Natural Gas Operations Maintenance Program.pdf

FRA Natural Gas Operations & Maintenance Program

Rev A 11/11/21 Kerry Aschenbach Original draft Rev B 4/6/22 Kerry Aschenbach Add Maintenance and Installation details Rev C 6/16/22 Kerry Aschenbach Add sections per 49CFR192.605 2020 revision

Table of Contents

1. Applicable Standards and Guides

2. Scope

e. Topics defined by 49 CFR 192.605(b) -192.617

3. Maintenance

a. Leak Surveys

b. Leak Repair

c. Exercise Valves

d. Corrosion Prevention

4. Material Selection

5. Installation

a. Aboveground

a. Below-ground

a. Welds

a. Leak Tests

6. Operation

a. Personnel

b. FRA Natural Gas Engineer

c. Annual Reviews by FRA Natural Gas Engineer

d. Starting up and Shutting off Pipeline

7. Emergency Response

1. Applicable Standards and Guides

a. 49CFR192 TRANSPORTATION OF NATURAL AND OTHER GAS BY PIPELINE: MINIMUM FEDERAL

SAFETY STANDARDS

i. Note: This program was written to 2020 revision.

b. ASME B31.8 Gas Transmission and Distribution Piping Systems

c. Fermilab Environment, Safety and Health Manual (FESHM)

d. FESS Design Guide

2. Scope

a. This program covers the roles and responsibilities of anyone performing a covered task on

Fermilab natural gas systems.

b. This manual and associated documents shall be reviewed and updated annually per 49 CFR

192.605(a) and as defined in Section 6(c)

c. This manual specifies material to be used for building natural gas piping.

d. This manual specifies the inspection and maintenance of FRA’s natural gas systems.

e. This manual shall cover all topics required by 49 CFR 192.605(b)

i. The topics defined by 49 CFR 192.605 topics can be found in this program as delineated below:

1. 49 CFR 192.605(b)1 Operating, maintaining, and repairing pipeline is defined in Sections 4, 5, 6 and 7.

2. 49 CFR 192.605(b)2 controlling corrosion is defined in Section 4(d)

3. 49 CFR 192.605(b)3 Making construction records available is defined by Section

6(c) by the dig permit process defined in FESHM 7030. excavation. Additionally, the FRA Engineer shall maintain an AutoCad drawing with details not yet included in the GIS system. These details include back up of new edits, locations of anodes, back up of pipe size and material, etc.

4. 49 CFR 192.605(b)4 is not applicable.

5. 49 CFR 192.605(b)5 Procedures for starting up and shutting down the pipeline are defined in Section 7(d).

6. 49 CFR 192.605(b)6 is not applicable.

7. 49 CFR 192.605(b)7 is not applicable.

8. 49 CFR 192.605(b)8 Procedures for reviewing work done by operator personnel are described in Section 6(c) and Section 7.

9. 49 CFR 192.605(b)9 precautions taken during excavation are described by

FESHM 7030.

10. 49 CFR 192.605(b)10 is not applicable.

11. 49 CFR 192.605(b)11 response to gas odor in or near a building is defined in

Section 4.a.ii.

12. 49 CFR 192.605(b)12 is not applicable.

13. 49 CFR 192.605(c) is not applicable.

14. 49 CFR 192.605(d)Safety related condition reports per 49 CFR 191.23 are defined in Section 6(c).

15. 49 CFR 192.605(e)

16. 49 CFR 192.613(a) The following shall be part of the FRA Natural Gas Engineer’s annual review per Section 6(c):

a. Changes in class locations

b. Failures leakage history

c. Corrosion

d. Substantial changes in corrosion prevention requirements

e. Other unusual operating and maintenance conditions.

17. 49 CFR 192.615 Emergency plans are defined in Section 8.

18. 49 CFR 192.617 Investigation of Failures is defined in Section 7 as part of the

FRA Natural Gas Engineer’s annual reviews as defined in Section 6(c).

3. Maintenance:

a. Leak surveys

i. Leak survey shall be performed on all natural gas and propane piping annually

1. Surveys shall not be more than 18 months apart.

2. There shall be a survey every calendar year.

ii. The piping inside and near buildings may be passively surveyed by occupants and their attention to the smell of odorant of natural gas.

1. Leaks of indoor leaks or leaks that are smelled near buildings shall be promptly reported to the FRA Fire Department by calling 630-840-3131.

a. The Fire Dept shall notify Facilities Engineering Services Section / Facilities Maintenance / Operations. Operations shall then assign either Mechanics or the FRA Natural Gas Engineer to repair the leak.

iii. All outdoor piping shall be surveyed using a meter.

1. Meter specifications and calibration shall be reviewed and approved by FRA

Natural Gas Engineer prior to annual survey.

2. Survey shall include all piping from the Nicor meters to each user or building penetration.

3. All leaks shall be reported to the Fermilab Natural Gas Engineer same day.

a. Leak shall be categorized per ASME B31.8 Table M-5.3

b. Cat I leaks shall be report immediately

c. Cat II and III leaks shall be reported at the end of the same day

b. Leak Repair

i. The Fermilab Natural Gas Engineer shall maintain a list of all natural gas and propane leaks on site.

1. List shall be archived for at least 8 years.

2. List shall include

a. Date found

b. Categorization per ASME B31.8 Table M-5.3

c. Date repaired

d. Location

e. Size of leaking pipe

f. Cost of repair

g. Billing information

h. Name of company or personnel who completed repair

i. Suspected cause

c. Exercise Valves

i. All above ground valves shall be maintenance free design.

ii. All polyethylene valves shall be maintenance free design.

iii. Underground steel valves shall be exercised and greased quarterly.

1. The person exercising the valve shall document:

a. Valve Number and location

b. Date and time

c. Degrees of turn

d. Amount of grease injected

e. Any maintenance issues

i. E.g. difficulty turning, gas smell, valve not holding pressure, material in valve box, damage to box or utility marker, etc.

d. Corrosion Prevention

i. Paint

1. All aboveground outdoor piping shall be visually inspected annually.

2. All paint that is found inadequate for corrosion prevention shall be repaired within 6 months.

3. All above ground piping shall be painted with safety-yellow, non-metallic paint appropriate for pipe and location.

a. Rust-Oleum for metal surfaces or equivalent to be approved by FRA NG

Engineer

4. All repairs to underground coating shall be

a. Epoxy coating

i. 3M SkotchKote Liquid Epoxy 323 or approved equal

ii. Surface preparation shall be at least to SA 2.5

1. Fermi Natural Gas Engineer shall inspect and approve surface preparation prior to epoxy application.

b. Tar paper and glue manufactured for the purpose.

i. Tar paper shall have a yellow outside surface.

ii. Tar paper shall wrap over at least 2” of good coating on each side of joint or defect.

ii. Cathodic Protection (CP)

1. See Fermilab Corrosion Control Policy for description of CP a.

Corrosion Control

Policy.doc

2. All steel piping installed underground shall be protected with Cathodic

Protection to slow corrosion.

3. Passive Cathodic Protection shall be used unless nearby high voltage or other design considerations dictate Active Cathodic Protection be used.

4. Passive Cathodic Protection

a. Passive CP systems shall be inspected annually.

i. The following shall be included in the report from the inspector for each test station:

1. Condition of test station

2. Condition of asset tag

3. Condition of surrounding area

4. Voltage readings

ii. Inspector shall perform minimal maintenance on the test stations:

1. Minor wiring repair

2. Cleaning test station, inside cap and test board

iii. Inspector shall inform FRA Natural Gas Engineer of any major maintenance needs.

iv. Report shall include recommendations for repairs

v. Report shall note any unconventional or unexpected findings.

b. There shall be testing stations to test the voltage differential at least every 0.5 mi of steel piping.

c. The voltage differential between the pipe and the anode shall be approximately -850 to -100 mV.

i. NOTE: The National Association of Corrosion Engineers (NACE) International SP0169-HD2007-SG, Control of External Corrosion on Underground or Submerged Metallic Piping Systems, which applies to the underground natural gas piping recommends the following for steel and cast iron piping: “1. A negative (cathodic) voltage potential of at least 850 millivolts with the cathodic protection applied. This potential is measured with respect to a saturated copper/copper sulfate reference electrode contacting the electrolyte. Voltage drops other than those across the structure-to-electrolyte boundary must be considered for valid interpretation of this voltage potential measurement. 2. A negative polarized potential of at least 850 millivolts relative to a saturated copper/copper sulfate reference electrode. 3. A minimum of 100 millivolts of cathodic polarization between the structure surface and a stable reference electrode contacting the electrolyte. The formation or decay of polarization can be measured to satisfy this criterion.”

d. If the voltage between the pipe and the anode is outside the design range (-850 to -100 mV) then the CP system shall be repaired.

5. Active Cathodic Protection

a. Active CP systems shall be used in the following areas

i. Where there is high voltage due to power lines or beam pipe, etc.

ii. Where there are multiple steel structures which could be negatively impacted by nearby CP, such as in utility corridors or next to beam pipe.

1. In this case anodes shall be placed deep in the ground in order to protect all structures of interest.

Otherwise, the CP system will work backwards and speed corrosion.

b. Active CP rectifiers shall be inspected monthly:

i. The following shall be included in the report from the inspector:

1. Condition of rectifier

2. Condition of asset tag(s)

3. Condition of surrounding area

4. Voltage readings and current readings

5. Shunt reading

6. Cycling of breakers and switches

7. Photos of the inside of the rectifier

ii. Inspector shall perform minimal maintenance on the test stations:

1. Voltage adjustments

2. Minor wiring repair

3. Replace spent fuses

4. Cleaning test station, inside cabinet

5. Note date of inspection and voltage and current numbers on inspection card inside the cabinet.

iii. Inspector shall inform FRA Natural Gas Engineer of any changes from previous inspection and any major maintenance needs.

c. Active CP remote test stations shall be inspected annually.

i. The following shall be included in the report from the inspector for each remote test station:

1. Condition of test station

2. Condition of asset tag

3. Condition of surrounding area

4. Voltage readings

ii. Inspector shall perform minimal maintenance on the test stations:

1. Minor wiring repair

2. Cleaning test station, inside cap and test board

d. Inspector shall inform FRA Natural Gas Engineer of any major maintenance needs.

e. Report shall include recommendations for repairs

f. Report shall note any unconventional or unexpected findings.

4. Material Selection

a. All products, materials, and equipment shall conform to ASME B31.8 Standard and 49 CFR 192.

b. All components shall be FM Approved.

c. Underground piping shall be HDPE YELLOWSTRIPE PE 3408 DSDR 11, or yellow print markings, or approved equal.

i. MDPE, DR10 may be used for applications below 45psi for pipe 2” and smaller. All MDPE pipe shall be yellow in color.

1. Manufacturer shall supply rating for pipe MAOP @ 73 deg or less and subcontractor shall ensure that pipe is rated for the operating pressure.

2. The material and rated shall be submitted to the FRA Natural Gas Engineer prior to purchasing for approval.

ii. Piping and fittings shall be manufactured for the purpose of transporting natural gas.

iii. Piping joints shall be butt fusions.

1. Each saddle and socket joint shall require approval from FRA Natural Gas Engineer.

2. Test joints shall be observed and inspected by the FRA Natural Gas Engineer prior to approval. Inspection shall include a lengthwise cross-sectional cut of the pipe to show the amount of melted and fused material inside the joint.

iv. Risers shall be HDPE to steel transitions manufactured for the purpose.

d. Installing new underground steel piping is only allowed if it is necessary to preserve the existing CP System.

1. Steel piping and its associated CP system shall be contiguous.

ii. All piping shall have coating installed by manufacturer for the purpose of underground installation.

iii. All joints shall be butt weld joints

1. Exception is that steel valves shall be flanged.

e. Valves shall be:

i. ¼ turn

ii. Same size as surrounding piping

iii. Full port

iv. 300#

v. Bubble tight shut off

vi. Below ground valves shall be:

1. Steel

2. Flanged

3. Greased

4. Have a 2” square key adapter installed on (and fixed to) the stem prior to backfill

a. The stem adaptor shall not obstruct the grease fitting

5. Have a 20-40 lb. Mg Anode installed per Drawing CU-10 and CU-12

a. Size of anode shall be determined by the Fermi Natural Gas Engineer.

vii. Aboveground valves shall be:

1. Brass

2. NPT threaded

3. Lockable

4. Handle installed

5. PTFE seat

6. Ball valves

viii. Regulators shall be SENSUS, Deval or approved equal.

1. Regulators shall be sized by an engineer from the distributor / manufacturer according to pressure and flow requirements supplied by FRA.

ix. Meter shall be Onicon F-5501-3115-3009

1. Thermal mass flow meter

2. Inline

3. With integral display

4. 4-20 mA output signals

5. MODBUS

6. Tag with building name and FIMS #

a. NOTE: each FIMS number shall have its own meter.

5. Installation

a. Above Ground

i. Joints shall be threaded NPT sealed with PTFE tape and Blue Monster thread dope or approved equal.

ii. Pipe trains shall have the following assembly outside the building per the above material selection criteria

1. Shut off valve

2. Dielectric Union

3. Upstream gauge

a. Gauge shall be installed on an assembly with

i. 0.5” shut off valve

ii. 0.5” vent valve

iii. vent shall have plug installed

iv. range shall be 150% of the operating pressure

4. Regulator(s)

a. Vent piping shall be installed on the regulator so that the outlet of the vent is at least 3ft above grade. The outlet shall gooseneck down to prevent water ingress. The outlet shall have a SS or aluminum screen to prevent insect ingress.

5. Downstream gauge

a. Gauge shall be installed on an assembly with

i. 0.5” shut off valve

ii. 0.5” vent valve

iii. vent shall have plug installed

iv. range shall be 150% of the operating pressure

6. Flow meter

a. Onicon F-5501-3115-3009

b. A bypass shall be piped around the flowmeter in the same pipe diameter.

c. There shall be unions installed upstream and downstream of the meter

/ bypass assembly.

d. Installation instructions from the manufacturer shall be followed regarding straight pipe length, sensor orientation, etc.

7. Additional shutoff valves shall be installed at each user / piece of gas firing equipment.

iii. Pipe trains shall be installed at least 17” above grade.

iv. Pipe supports shall be electrically isolated.

1. Rubber pads or rubber pipe clamps are acceptable.

v. Bollards shall be installed in front of the gas train if the piping is installed in a roadway or parking lot.

1. Bollard shall be installed per attached drawing CU-6 Bumper Post.

2. There shall be a minimum of two bollards.

3. Galvanized pipe shall be painted safety yellow underneath the plastic sleeve.

4. Location of bollards shall be approved by FRA Natural Gas Engineer prior to installation.

vi. Building penetration shall be sealed with Firestop caulk and covered with a stainless steel escutcheon.

1. Exception: when walls are corrugated, slanted, or otherwise uneven, then the escutcheon shall be omitted. Waterproof caulk shall be selected to match the building finish and used to cover the firestop caulk. Caulk shall be smoothly applied, and any excess shall be cleaned off the building.

vii. All above ground piping shall be painted safety yellow using nonmetallic paint.

1. Paint shall be appropriate for outdoor applications.

2. Paint shall be manufactured for application on rough steel.

3. Paint shall be Rust-Oleum or approved equal.

4. Any leak testing shall be performed prior to painting.

5. Regulators, flow meters, gauges and other items manufactured with corrosion resistant finishes may be omitted from the painting scope.

6. Paint shall cover all sides of the pipe and every joint.

7. Painter shall clean off any overspray onto the building or surrounding area.

b. Below Ground Piping shall be installed per FESS Design Guide Drawing CU-5

i. Shall be installed 36” below grade unless approved by the FRA Nat Gas Engineer and allowed by 49 CFR 192.327.

ii. Tracer wire shall be installed on all poly pipe per FESS Design Guide.

1. Tracer wire shall be stainless steel

iii. Shall have sand bedding 6” in all directions.

1. Sand shall be FA-6 or approved equal.

iv. Warning tape shall be installed on top of the sand bedding.

v. Backfill shall be compacted to 95% density.

1. Backfill shall be compacted every 18”.

vi. Topsoil shall be

1. at least 6” thick

2. Shall be black dirt without rocks or aggregate

3. Shall be levelled prior to seeding.

vii. Grassy areas shall be restored to condition prior to construction.

1. Grass seed shall be on the preferred list of FESS Design Guide 2-0-C Sitework

2.1.

viii. All grass seed shall be protected with straw.

ix. All utility flags shall be removed by the subcontractor as part of area restoration.

c. Welds

i. Pipefitter or subcontractor’s foreman shall supply WPS and PQR for each type of joint / weld prior to start of each project.

1. All Welding Procedure Qualifications and Procedure Qualification Records shall be submitted to and approved by the FRA Natural Gas Engineer and approved by FRA prior to start of work.

2. NOTE: welder shall have welded per the approved WPS in the previous six months.

ii. Pipefitters shall supply a test weld prior to start of construction

1. Fusion Joints

a. A test Fusion Joint shall be of each type of joint shall be supplied to the FRA Engineer for approval each day that fusion joints shall be made.

b. Each joint shall be cut perpendicular to the fusion material so that the FRA Natural Gas Engineer can inspect the material fusion, bead, and alignment.

2. Welded Metal Joints

a. A test Joint of each configuration shall be submitted to the FRA Natural Gas Engineer once prior to start of construction.

b. Each test joint shall be cut in half so that the FRA Natural Gas Engineer can inspect the weld material, fusion, alignment, and heat affected zones.

iii. Inspection reports and joint records

1. The FRA Natural Gas Engineer shall keep photos and videos of all test joints and all installed joints.

2. The records shall be kept with the Daily Construction Log which tracks the progress of the installation.

3. Records shall include:

a. Date of weld

b. Name of pipefitter

c. WPS and PQR

d. Name of inspector

e. Pass or failure

f. Notes on condition of weld bead, alignment, and any irregularities

g. Type of inspection (visual, pressure, destructive, etc.)

d. Leak tests

i. New systems shall be tested per 49CFR192 Subpart J.

ii. Repairs shall be leak tested using operating pressure and bubble test.

1. Bubble test liquid shall be manufactured for such purpose.

2. Bubble test shall be witnessed by the FRA Natural Gas Engineer.

3. Bubble test shall be videoed.

6. Operation:

a. Personnel

i. Any person involved in maintenance or operation of natural gas lines must be trained and provide certification to the FRA Natural Gas Engineer.

1. Attachment A for list of Covered Tasks as defined 49CFR192.801(b).

2. Covered Tasks are any actions that affect the operation or integrity of the pipeline. This includes, but is not limited to:

a. Turning valves

b. Excavation for repair of natural gas

c. Welding / hot fusing underground piping

d. Leak Surveying

e. Inspecting cathodic protection

f. Inspecting welds and installations

b. The FRA Natural Gas Engineer shall define:

i. New Construction requirements

1. Material and engineering specifications

2. Approve and maintain records of WPS, WPQ, Hot Fusion Procedure Specifications and qualifications

ii. What qualifies as a Covered Task.

iii. What trainings and certifications qualify personnel to perform Covered Tasks.

iv. Ensure that all required maintenance is performed per 49CFR192.805

v. Ensure that all personnel performing Covered Tasks are qualified to do so

vi. Work with other FRA employees to maintain records of qualifications

c. Annual Reviews by FRA Natural Gas Engineer:

i. Creating a list of all leaks and required repairs per Section 7(b)

ii. Review this program

1. At least every 15 months, and at least every calendar year

2. Review shall include review of documents and a system condition history per 49

CFR 192.613(a).

a. Changes in class locations

b. Failures leakage history

c. Corrosion

d. Substantial changes in corrosion prevention requirements

e. Other unusual operating and maintenance conditions.

iii. Review all drawings

1. Review GIS map of Natural gas system

a. Check for changes within the last year and any anomalies

2. Review AutoCad drawings

iv. Review the Cathodic Protection program and all reports from cathodic protection inspections

v. Review Annual Leak Survey Report and Leak list for all

vi. Map all the failures for the year and inspect for any patterns.

vii. Review all above changes and lists to determine what preventative maintenance should be performed.

viii. Write an annual Natural Gas Utility Assessment. The report shall include

1. List of leaks with

a. Full list with location, date found, date repaired, Category, cost to repair, etc.

b. Summary table with

i. Number of leaks of each Category per AMSE B31.8 Table M-5.3

ii. Time to repair leaks (max, min, and average per Category)

iii. Legal limits for time to repair by Category

2. Results of annual inspections, including:

a. Suggested paint repairs

b. Suggested Cathodic Protection repairs

c. Status of flow meters

3. An analysis of the state of the utility, suggested preventative maintenance, and major renovations.

4. Summary of the cost of maintenance of the Natural Gas Utility.

d. Starting and Shutting Down Pipeline

i. All components shall be selected to make it impossible to exceed the Maximum

Allowable Operating Pressure (MAOP) of the Fermi natural gas system (or propane systems).

ii. When a section of pipe is isolated / shut down:

1. an Outage Notification shall be released per the FESS / Facility Management

Procedures.

2. A WO shall be placed to have an FRA Mechanic turn the valves to isolate the gas.

3. The FRA Natural Gas Engineer shall accompany the FRA Mechanic when turning valves if possible.

4. The valves shall be turned slowly to allow pressure differentials to slowly acclimate.

5. FRA Natural Gas Engineer is responsible for contacting HVAC Service Manager and the Area Facility Managers.

6. The Area Facility Managers are responsible for notifying the building tenants and affected projects.

iii. When section of pipe is started up / returned to service:

1. The FRA Natural Gas Engineer is responsible for notifying the FRA Mechanic that the pipeline is safe to return to service.

2. The FRA Natural Gas Engineer shall accompany the FRA Mechanic when opening valves.

3. The FRA Mechanic shall open the valves.

4. The valves shall be turned slowly to allow pressure differentials to slowly acclimate.

5. The FRA Mechanics shall be responsible for venting air out of the line and lighting pilots, un-isolating individual services, ensuring that service is restored inside of buildings.

7. Emergency Response:

a. Emergency response to leaking gas is defined by attached “Emergency Gas Line Check-list”

i. Fermi Emergency Line (630-840-3131) shall immediately notify the Fermi Fire Department of any leaking gas.

ii. The Fire Department shall notify the FESS / FM / Operations Manager of the gas leak, who shall assist in shutting off and venting gas pressure if necessary.

iii. The FESS / FM / Operation Manager shall notify the FRA Natural Gas Engineer, who shall assess the leak for the appropriate response.

b. Prompt response to fire, leak and natural disaster is the responsibility of the Fermi Fire Department.

c. Prompt assessment and repair is the responsibility of the FRA Natural Gas Engineer.

d. After every emergency the FRA Natural Gas Engineer shall:

i. Review the actions all involved parties to assure that they were knowledgeable and acted properly according to this program and to verify that their trainings are effective.

ii. If any gaps or errors are identified then the FRA Natural Gas Engineer shall promptly suggest training to the individuals and supervisors who require it and shall update this program accordingly.