AND HANDLING
A.
Maintain the job set of Record Documents completely protected from deterioration
and from loss and damage until completion of the Work and transfer of all recorded
data to the final Project Record Documents.
B.
In the event of loss of recorded data, use means necessary to again secure the data
to the Engineer's approval.
PROJECT RECORD DOCUMENTS
01 78 39-1
PROJECT 29151.01
1.
Such means shall include, if necessary in the opinion of the Engineer, removal
and replacement of concealing materials by Contractor at his cost.
2.
In such case, provide replacements to the standards originally required by the
Contract Documents by Contractor at his cost.
PART 2.
2.01
A.
PRODUCTS
RECORD DOCUMENTS
Job set: Promptly following the Effective Date of Agreement secure from the
Engineer at no charge to the Contractor one complete set of all Documents
comprising the Contract.
PART 3.
3.01
101012
EXECUTION
MAINTENANCE OF JOB SET
A.
Immediately upon receipt of the job set described in Paragraph 2.01-A above,
identify each of the Documents with the title, "RECORD DOCUMENTS - JOB SET."
B.
Preservation:
C.
1.
Considering the Contract completion time, the probable number of occasions
upon which the job set must be taken out for new entries and for examination,
and the conditions under which these activities will be performed, devise a
suitable method for protecting the job set to the approval of the Engineer.
2.
Do not use the job set for any purpose except entry of new data and for review
by the Engineer, until start of transfer of data to final Project Record
Documents.
Making entries on Drawings:
1.
Using an erasable colored pencil (not ink or indelible pencil), clearly describe the
change by graphic line and note as required.
2.
Date all entries.
3.
Call attention to the entry by a "cloud" drawn around the area or areas affected.
4.
In the event of overlapping changes, use different colors for the overlapping
changes.
D.
Make entries in the pertinent other Documents as approved by the Engineer.
E.
Drawings shall clearly show actual installed locations, depth, and sizes of:
1.
Electrical Utility Poles
PROJECT RECORD DOCUMENTS
01 78 39-2
PROJECT 29151.01
F.
Conversion of schematic layouts:
1.
In some cases on the Drawings, arrangements of conduits, circuits, piping,
ducts, and similar items, is shown schematically and is not intended to portray
precise physical layout.
a.
b.
2.
G.
3.02
101012
Final physical arrangement is determined by the Contractor, subject to the
Engineer's approval.
However, design of future modifications of the facility may require accurate
information as to the final physical layout of items which are shown only
schematically on the Drawings.
The Engineer may waive the requirements for conversion of schematic layouts
where, in the Engineer's judgment, conversion serves no useful purpose.
However, do not rely upon waivers being issued except as specifically issued in
writing by the Engineer.
Review and submittal:
1.
Submit the completed set of Project Record Documents to the Engineer as
described in Paragraph 1.02-D above.
2.
Participate in review meetings as required.
3.
Make required changes and promptly deliver the Project Record Documents to
the Engineer.
FINAL DRAWINGS
A.
At completion of project, the Contractor shall incorporate all revisions into the shop
drawings to provide a complete set of final drawings. The drawings shall be marked
as "Final-As Constructed".
B.
Submit three (3) paper copies of all shop drawings. Maximum size of all drawings is
22"x34".
C.
One (1) copy of electronic data files of all drawings prepared for the project. Format
shall be CAD format (.DGN or .DWG) or PDF format. Media shall be CD-ROM.
END OF DOCUMENT
PROJECT RECORD DOCUMENTS
01 78 39-3
PROJECT 29151.01
101012
SECTION 31 11 00
CLEARING AND GRUBBING
PART 1.
1.01
A.
1.02
GENERAL
SECTION INCLUDES
Clearing and Cleaning areas outside State Right-of-Way of Plant Life, Trees, Shrubs,
and Debris.
RELATED SECTIONS
A.
DIVISIONS 0 and 1 - PROPOSAL DOCUMENTS, MATERIALS CONTRACT AND
GENERAL REQUIREMENTS: These shall apply to all work included in this section.
B.
Section 01 22 00 – MEASUREMENT AND PAYMENT
PART 2.
2.01
A.
EXECUTION
CLEARING AND GRUBBING
Clear and Grub the Following Areas:
1.
All areas outside of State Right-of-Way as required to clear the construction,
and/or to the limits indicated on the Contract Drawings.
B.
In all areas requiring clearing and grubbing, completely remove all trees, stumps,
roots, brush, weeds, vegetation, and other unsuitable materials. Refill to proper
elevation all holes resulting from the grubbing operations, and compact the fill as
specified in other sections.
C.
Dispose of all spoil materials by removal to a TDOT approved disposal area away
from the project site.
D.
Clean and clear out undergrowth and dead wood, without disturbing compaction of
subsoil.
E.
Burning of debris on the site shall NOT BE PERMITTED.
2.02
PROTECTION
A.
Protect plant growth and features remaining as final landscaping.
B.
Protect bench marks and existing work from damage or displacement.
C.
Maintain designated site access for vehicle and pedestrian traffic.
END OF SECTION
CLEARING AND GRUBBING
31 11 00-1
PROJECT 29151.01
101012
SECTION 33 71 00
OVERHEAD ELECTRICAL LINE CONSTRUCTION
PART 1.
1.01
GENERAL
SECTION INCLUDES
A.
Overhead electric system line construction.
B.
Furnishing necessary equipment and incidental materials to install the specified
assemblies in the quantities required by the Contract Drawings and these
Specifications to provide a complete and working installation.
C.
Basic methods and test reports.
D.
Removals of existing facilities as shown in the Contract Drawings.
1.02
RELATED SECTIONS
A.
DIVISIONS 0 and 1 – CONTRACT DOCUMENTS AND GENERAL REQUIREMENTS:
These shall apply to all work included in this section.
B.
Section 01 11 13 – SUMMARY OF WORK
C.
Section 01 22 00 – MEASUREMENT AND PAYMENT
D.
Section 33 71 16 – ELECTRICAL UTILITY POLES
E.
Section 33 71 26 – OVERHEAD ELECTRICAL LINE MATERIALS
1.03
A.
REFERENCES
Published Specifications, standards, tests, or recommended methods of trade,
industry, or governmental organizations apply to work in this section where cited in
Section 01 42 19 – REFERENCE STANDARDS and in the listing below:
1. “The Lineman’s and Cableman’s Handbook”, McGraw-Hill Publishing Company.
2. “National Electric Safety Code”, ANSI – C2 (NESC).
3. “NFPA 70 National Electrical Code – 2002 Edition”, National Fire Protection
Association.
4. “Guide to Transmission and Distribution
Tennessee Valley Public Power Association.
Standards
and
Specifications”,
5. “Specifications and Drawings for 24.9/14.4 kV Line Construction”, Rural Utilities
Service Bulletin 1728F-803.
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-1
PROJECT 29151.01
1.04
A.
101012
SUBMITTALS
Submittal information and shop drawings shall be submitted for approval in
accordance with Section 01 32 19 – SUBMITTALS and Section 01 33 23 – SHOP
DRAWINGS.
1. Sagging method chosen, proposed procedure, and test results.
1.05
ASSEMBLY GUIDE DRAWINGS AND PROJECT CONSTRUCTION DRAWINGS
A.
The Construction Drawings are diagrammatic indicating major items of materials and
general arrangement of assemblies to establish a standard of construction.
B.
Conditions encountered in the field may vary from those shown on Contract
Drawings, and the construction shall be modified as required to accommodate the
field conditions involved. The general arrangement of circuits and clearances
indicated on the assembly guide drawings shall be maintained. The Engineer shall
approve any deviation from Contract Drawings prior to construction.
1.06
ASSEMBLY UNIT BASIS
A.
The Construction assemblies are on a unit basis so that the Utility Owner may
authorize any combination, addition or deletion, or construction units desired.
B.
The descriptions apply to those assemblies on the project drawings and assembly
guide drawings and includes all necessary labor and incidental installation materials
required to install the assemblies complete. Unit descriptions are provided in Section
01 22 00 – MEASUREMENT AND PAYMENT.
1.07
A.
WARRANTY
All labor, materials, and equipment supplied under this specification shall be
warranted as outlined in the GENERAL CONDITIONS.
PART 2.
2.01
EXECUTION
POLE-TOP ASSEMBLIES
A.
Crossarms shall be installed as per the Manufacturer’s installation instructions.
B.
Level all support crossarms and conductor supports. Those on tangent construction
shall be at right angles to the conductors they support. Balance the conductor
loading equally between the supports
C.
Field drilled holes shall be in line with the strain or at right angles to the assembly
they support. Assemblies mounted on uneven pole surfaces shall be adjusted with
metal shims where practical.
D.
Install assemblies and equipment rigid and secure, plumb and level, and in
alignment with related and adjoining work. Welding or cutting of materials or
deviation from Manufacturer recommendations for attachment or support shall be
prohibited.
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-2
PROJECT 29151.01
101012
E.
Where subsequent alteration, adjustment, or reworking of existing assemblies is
required, it shall be performed using materials and workmanship to match those of
the original installation; and restored at least to the conditions which existed, unless
otherwise indicated.
F.
Install new materials and equipment and connect to existing installations, where
indicated, with minimum interference to existing facilities.
G.
Align suspension units with the bisector of the line angle on vertical angle
construction. Insure all cotter keys are in place in suspension units.
H.
Extra care shall be exercised during all phases of construction to prevent scarring or
abrading the surface of any assembly item. Ladders may be hung from assembly to
simplify clipping-in operations; however, the ladder hooks shall be covered with a
rubber hose or otherwise padded to prevent damage to the protective coating.
2.02
INSULATORS
A.
Exercise care in handling and installing insulators and in assembling suspension
units.
B.
Each insulator unit shall be inspected and when installed shall be free of cracks,
chips, bent pins, and other defects. Defective insulators shall be removed from the
work site immediately.
C.
All insulators installed shall have surfaces cleaned of all foreign material and
porcelain insulators shall be wiped to a bright finish.
D.
Install horizontal mounted insulators at right angles to the conductors they support.
E.
Deadend insulator strings, when completely assembled, shall have all cotter pins
fully seated. Deadend insulator strings must be attached to the structure after
setting the poles. The insulator strings shall be hoisted into position with slings or
wires in a manner so as not to cause damage.
F.
When material items are mounted on each structure prior to setting the poles, the
structures shall be supported off the ground before pole setting to maintain clean
surfaces and to avoid damage to the assemblies.
2.03
A.
CONDUCTORS AND APPURTENANCES
Stringing
1. All poles shall be plumb before stringing conductors.
2. Carefully handle conductors. Do not drag them over sharp objects nor allow
them to be stepped upon or run over by vehicles. Avoid kinking, twisting or
abrading the conductors in any manner. Inspect the conductor as it is unreeled
for cuts, abrasions, and other injuries. Cut out the faulty sections and splice the
conductor as required.
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-3
PROJECT 29151.01
101012
3. Install the conductors and accessories in accordance with Manufacturer’s
recommendation. Pull the conductors over suitable rollers or stringing blocks.
Properly mount on the pole or crossarm to insure proper sagging. Prevent
binding while stringing.
4. Conductors shall be strung by controlled-tension method using proper stringing
blocks. Conductors larger than 1.0 inches in diameter and ACSR conductors of
multiple stranded steel cores shall be strung using neoprene lined or similar type
blocks. The stringing equipment shall have groove sizes that will in no way
damage the conductor, and capable of maintaining preset tensions and pulling
speed. Maintain sufficient continuous tension to keep conductors clear of the
ground or obstructions that could cause damage to or by the conductor.
5. The tension on any conductor during stringing shall not exceed 50 percent of the
ultimate strength of the conductor at the temperature existing at the time of
stringing.
6. When, during the stringing operation, a conductor contacts another conductor,
the ground, or some other object which might cause damage, the conductor shall
be lowered, wiped clean, and closely inspected by the Engineer to determine the
extent of damage. Depending on the severity of damage and the length of the
damaged section, repairs shall be made by smoothing of the conductor with fine
sandpaper or by cutting out the damaged section and splicing.
7. Locate the cable pullers, tensioners and pulling machines as near midspan as
possible. In no case shall the slope of the conductor between the machine and
the stringing block at the first structure be steeper than three horizontal to one
vertical.
B.
Sag Operations and Tests
1. The length of conductor sagged in one operation shall be limited to the length
that can be sagged satisfactorily, or as approved by the Engineer.
2. Sag in as level and as average a ground span as possible.
3. Sag all conductors in accordance with Sag Tables that will be furnished by the
Engineer. Where new and existing conductors are strung together, sag both
conductors with the sag tables, unless otherwise specified by the Engineer.
4. The Contractor may select one of three methods to sag conductor:
a. Transit Method - Use of a transit to accurately measure the sag by calculated
angle of sight method, calculated target method, or horizontal line of sight
method.
b. Dynamometer Method - Insertion of a dynamometer in line with the sagging
equipment to verify actual tension of the line.
c. Stopwatch or Time-Wave Method - measurement of return waves after
striking or jerking the conductor to produce an initial wave.
5. In sagging one reel length, the sag of two spans shall be checked. In sagging
lengths of more than one reel, the sag of three or more spans near each end and
the middle of the length being sagged shall be checked. The length of the spans
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-4
PROJECT 29151.01
101012
used for checking shall be approximately equal to the ruling span. At the option
of the Engineer, all spans which exceed the ruling span by 25 percent or more
shall be checked for sag; and, at sharp vertical angles, the sag shall be checked
on both sides of the angle. The following spans are unacceptable for sagging
tests: Inclined spans, tangent to vertical configurations, deadends, tangent to
angles, spans with splices,
6. Sagging shall not be performed when wind or other adverse weather conditions
prevent satisfactory sagging. Sagging shall not be performed at temperatures
below 20 degrees Fahrenheit.
7. The air temperature at the time and place of sagging shall be determined by a
certified etched-glass or a highly accurate bimetal thermometer. Record the
temperature at which the conductor is sagged and the spans in which sags are
measured and furnish this information to the Engineer.
8. The Contractor shall verify the electrical clearances to foreign wire crossings or
other supports after sagging operation is complete. Record clearances and
submit to Engineer.
C.
Clipping In
1. Clipping may begin as soon as the conductor has been sagged. Tape or ink mark
a reference point on the conductor measured from the center of the stringing
block location. After clipping-in verify that the conductor has not moved from its
sagging point. Clipping should progress so as to avoid trapping uneven sags
between clipped sections.
2. Long spans, inclined spans, and deadend spans shall be clipped in first, so as to
minimize conductor movement. At the option of the Engineer, the Contractor
may be directed to also clip in at the mid-point and one-quarter points of sagging
operation.
3. Lifting of the conductors shall be done with a hoist and lifting hook that will not
notch or severely bend the conductors. The conductor lifting hook should have
an elastomer cover so as not to damage the surface of the conductors. The
conductors shall not be lifted high enough such that the conductor will creep in
adjacent spans.
4. Bundled conductors may be lifted simultaneously be the use of a yoke
arrangement supporting the hooks and a single method of lifting.
5. Conductors shall NOT remain in lifting blocks for more than 72 hours to avoid
damage to conductors or sheaves.
6. If shown on the Contract Drawings, dampers shall be installed immediately after
clipping to prevent possible wind vibration damage.
D.
Conductors shall be cut out and spliced in any location where damage on the cable
has occurred. Repair sleeves may be used to repair damaged conductor when the
damage is concentrated in a small area or when the number of broken strands is less
than 10% of the strands on the outer layer. Any damaged location shall be reported
to and reviewed by the Engineer, prior to repair.
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-5
PROJECT 29151.01
2.04
101012
SPLICES AND TIES
A.
New conductors shall not have more than one splice per conductor in any span. Do
not locate splices in new conductor within 10 feet of any conductor support. Cut out
and re-splice improperly located splices, injured portions, crooked or imperfect
splices. Do not leave bent or curved splices in the conductors.
B.
Where existing conductors are reworked, splices may be located less than 10 feet
from a support or hardware, if sufficient distance is provided for future maintenance;
but in no case shall a splice be located within 2 feet of conductor hardware or
supports.
C.
Splices in new conductors shall not be located in NESC defined Grade B crossing
spans. No extra pay will be made for any splices that may be required for any reason
in existing conductors left in place.
D.
Clean the contact surfaces thoroughly before splicing and carefully follow
Manufacturer's recommendations. Use the proper die and crimping tool that is
mated to the splice. Insure that the proper spacing and number of crimps are made.
E.
Use the Manufacturer’s recommended inhibitor when splicing and installing
connectors to aluminum conductors. Use a pressure gun with tapered nozzle to
inject the inhibitor into splicing sleeves.
F.
Splices and compression connectors on conductors larger than 0.60 inches diameter
shall be hydraulically crimped. Automatic splices may be used, as approved, but
only in full tension conductors.
G.
When a bow (non-hex) die is used, the crimping tool is to be rotated 90 degrees
between crimps in order to avoid banana bowing of the splice. If a connector bows it
shall be cut out and replaced. It shall not be repaired by hammering on it.
H.
Ties shall be of the type and configuration as required for the conductor and support
used, and in accordance with the Contract Drawings. Tie wire shall be tightly drawn
around the conductor support and armor rod so that no slack space occurs. Tie
wires around insulators shall not be cris-crossed.
I.
Pre-formed conductor ties may be used for re-working of energized conductors if
approved. Hot line ties shall not be used.
2.05
CLAMPS, JUMPERS, AND CONNECTORS
A.
Use proper size connections and only those which will not cause galvanic action
where conductors are of dissimilar metals. The contact surfaces of clamps and
conductors shall be cleaned and bright using a steel brush as the principal cleaning
medium. Where bolted connectors are approved the bolts shall be brought down
hard, but the threads shall not be overstressed.
Use a suitable inhibitor on
aluminum surfaces for all connectors, hot-line clamps, etc.
B.
Exercise utmost care when installing parallel groove clamps where specified. Clean
the contact surface of the clamp and the wire. Bolts shall be brought down hard, but
the threads shall not be over stressed. Bolted clamps shall not be used on grounding
connections.
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-6
PROJECT 29151.01
101012
C.
Install hot-line clamps so that they are permanently bonded to the load side of the
line, allowing the jumper to be de-energized when the clamp is disconnected from
the supply line.
D.
Allow sufficient, but not excessive slack in jumpers and other leads. Make them neat
and uniform in appearance and in general run in horizontal and vertical planes with
rounded turns.
Support all jumpers to prevent excessive movement between
supports and to clear all conflicts and maintain clearances as required by NESC. Do
not use broom-stick coils in any jumpers.
E.
At points of deadends, taps and take-offs of the main supply line, conductor tails
shall be left long enough to be used as jumpers and such that splices or connections
shall be limited to one per phase.
F.
Existing conductors to be connected to transformers, line equipment, or other
conductors shall be thoroughly cleaned and connections made as would be for new
conductors.
G.
Size each jumper, whether existing or new, to be at least as large as the conductor
on the load side.
H.
All line and service connections shall be made with compression connectors. Use of
bolted connection shall have prior approval from the Engineer. Aluminum to copper
connections shall be made with connectors suitable for use with dis-similar metals.
I.
Service connections, with the exception of the neutral connection, shall be covered at
the point of connection with black all-weather vinyl electrical tape, or if approved, a
polyethylene plastic cover.
3.07
GROUNDS
A.
Where ground rods are specified, drive ground rods the full length in undisturbed
earth a minimum of 2'-0" from the surface of the pole, with the top of the rod and
the grounding jumper a minimum of 1'-0" below natural grade. Install ground rods
at all transformer and equipment locations and as shown in the Contract Drawings.
B.
Interconnect all equipment grounds, neutral wires, and protective equipment and
attach to a common pole ground wire. Make at least two (2) continuous connections
on all equipment from the equipment frame or case of equipment tank to the multigrounded system.
C.
Leave each ground rod uncovered from the rod clamp to the pole until the Engineer
authorizes backfilling. DO NOT LEAVE HOLES EXPOSED THAT WILL ENDANGER THE
PUBLIC.
D.
Alternative ground rod installation locations and arrangements shall be approved by
the Engineer on a case by case basis.
E.
Sufficiently tighten offset down-lead wires to make a secure assembly of uniform
appearance. Maintain evenly spaced distance between the offset downlead wire and
the adjacent phase conductors.
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-7
PROJECT 29151.01
3.08
101012
GUYS
A.
Provide guys at all points of unbalanced strain in conductor and structures at
corners, junctions and deadends as shown on the Contract Drawings. Attach guys to
poles at the load centers.
B.
Provide span guys at all locations where down guys cannot be used, at all
unbalanced loads on crossarms, and use stub poles where required to obtain proper
guying clearance requirements. Do not install any guy in violation with NESC
requirements.
C.
Install each guy centered on the pole without pulling to either side or causing an
unequal strain on guy hooks, clamps, or sections of the guy and hardware. Neatly
sever or cut all guy tails.
D.
Unless specified elsewhere, install down guys with a one-to-one (45 degree) lead-toheight ratio.
E.
All guys shall be bonded to the pole grounding system unless otherwise directed by
the Engineer. Grounding jumpers shall be of minimum conductivity equivalent to the
pole ground wire. Grounding connectors to the guy and the system ground wire
shall be compression type suitable for dissimilar metals.
F.
Guys shall be placed before the conductors are strung. Insure proper adjustment of
guys when stringing operations are being performed so that loading on structures
will be balanced.
G.
Unless specified otherwise, guy attachment, hooks or plates shall only have one guy
attached.
H.
Guy primaries and secondaries separately.
3.09
ANCHORS
A.
Anchors shall be installed according to Manufacturer’s instructions.
B.
Locate anchors as far as practical from street crossings, driveways, crosswalks, and
foot paths.
C.
Install all anchor rods in line with the strain and the guy slope. DO NOT INSTALL
ANCHOR RODS VERTICALLY AND THEN BEND OR TRENCH THEM INTO POSITION.
Leave no more than 6 inches of the rod exposed above ground. In cultivated fields,
or disturbed soils where the rod might become covered, leave no more than 12
inches of the rod exposed above ground. In no case shall the eye of the rod be
covered by soil.
D.
On expanding anchors or rock anchors use an auger that will excavate a hole just
large enough to accommodate the unexpanded anchor, such that, upon installation
and expansion of the anchors the maximum holding capacity can be obtained. DO
NOT USE A LARGE AUGER SUCH AS THE POLE AUGER.
E.
The backfill for the anchor hole shall be thoroughly tamped with suitable soil the full
length of the anchor hole.
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-8
PROJECT 29151.01
101012
F.
Anchors shall be installed to sufficient depth and with sufficient torque such that
each installation shall hold a total guy load of 30,000 pounds maximum.
G.
For power installed screw anchors, a double helix anchor shall be installed at a depth
no greater than 14 feet. If the required torque is not achieved, the anchor shall be
removed and a double-helix square shaft or other multi-helix square shaft anchor
shall be installed.
H.
If difficulty is encountered in installing anchors, the Engineer shall be contacted to
recommend additional installation methods.
2.10
HARDWARE AND BOLTS
A.
Securely tighten all hardware.
B.
Provide a washer at each point where a bolt head or nut bears on the surface of a
pole or crossarm.
C.
Provide a locknut with each nut, eyenut, or other fastener on all bolts or threaded
hardware.
D.
Carefully select bolts for proper length. Bolts shall extend at least ½ inch and not
more than two (2) inches beyond nuts or locknuts. Eyebolts shall be in line with the
strain at all deadends, and shall bisect the line angle and at all angles made that are
not deadends. All bolts shall be in a level plane to the hardware attached.
E.
DO NOT CUT OFF BOLTS THAT ARE TOO LONG - REPLACE THEM WITH PROPER
LENGTH BOLTS.
F.
All connections shall be bearing type connections. Bolt length shall provide for nuts,
locknuts, and washer.
G.
High strength bolts and their installation and bolting tools and equipment shall be in
accordance with the structure manufacturer’s recommendations and the
“Specifications for Structural Joints Using ASTM A325 or A490 Bolts” including the
commentary given therewith, as approved by the Research Council on Riveted and
Bolted Structural Joints of the Engineering Foundation and endorsed by AISC, except
as otherwise modified or supplemented herein. Bolt length shall be selected in
accordance with the Research Council specification.
The Research Council
specification is dated August 14, 1980. All methods, tools, and equipment shall be
subject to the acceptance of the Engineer.
2.11
SWITCHES
A.
Use proper size compression spades for terminal pads.
B.
Adjust switches to Manufacturer recommendations.
subject to inspection prior to energizing.
C.
On pipe operated switches the set screws shall not be punched in until the switch is
inspected.
OVERHEAD ELECTRICAL LINE CONSTRUCTION
Switch operation shall be
33 71 00-9
PROJECT 29151.01
D.
2.12
A.
101012
Provide two connections to ground on metal support frames.
MISCELLANEOUS
Grounding Platform Installations:
1. For grounding platform installations at overhead line switches, install an area of
4” deep crushed aggregate extending a minimum of 1’ beyond the edges of the
grounding platform. Grade area to ensure proper drainage and to keep adjoining
soil from washing into the aggregate.
2.13
PHASING OF CONDUCTORS
A.
Phasing shall be in accordance with the Contract Drawings where indicated. Where
phasing is not indicated the phasing placement and connection shall be as approved
by the Engineer.
B.
Verify phasing, whether indicated or not, by site review of each source connection at
substation.
Final phase rotation and placement is the responsibility of the
Contractor.
2.14
REMOVALS
A.
Keep careful and accurate records of all materials removed or reused as specified.
B.
When backfilling holes at pole removal locations do not dig holes in the landscape to
obtain backfill. Obtain backfill dirt by scooping or scraping within the designated
right-of-way or by fill dirt obtained locally. Do not dig seeded areas within highway
or public rights-of-way. Do not place foreign objects in backfill.
C.
Reuse only those materials as specified or as indicated that are equivalent in size,
rating, capacity and other requirements of new materials and not damaged or
deteriorated.
Reuse of any other materials shall have prior approval by the
Engineer. Upon this approval careful and accurate records shall be kept and
submitted to the Engineer itemizing the particular materials reused and the location
of their use.
D.
Immediately remove from the job site any materials that are removed from existing
assemblies.
END OF SECTION
OVERHEAD ELECTRICAL LINE CONSTRUCTION
33 71 00-10
PROJECT 29151.01
101012
SECTION 33 71 16
ELECTRICAL UTILITY POLES
PART 1.
1.01
GENERAL
SECTION INCLUDES
A.
Pole materials and installation.
B.
Basic methods.
C.
Installation of suitable aggregate, concrete, or earth backfill.
D.
Removals of existing facilities as shown in the Contract Drawings.
1.02
RELATED SECTIONS
A.
DIVISIONS 0 and 1 – CONTRACT DOCUMENTS AND GENERAL REQUIREMENTS:
These shall apply to all work included in this section.
B.
Section 01 11 13 – SUMMARY OF WORK
C.
Section 01 22 00 – MEASUREMENT AND PAYMENT
D.
Section 33 71 26 – OVERHEAD ELECTRICAL LINE MATERIALS
1.03
A.
REFERENCES
Published Specifications, standards, tests, or recommended methods of trade,
industry, or governmental organizations apply to work in this section where cited in
Section 01 42 19 – REFERENCE STANDARDS and in the listing below:
1. “The Lineman’s and Cableman’s Handbook”, McGraw-Hill Publishing Company.
2. “National Electric Safety Code”, ANSI – C2 (NESC).
3. “NFPA 70 National Electrical Code – 2002 Edition”, National Fire Protection
Association.
4. “Guide to Transmission and Distribution
Tennessee Valley Public Power Association.
Standards
and
Specifications”,
5. Alabama Highway Department Standard Specification for Highways and Bridges,
Section 825, Crushed Aggregate Base Materials, Type A.
6. Mississippi Standard Specification Road and Bridge Construction, Section 703.062
Dense-Graded Crushed Stone.
7. Tennessee Department of Transportation Standard Specifications for Road and
Bridge Construction, Section 903.05, Aggregate for Mineral Base and Surface
Courses, Grading D.
ELECTRICAL UTILITY POLES
33 71 16-1
PROJECT 29151.01
8. ASTM C29
ASTM C33
ASTM C136
1.04
A.
1.05
A.
1.06
A.
1.07
A.
A.
Unit Weight of Aggregate
Standard Specification for Concrete Aggregates
Sieve or Screen Analysis of Fine and Coarse Aggregate
SUBMITTALS
Submittal information and shop drawings shall be submitted for approval in
accordance with Section 01 32 19 – SUBMITTALS and Section 01 33 23 – SHOP
DRAWINGS.
PROJECT CONSTRUCTION DRAWINGS
Conditions encountered in the field may vary from those shown on Contract
Drawings, and the construction shall be modified as required to accommodate the
field conditions involved. The Engineer shall approve any deviation from Contract
Drawings prior to construction.
UNIT BASIS
The descriptions apply to those poles that are on the project drawings and includes
all necessary labor and incidental installation materials required to install the poles
complete. Unit descriptions are provided in Section 01 22 00 – MEASUREMENT AND
PAYMENT.
WARRANTY
All labor, materials, and equipment supplied under this specification shall be
warranted as outlined in the GENERAL CONDITIONS.
PART 2.
2.01
101012
PRODUCTS
GENERAL
Pole Materials and Classifications
1. Metal Poles shall be made of Ductile Iron with a minimum yield strength of 42ksi.
See Section 33 81 23 – OVERHEAD COMMUNICATIONS MATERIALS for additional
information.
2. Pole classifications and properties shall conform to ANSI Standards as indicated
in the table below:
POLE
CLASS
HORIZONTAL
LOAD (LBS)
LENGTH
RANGE (FT)
MINIMUM TIP
CIRCUMFERENCE
MINIMUM
CIRCUMFERENCE
AT 6FT FROM BUTT
H5
10,000
45-125
37
56
H4
8,700
40-125
35
51
H3
7,500
40-125
33
48.5
H2
6,400
35-125
31
43.5
ELECTRICAL UTILITY POLES
33 71 16-2
PROJECT 29151.01
101012
H1
5,400
35-125
29
41.5
1
4,500
35-125
27
41
2
3,700
20-125
25
34
3
3,000
20-90
23
32
4
2,400
20-70
21
29.5
5
1,900
20-50
19
27.5
6
1,500
20-45
17
21
7
1,200
20-35
15
19.5
9
740
20-30
15
17.5
10
370
20-25
12
14
2.03
COARSE AGGREGATES
A.
ASTM C33 No. 67 gradation.
B.
If filler, in addition to that naturally present in the aggregate material, is necessary
for satisfactory compaction, it shall be uniformly blended with the aggregate material
at the crushing plant.
C.
If the additional filler is composed of sand, the amount of sand shall not exceed 20
percent by weight of the total combined aggregate.
2.04
CONCRETE
A.
Portland Cement ASTM C150: Type 1.
B.
Coarse and Fine Aggregates: ASTM C33.
C.
Water: Clean and free of injurious amounts of oil, alkali, organic matter, or other
deleterious materials.
D.
Mix:
E.
Provide air entraining admixture conforming to ASTM C260.
F.
Slump: Three inch maximum, one inch minimum.
2.05
Compressive Strength (7 day) 2100 psi.
Compressive Strength (28 day) 4000 psi.
WETHERING SEVERITY
A.
Provide materials in accordance with ASTM C33 table 3 to the requirements for Class
3S weathering regions.
B.
Do not use crushed concrete or recycled concrete for materials.
ELECTRICAL UTILITY POLES
33 71 16-3
PROJECT 29151.01
PART 3.
3.01
A.
101012
EXECUTION
GENERAL
Existing Underground Installations:
1. Existing underground installations such as water lines, gas mains, and sewers in
the vicinity of pole foundation drilling locations are indicated on the Drawings
only to the extent that such information has been made available to or
discovered by the Utility Owner/Engineer in preparing the Drawings. There is no
guarantee as to the accuracy or completeness of such information, and all
responsibility for the accuracy and completeness thereof is expressly disclaimed.
2. The Contractor shall be solely responsible for locating all existing underground
installations prior to drilling pole holes. The Contractor shall use his own
information as shall not rely upon any information indicated on the Drawings
concerning existing underground installations.
3. The Contractor will be held responsible for any interruption in the service of
underground facilities resulting from his operations, unless the facilities owner
has given specific approval for the interruption in each case.
4. Except where the damaged parties desire to conduct their own repair and
restoration work, the Contractor shall repair and fully restore any underground
facility damaged during the construction period to a condition equal to or better
than that which existed at the time of damage. All repair and restoration work
shall be done to the complete satisfaction of the damaged parties and the Utility
Owner.
5. The Contractor shall make his own arrangements with any jurisdictional authority
requiring inspection of repaired or reconditioned utility facilities. All inspection
fees applicable shall be pain by the Contractor.
6. Where the damaged parties desire to conduct their own repair and restoration
work, the Contractor shall render all assistance to facilitate this corrective work.
The Contractor shall assume all just and reasonable expenses thus incurred by
the damaged parties.
7. Each underground facility encountered shall be accurately located on the Project
Record Drawings, indicating the original location and relocation, if any. When all
work is completed, the marked copy of the Drawings shall be submitted to the
Utility Owner as part of the field records.
3.02
POLE INSTALLATION
A.
Handle poles carefully. Do not drop them from transportation vehicles. Use
appropriate slings. Steel tongs or other grips that cause damage to pole surfaces
are not acceptable.
B.
The diameter of each pole hole shall be as required for compaction of backfill around
the pole, but not less than the pole diameter at the butt plus 6 inches.
ELECTRICAL UTILITY POLES
33 71 16-4
PROJECT 29151.01
101012
C.
Pole hole excavation shall include removal of stumps, roots, and other obstructions
as necessary to provide a clean hole to the required depth.
D.
Poles shall be immediately set and plumbed after hole excavation.
E.
The minimum setting depth shall be as follows:
LENGTH OF POLE
(FEET)
SETTING DEPTH
(FEET)
LENGTH OF POLE
(FEET)
SETTING DEPTH
(FEET)
25
4.5
70
9.0
30
5.0
75
9.5
35
5.5
80
10.0
40
6.0
85
10.5
45
6.5
90
11.0
50
7.0
95
11.5
55
7.5
100
12.0
60
8.0
105
12.5
65
8.5
110
13.0
1. On a sloping ground, measure the depth of the hole from the low side of the
slope.
2. Each pole in single-pole structures and in multi-pole structures on level ground
surfaces shall be set no greater than 3 inches of the depth specified in the
preceding table. When conditions are encountered that warrant setting depths in
excess thereof the Engineer shall be notified prior to setting the pole.
F.
Pole hole excavation by hand digging or other means that shall be at the option of
the Contractor.
G.
Tamp thoroughly by mechanical method with earth backfill around the poles for the
full depth of the hole. Mechanical tamping shall be in maximum 6-inch layers. Bank
excess dirt up around the pole. Refill and thoroughly tamp to the ground line any
settlement that occurs until completion of the Contract.
H.
Poles shall be set in alignment and plumb with and across the line, except at angles
where vertical suspension insulators or offset framing is used. Poles set on these
type angles unless otherwise indicated shall be offset on the bisector of the angle so
that the conductors shall hang directly over the point of intersection and in line with
the poles in both directions either side of the angle.
I.
Where rocks and gravel larger than 2 inches and without at least 50 per cent soil
composition, and where swampy type soils are encountered in hole digging, this shall
not be used as backfill. Do not use sod or grassy soil or place foreign objects in the
backfill.
ELECTRICAL UTILITY POLES
33 71 16-5
PROJECT 29151.01
101012
J.
Each pole shall be set within ±1-1/2 inches transversely of the location indicated on
the Drawings. Longitudinal location shall be within ±1 foot. Vertical alignment of all
poles shall be within 3 inch of plumb.
K.
When raking is specified, poles shall be raked one inch for each 10 feet of pole out of
the ground. Poles shall be raked only upon prior approval from the Engineer.
3.03
TUBULAR STEEL, DUCTILE IRON AND CONCRETE POLES
A.
All structure components shall be handled with care to prevent damage to the finish.
Padded cradles and nylon slings shall be used when handling the structures.
B.
Poles shall be lifted by appropriate lifting rigs, utilizing a two point pickup when
required. When lifting poles it is important to use lift points indicated by the
manufacturer to prevent pole cracking or structural damage.
C.
Tubular shafts which are shipped in more than one piece shall be assembled using
two jacks placed on opposite sides of the shaft. Shaft assembly shall be performed
according to the Manufacturer’s instructions, drawings and recommendations.
D.
Bolts:
1. Tightening of galvanized bolts shall be done by the “turn-of-nut” method only. A
washer shall be used under the element to be turned in tightening.
2. Bolt installation and bolting tools and equipment shall be in accordance with the
structure Manufacturer’s recommendations. Nuts and bolts shall be handled and
installed in a manner that will not damage the galvanized finish. Wrenches which
deform the nut or bolt head or which mar the galvanized finish shall be replaced
by wrenches acceptable to the Engineer. The Contractor shall replace, without
cost to the Utility Owner, all bolts and nuts damaged during installation with new,
undamaged bolts and nuts of the same type, size, and quality as the original
bolts.
3. Bolted connections shall be drifted to proper position and the holes inspected to
ensure that bolt threads will not be damaged by forcing the bolts in place.
4. The Contractor shall make a thorough inspection to ensure that all bolts are
tightened and that a locknut has been installed and tightened on each bolt where
required.
5. Any structure bolt which has been tightened shall not be loosened and retightened. Bolts which have been loosened after tightening shall be discarded and
new bolts used in their place. New bolts shall be furnished by the Contractor at
no cost to the Utility Owner.
E.
All damaged galvanized surfaces shall be cleaned of grease, scale, and all foreign
matter and repaired with “AMCO 322 Galvanizing Sticks” or “AMCO 321 Galvanizing
Powder” as manufactured by Force Chemicals Division of American Solder and Flux
Co., Inc. of Paoli, Pennsylvania, or an acceptable equal material. The touchup
galvanizing material shall be applied in strict accordance with the manufacturer’s
application instructions to provide a uniformly coated surface. The Contractor shall
furnish and apply the touchup galvanizing material to any surface where the
ELECTRICAL UTILITY POLES
33 71 16-6
PROJECT 29151.01
101012
galvanizing coating is broken or removed. Where practical, the galvanizing repair
shall be done before the structures are set. Repair to galvanized surfaces damaged
by the Contractor shall be at no cost to the Utility Owner.
F.
Where ground-line protection sleeves are furnished, they shall be centered at the
standard depth that allows this protection sleeve to extend below and above the
ground-line on individual poles. If the setting dimension or side hill slope causes the
sleeve not to be 6" above or below the ground-line, the pole shall have a coating of
bitumastic applied at ground-line to extend 1 foot above and below the ground-line.
G.
Aggregate Placement:
1. Backfill aggregate shall be placed in compacted 6 inch lifts by means of
mechanical or hydraulic tamping.
2. Bank aggregate around the structure to a height 6 inches above existing grade
and taper to the edges of the backfilled hole. Refill and thoroughly tamp any
settlement that occurs until completion of the contract.
3. Do no place foreign objects in backfill.
H.
Concrete Placement:
1. Earthen form work is to be used in stable soils. Where soils are unsuitable, use
forms for round columns spirally constructed of laminated plies of fiber similar to
Sonotube Fiber Forms, or an approved equal.
2. Where round form work cannot be utilized, Contractor, at his option, may use
form work of No. 2 common lumber or better. The form work may be square,
but encompass as a minimum the circular diameter indicated in the Contract
Drawings. Square form work shall penetrate below grade at least 2 feet, to a
depth reached as suitable soils. The square adjoinment to circular shall be a
monolithic pour.
3. Slope the exposed concrete to drain away from structure with at least ½ inch of
slope reaching to the outer limit of the filled area.
4. Form-work shall not be removed for 24 hours after placement.
I.
Structure Stabilization:
1. Structures shall be stabilized by holding, guying, or bracing until placement of
special backfill has been completed.
3.05
REMOVALS
A.
Keep careful and accurate records of all materials removed or reused as specified.
B.
When backfilling holes at pole removal locations do not dig holes in the landscape to
obtain backfill. Obtain backfill dirt by scooping or scraping within the designated
right-of-way or by fill dirt obtained locally. Do not dig seeded areas within highway
or public rights-of-way. Do not place foreign objects in backfill.
ELECTRICAL UTILITY POLES
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PROJECT 29151.01
101012
C.
Re-use only those materials as specified or as indicated that are equivalent in size,
rating, capacity and other requirements of new materials and not damaged or
deteriorated.
Reuse of any other materials shall have prior approval by the
Engineer. Upon this approval careful and accurate records shall be kept and
submitted to the Engineer itemizing the particular materials reused and the location
of their use.
D.
Immediately remove from the job site any materials that are removed from existing
assemblies.
END OF SECTION
ELECTRICAL UTILITY POLES
33 71 16-8
PROJECT 29151.01
101012
SECTION 33 71 26
OVERHEAD ELECTRICAL LINE MATERIALS
PART 1.
1.01
GENERAL
SECTION INCLUDES
A.
Overhead electric system construction
B.
Materials and Equipment
1.02
RELATED SECTIONS
A.
DIVISIONS 0 and 1 – CONTRACT DOCUMENTS AND GENERAL REQUIREMENTS:
These shall apply to all work included in this section.
B.
Section 33 71 00 – OVERHEAD ELECTRICAL LINE CONSTRUCTION
C.
Section 33 71 16 – ELECTRICAL UTILITY POLES
1.03
A.
REFERENCES
Published Specifications, standards, tests, or recommended methods of trade,
industry, or governmental organizations apply to work in this section are in the
listing below:
1. “The Lineman’s and Cableman’s Handbook”, McGraw-Hill Publishing Company.
2. Rural Utilities Service Bulletins 1753F-152 and 1753F-151.
3. “National Electric Safety Code”, ANSI – C2 (NESC).
4. Special Provision regarding Buy American Requirements – SP106A (State of TN).
1.04
SUBMITTALS
A.
Shop drawings shall be submitted for approval in accordance with Section 01 32 19 –
SUBMITTALS and Section 01 33 23 – SHOP DRAWINGS.
B.
Final Drawings, Manuals, and Test Reports shall be provided prior to shipment on
accordance with Section 01 78 39 – PROJECT RECORD DOCUMENTS.
1.05
QUALITY ASSURANCE
A.
All materials, equipment and appurtenances used in construction of this project shall
be new and shall conform to those acceptable by standard publications used in line
construction, unless otherwise specified herein.
B.
Supply all equipment and accessories new and free from defects.
OVERHEAD ELECTRICAL LINE MATERIALS
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PROJECT 29151.01
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C.
Supply all equipment and accessories in compliance with applicable standards and
with all applicable national, state, and local codes.
D.
All items of a given type shall be the products of the same Manufacturer.
PART 2.
2.01
PRODUCTS
ACCEPTABLE MATERIALS
A.
All materials, equipment and appurtenances used in construction of this project shall
be new, carry a minimum 1 year warranty for a period beginning with acceptance of
the project by the Utility Owner, and shall conform to those as specified herein.
B.
Manufacturer’s names and catalog numbers are specified to establish the reliability,
type, size, rating or capacity, design, or other features of the materials required. A
closed specification is not intended and duplicating items of other reputable
manufacturers will be acceptable upon the Utility Owner’s approval, unless otherwise
specified.
C.
In accordance with Code of Federal Regulations 23 CFR 635.410, any materials that
contain iron and/or steel shall be manufactured in the United States and shall be
Certified accordingly by the contractor prior to construction.
2.02
CROSSARMS
A.
Tangent Crossarms: 10’-0” length, Un-braced Fiberglass crossarm with brown finish,
PUPI #TB200012005X2, or as approved.
B.
Deadend Crossarms: 10’-0” length, Un-braced Fiberglass crossarm with brown finish,
PUPI #DA3000120E3B9X3 and #DA3000120S3B9X3, or as approved.
2.03
A.
2.04
A.
2.05
A.
POLES
All poles shall be Ductile Iron, Natural Finish (weathered appearance) with HDPE cap,
with size and class as specified on the Contract Drawings, and manufactured by
McWane Poles, or as approved by the Utility Owner/Engineer.
INSULATORS
Distribution:
1. Vertical Post/Pin: MacLean DP55-4, or as approved.
2. Suspension/Strain: MacLean DS-15M, or as approved.
CONDUCTORS AND APPURTENANCES
Conductors:
1. 795 AAC “Arbutus”
2. 336 AAC “Tulip”
OVERHEAD ELECTRICAL LINE MATERIALS
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B.
Miscellaneous Conductors:
1. Miscellaneous sizes and types as required for jumpers, connections, ties, etc.,
and handling, holding, tying, re-tying, sagging, etc.
C.
Appurtenances:
1. Splices: AAC
a. All 1 piece compression type.
2.06
2.
Vertical Insulator Pins:
a. Clamp type Crossarm Pin, Hubbell #14322P, or as approved.
3.
Connectors:
a. All main line connections of AAC, use compression connections as approved.
b. Miscellaneous sizes and types as required.
4.
Conductor Clamps:
a. AAC and ACSR:
1) Strain clamps: 20,000-lb rated bolted, as recommended by insulator
manufacturer.
5.
Fused Cutouts:
a. 100A loadbreak – ABB #Y1NCANQA11, LBUII, or as approved.
6.
Fuses: ABB #12A00128H01, or as approved.
7.
Stirrup: MacLean #HLS-795-E, or as approved.
8.
Terminators: Elastimold PCT1-1X-3
POLE LINE HARDWARE
A.
All hardware shall be hot-dip galvanized.
B.
Locknuts type MF.
2.07
A.
GUYS AND ANCHORS
Guys:
1. Guy Strand: 3/8 inch high strength steel, 7 strand class A galvanized.
2.
Guy bonding clamps for anchor rod eyes, malleable iron with hot-dip galvanized
steel bolt, sized to rod eye type and guy strand.
3.
Grounding jumpers AWG No. 4 soft drawn copper using suitable compression
connectors.
4.
Guy deadends – preformed type
5.
Guy Marker plastic PVC material 8 ft. yellow with spiral grip.
6.
Guy Insulator: Chance #GS30018CCI, or as approved.
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B.
2.08
101012
Anchors:
1. 12” Expansion Anchor, Chance #1283, with 1¼” rod and twin-eye eyebolt
assembly, Chance # 15129, or as approved. Entire assembly noted as F3 on
Contract Drawings.
GROUNDS
A.
Pole ground wires shall be No. 4 AWG solid soft drawn copper, unless otherwise
noted on Contract Drawings.
B.
Solid soft drawn copper for grounding jumpers, same size as pole grounds.
C.
All connections for pole grounds shall be compression type.
D.
Ground rods copper clad ¾” X 10’-0”.
E.
Ground rod clamps, hex head set screw, Chance #C2030345, or as approved.
2.09
A.
SWITCHES
Distribution:
1. 900 Amp, 14.4kV disconnect switch, S&C #4752R9D2, or as approved, meeting
all ANSI/IEEE applicable Standards, mounted as show on the Contract Drawings,
and including the following capabilities:
a. ¾” ice breaking
b. 40 kA momentary
c. 25kA 3 second
END OF SECTION
OVERHEAD ELECTRICAL LINE MATERIALS
33 71 26-4
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