underground house piping specifications

PHILADELPHIA GAS WORKS

SPECIFICATION FOR INSTALLING

PRIVATELY OWNED

UNDERGROUND NATURAL GAS PIPING

FOR

HOUSING PROJECTS, CONDOMINIUMS, APARTMENTS, INDUSTRIAL SITES OR SIMILAR

COMPLEXES

PGW UNDERGROUND HOUSE PIPING MANUAL 10/’2009

TABLE OF CONTENTS

Subject: Specifications for Installing Private Underground Gas Piping for Housing Projects, Condominiums, Apartments, or Similar Complexes

Section 01. Scope of Specifications ____________________________________________ 1

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11

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12

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Section 17. Pipe Joint Assembly _____________________________________________ 12

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28

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Section 02. PGW Contact and Source of Information ____________________________ 2

Section 03. Pennsylvania Act 187 _____________________________________________ 2

Section 04. Authority to Install Underground Gas Piping _________________________

Section 05. Inspection_______________________________________________________

Section 06. Turn-on of Gas __________________________________________________

Section 07. Location and Depth_______________________________________________

Section 08. Distance from Other Structures ____________________________________

Section 09. Joint Trenching __________________________________________________

Section 10. Corrosion Control Requirements for Steel Pipe _______________________

Section 11. Materials – General ______________________________________________

Section 12. Pipe Sizes and Material ___________________________________________

Section 13. Pipe Lengths ___________________________________________________

Section 14. Protective Pipe Coating __________________________________________

Section 15. Transporting and Handling Coated Pipe ____________________________

Section 16. Pipe Joints and Fittings __________________________________________

Section 18. Welding _______________________________________________________

Section 19. 4.6.5.3 Bending of Pipe___________________________________________

Section 20. Plastic Fusion Procedure – GENERAL _____________________________

Section 21. Valves and Housing for Valves ____________________________________

Section 22. Trenching, Installation and Backfilling of the Underground System _____

Section 23. Drip Pots, Drip Rods, and Drip Boxes ______________________________

Section 24. Termination of Piping from Underground Into Buildings or Outside

Meter Sets__ ____________________________________________________

Section 25. Installation of 1-¼” and 2” Services ________________________________

Section 26. Installation of 3” and Larger Services ______________________________

Section 27. Installation of Corrosion Control Devices ___________________________

Section 28. Pressure Test for Leaks __________________________________________

Section 29. Damage Prevention Standards_____________________________________

Section 30. Drawings and Standards _________________________________________


APPENDIX A – Corrosion Control _____________________________________ A-1

APPENDIX B - List of Suppliers________________________________________ B-1

APPENDIX C – Notification Form ______________________________________ C-1

APPENDIX D - Joint Trenching Detail __________________________________ D-1

APPENDIX E – PA ACT 187 __________________________________________ E-1

CHECKLIST for ONSITE INSPECTION for GAS TURN-ON _______________F-1


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File No. 32.3.4

Subject: Specifications for Installing Private Underground Gas Piping

for Housing Projects, Condominiums, Apartments, or Similar Complexes

NOTE: These specifications are subject to change without notice. Consult with the

Distribution Department of the Philadelphia Gas Works before starting any installation (See Section 02 PGW Contact and Source of Information). All references to statutes, rules or regulation are current as of the date of publication, but remain the responsibility of the Owner/Contractor with respect to modification or other change in law or regulation. PGW makes no warranties or certifications express or implied with respect to the methods or procedures contained herein.

Section 01. Scope of Specifications

1. These specifications apply to privately owned and installed underground gas piping systems (all 2” and larger, steel or plastic underground gas lines) supplied through and downstream of a PGW meter. These installations can include but are not limited to:

a) Major Installations:

(i) Housing Projects or PHA sites

(ii) Condominiums

(iii) Apartments

(iv) Universities or College campuses

(v) Industrial campuses or complexes

b) Minor Installations:

(i) Individual Separate buildings

(ii) Garages

(iii) Incinerators

(iv) Pool Heaters

2. Installations of pipe smaller than 2” should be forwarded to PGW for review and determination of the proper installation and inspection procedures.

3. Failure to follow the specifications and procedures set forth in this manual will result in PGW not connecting or approving for connection the underground gas piping system to PGW’s Distribution system.


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4. PGW will not connect or approve for connection, any underground gas piping system to PGW’s Distribution system until all inspection and testing deemed necessary by PGW is completed satisfactorily.

a) All post-construction engineering review, inspection services, testing services, corrosion control validation and documentation services will be billed to the Owner at PGW’s current hourly rate until completion of the job.

5. Responsibility for compliance with Title 49, Code of Federal Regulations, Part 192 remains with the Owner of the underground piping system. Federal Regulations consider the Owner as an Operator of a gas piping system and the Operator must conform to all requirements of Title 49, Code of Federal Regulations, Part 192. PGW requests the Owner of the underground gas piping system to supply the information requested in the letter attached in APPENDIX C – Notification Form - in this manual.

6. Specifications for piping within a building are contained in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (1999) and the Philadelphia Gas Works “Piping Specifications for Fuel Lines and Equipment Installation, January 2000” which is PGW’s supplement to the National Fuel Gas Code. PGW is not permitted to connect the piping within the buildings to the underground piping system until the leak tests have been completed.

7. These are minimum specifications and are intended to assist Owners/Contractors working within the City of Philadelphia and/or working on the installation of underground gas piping supplied by a PGW meter. The Owner/Contractor should follow all other applicable Federal, State, and local building, piping and fire codes as relevant to natural gas piping.

8. The Owner/Contractor must immediately notify PGW of any changes in scope of a project, before or during installation of Gas facilities

Section 02. PGW Contact and Source of Information

1. All matters related to underground gas piping shall be referred to the Planning Section of the Distribution Department of PGW at 800 W. Montgomery Avenue, Philadelphia, PA 19122. Phone calls are also accepted at (215) 684-6384, General Supervisor – Corrosion, or (215) 684-6207, Manager, Planning Section, Distribution Department.

2. Proper application for increased consumption will need to be completed by PGW’s Marketing Department. The key contact will be the Residential/Commercial Sales Support Coordinator at 215-684-6838.


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Section 03. Pennsylvania Act 187 – One Call

1. In keeping with the Underground Utility Line Protection Act 287 of 1974 as amended in 1996 by Act 187, which expanded protection efforts to underground utilities by designating the Department of Labor and Industry as the enforcement agency for the PA One Call Legislation, it is the Owner/Contractor’s responsibility to provide timely notification to other interested Government Agencies, Local traffic Control Center, and the necessary Utility Companies whose structures could be affected by the Owner/Contractor’s operations.

2. The Owner/Contractor is advised that members of the Pennsylvania One Call System may be contacted by telephoning 1-800-242-1776. The Owner/Contractor is also advised that non-members of the Pennsylvania One Call System must be individually notified.

3. As Owner/Operator of an underground facility, PA ACT 187 requires the Owner to become a member of PA One Call, receive contractor notifications in the future and respond accordingly to mark-out the Owners facilities whenever an Excavator digs in the vicinity of the underground system.

4. For more information, see APPENDIX E – PA ACT 187

Section 04. Authority to Install Underground Gas Piping

1. PGW does not have permitting authority. Accordingly, any review of piping by PGW does not act as any authorization to install underground gas piping in City Streets, dedicated or undedicated, or property dedicated to public use.

2. No gas pressure design work or gas pipe sizing should be done before consulting with PGW to confirm and determine the availability and/or the ability to supply adequate upstream pressure or capacity within the Philadelphia Gas Works distribution system.

3. No Owner/Contractor should install underground piping without first submitting three (3) sets of drawings drawn to acceptable scale to the Distribution Department Planning Section. The drawings should describe in full the proposed piping with appropriate installation details and material specifications for review and approval.

a) Each submitted drawing shall include the following where applicable:

(i) Tract boundary (include bearings and distances)

(ii) Public and Private streets

(iii) Lot lines

(iv) Street centerlines

(v) Public utility easements


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(vi) Building footprints

(vii) Driveways

(viii) Walls (retaining, landscape, etc.)

(ix) Curbs & gutters, Public sidewalks and contours

(x) Substructures - water, sewer, storm drains and any other utilities available (future and existing)

b) Each drawing should adhere to the following:

(i) Dimensioning for all features listed above

(ii) Legends identifying features and symbols

(iii) Scale (English/Metric)

(iv) Revision dates

(v) Detailed site vicinity map

4. All components of the proposed underground gas piping system shall be identified (manufacturer, model number, style, and material) at a minimum by:

a) Sizes of the pipe

b) Length of each section between fittings

c) Branches

d) Turns

e) Valves

f) Drips

g) Any other important points where there is a change of size, material, direction and depth should be shown on the drawings.

5. Underground systems that carry natural gas at a pressure greater than 5 PSIG shall be welded steel pipe. Those systems that operate at a pressure equal to or less than 5 PSIG may be steel or plastic pipe. Piping, regardless of the material, shall be installed as directed by this specification book.

NOTE: The Owner/Contractor may request, in writing, an exception to the welded steel pipe requirement for underground systems with an operating pressure greater than 5 PSIG. The use of plastic pipe or mechanical couplings on these systems will be reviewed by PGW on an individual basis. Approval will be granted based on but not limited to:

(i) Type of installation

(ii) Location of installation

(iii) Proximity of surrounding structures

(iv) “Wall to Wall” paving


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(v) Future construction activity in the area

6. No Owner/Contractor should install underground piping without having received approval on the drawings for installation from PGW’s Distribution Department. A signed copy of the Owner/Contractor’s drawings noting PGW’s approval will be returned to the Owner/Contractor after the review process.

7. If the drawings are not approved, PGW will inform the Owner/Contractor the reason and what requirements are need to gain PGW’s approval.

8. A copy of the approved drawings should be kept on the jobsite and made available to PGW inspectors or engineers during the installation of the project.

Section 05. Inspection

1. After approved installation drawings have been received from PGW and not less than 5 (five) working days before starting the installation, the Owner/Contractor shall notify the Distribution Department (Telephone (215) 684-6384, General Supervisor – Corrosion) of the proposed starting date, so that if desired, PGW can make either a continuous or intermittent inspection during the installation.

2. If deemed appropriate, PGW will provide a Field Drafter to field measure and produce an “As-Built” drawings to document as part of PGW’s permanent record the exact locations of the underground piping system.

a) These “As-Built maps” are extremely important for reference for any future maintenance or construction or damage prevention mark-out.

3. Although PGW voluntarily inspects privately owned gas installations, it is understood that PGW does not guarantee or certify the present or future soundness of the piping system or proper piping design or sizing.

4. Problems discovered by PGW’s inspection shall be corrected to the satisfaction of PGW. PGW will not energize a system until and unless all problems are corrected.

Section 06. Turn-on of Gas

1. PGW reserves the right to refuse to introduce gas into the underground piping system until the system has been installed in accordance with these Specifications and has fulfilled the requirements of Section 28 - Pressure Test for Leaks and has been approved by PGW.

2. PGW reserves the right to be the sole authority to introduce gas into the underground piping system or be present when the Owner/Contractor energizes the underground piping system. This decision will be based on:


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a) Pipe size of the underground piping system.

b) Total installed footage of the underground piping system.

c) Existence and location of PGW upstream facilities including PGW meters and pressure control devices (Distribution Department regulators).

d) Underground system operating pressure.

3. At the time that the underground system drawings are being reviewed, PGW will make the recommendation whether the system can be energized by the Contractor or requires PGW to complete the Turn-On.

Section 07. Location and Depth

1. The location of the pipe, in respect to building, curbs, sidewalks, and other underground structures, should be carefully chosen so that future maintenance work will be expedited. All pipe locations should be clearly shown on the drawings required in. Wherever possible, the depth of services at the building wall shall be 2’0” or greater. In no case shall the depth be less than 1’6”. The depth below final grade of main shall be between 2’6” and 3’6” to top of pipe, but this 2’6” minimum is permissible only provided the requirements for grading and depth of piping entering buildings have been fully met.

2. Caution tape, and in some instances tracer wire, is to be installed with direct burial of plastic pipe. See Drawing D.S. 56.0.

Section 08. Distance from Other Structures

1. When a gas pipe parallels other underground structures, a clear horizontal distance of at least 36” between the two structures shall be maintained, unless otherwise approved by PGW.

2. When gas piping crosses over or under other underground structures, a clear Vertical distance of at least 6” shall be maintained.

a) If 6” clearance cannot be maintained, the underground gas piping shall be protected by the installation of a “Lily Pad” as shown on Drawing D.S. 23.3

3. Also See Section 09 - Joint Trenching.

Section 09. Joint Trenching

1. Trenches shall be of such size as to provide a minimum vertical clearance of twelve inches from power conductors of any size and a minimum separation of six inches from all other substructures.


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2. All gas main piping shall have a minimum thirty inches cover below finished grade. All services shall have a minimum of twenty-four inches cover below finished grade. All trenches must be level and free of debris at the time gas lines are to be installed.

3. All joint trenches will be backfilled with sand to be a minimum of six inches of cover over all gas main and service pipe in normal soil and a minimum of twelve inches in rocky soil.

4. Joint trenches shall have a minimum six-inch sand pad in rocky soil conditions. Actual depth to be determined by PGW at time of installation. The Owner/Contractor is responsible for supplying rock-free sand or PGW approved material suitable for backfilling.

Section 10. Corrosion Control Requirements for Steel Pipe

1. Owner/Operators must establish procedures to implement a corrosion control program for their piping system. These procedures shall include the design, installation, operation, and maintenance of a Cathodic Protection System. These procedures must be carried out by, or be under the direction of, a person qualified by experience and training in pipeline corrosion control methods.

2. All buried steel pipe must be properly coated, insulated, and have a Cathodic Protection System designed to protect the pipe in its entirety. Cathodic protection as referred to in these specifications, is a procedure by which underground gas facilities are protected against corrosion.

3. Owner/Consultants can provide the necessary expertise to design, install, inspect, and monitor Cathodic Protection Systems.

4. These specifications include the necessary minimum requirements to insure that the Piping system is properly coated. A qualified Corrosion Consultant should provide the other facets of Cathodic Protection.

Section 11. Materials – General

1. The Contractor must receive PGW’s written permission to use any materials not listed in this standard. Approval to use a different material than listed in this manual is granted on a “per job” basis. The Contractor shall not assume prior approval of materials used will guarantee future approval to use the same materials.

2. All materials shall be new, free of material defects, and in good condition, unless otherwise specified and agreed to for the specific job by PGW.


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3. Pipe, valves, fittings, and other gas system components must be designed and tested to mandatory industry specifications. The specifications are incorporated by reference into 49 CFR Part 192, the gas pipeline safety regulations. Components meeting the requirements are qualified for gas service and marked with the "approved" markings.

4. A valve may not be used under operating conditions that exceed the applicable pressure-temperature rating. The valve will be stamped with the maximum working pressure rating (psig). Never operate valves at pressures that exceed their rating. The maximum working ratings are applicable at temperatures from -20o F to 100oF. Metal valves will often be stamped with the symbols "WOG.” This means that they are suitable for service for water, oil, or gas. Sometimes just the letter "G" (for gas) appears. The valves must be rated for at least 100 psig.

5. Plastic pipe is unsuitable for aboveground installation. Plastic pipe must be buried or inserted.

6. Owner/Contractors must follow the manufacturer's procedures for installation and joining their products and joining other materials to their products.

7. References to specific products, by trade names, shall mean that product or equal (as determined by PGW) and shall not be construed as an endorsement for that material or derogatory to other competitive products.

8. Refer to APPENDIX B - List of Suppliers, for suppliers.

Section 12. Pipe Sizes and Material

1. Steel Pipe

a) All pipe shall be new steel, API-5L, Grade B – seamless, or electric resistance welded. Butt-welded pipe is acceptable only in 2” and smaller sizes. Weight and wall thickness shall conform to the following:


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Nominal Size (In.)

Wall Thickness

(In.)

Schedule No.

ANSI B36.10

1-¼” .140 40 2” .154 40 3” .216 40 4” .237 40 6” .280 40 8” .322 40 12” .375 * 16” .375 30

*There is no corresponding schedule number for 12” pipe per ANSI B36.10

b) No steel pipe smaller than 1-¼” shall be installed underground.

2. Plastic Pipe Specifications

a) Plastic pipe is commonly used for mains and services by the gas industry. Polyethylene (PE) pipe is recommended as the most suitable plastic pipe for natural gas piping. Acceptable PE plastic pipe is manufactured according to standard ASTM D2513 and is marked with that number.

b) Pipe supplied by the Contractor shall be PE 2406 or PE 3408, Performance, Uponor or CSR pipe. All IPS pipe will be:

IPS Pipe Size PE 2406 PE 3408

2” SDR 11 SDR 11

3” SDR 11.5 SDR 11

4” SDR 11.5 SDR 11

6” SDR 11.5 SDR 11

8” SDR 13.5 SDR 13.5

c) All plastic pipe to be used as gas pipe MUST be manufactured under the ASTM D2513 specification. The pipe must have ASTM D2513 marked on it. For more information, refer to Subpart B of 49 CFR Part 192.59 and 192.63


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SDR-11 PE2406 CEC ASTM D2513 GAS PIPE 2”

The figure above shows a properly marked PE pipe. ASTM D2513 is clearly marked on the pipe. If ASTM D2513 is not marked on a pipe, do not purchase it.

d) Listed below are the color designations of the print line you will find on each type of black high density pipe and an example of a yellow print line for gas pipe.

Print line color Pipe Application Yellow Gas

Blue Water Red Fire water

Green Wastewater

PE 3408 o

r PE 2406

Plastic Pipe Size: Outside

Diameter

Wall Thickness

(In.)

Wall Thickness

(In.)

¾” CTS Plastic Tubing 0.875” x 0.090” ---

1” CTS Plastic Tubing 1.125” x 0.090” 0.090”

1 ¼” CTS Plastic Tubing 1.375” x 0.090” ---

1 ¼” IPS Plastic Pipe 1.660” x 0.151” ---

2” IPS Plastic Pipe 2.375” x 0.216” 0.216”






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Section 13. Pipe Lengths

1. Steel pipe shall be procured with ends beveled for welding. Individual single random lengths, as received on the job, shall not be less than 18’ long. Not more than one “cut length” shall be used between any two fittings. For this purpose, a valve shall be considered as a fitting.

2. Plastic pipe shall be procured as follows: All CTS pipe in coiled rolls, 1-¼” IPS pipe in 500’ coils or 40’ lengths, 2” IPS pipe in 500’ coils or 40’ lengths, 3”, 4”, 6” and 8” IPS pipe in 40’ lengths.

Section 14. Protective Pipe Coating

1. All steel pipes shall be completely coated. Individual lengths of pipe shall be procured with a mill applied coating. Coating systems shall be Pritec as follows:

a) Pipe sizes 1-¼” and 2” shall be coated with a standard coating of 5” at the pipe ends. Pipe coating thickness for 1-¼” pipe shall be .010” of adhesive and .025” of plastic. Pipe coating thickness for 2” pipe shall be 0.10” of adhesive and 0.30” of plastic.

b) Pipe sizes 3” and larger shall be Pritec coated with a standard coating cutback of 6” at the pipe ends. Pipe coating thickness for all sizes shall be 0.10” of adhesive and .060” of polyethylene.

c) Weights per foot of various sizes of coated pipe will be approximately as follows:

Pipe Size Pritec (pounds per

foot) 1-¼” 2.4

2” 3.8 3” 7.9 4” 11.3 6” 19.6 8” 29.4 12” 50.8 16” 64.1

2. Field coating of welds, couplings, valves, pipe, main connection, fittings, and miscellaneous fittings associated with Pritec coated pipe shall be done according to Appendix A.

3. Operating parts of valves shall not be coated.

4. Piping inside sleeves require coating.


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Section 15. Transporting and Handling Coated Pipe

1. Coated pipe shall be handled with equipment such as wide reinforced canvas slings and wide padded skids designed to prevent damage to the pipe coating. All handling and hauling equipment shall be approved by PGW.

2. Stored pipe shall be supported by wooden timbers placed under the uncoated ends to keep the coated pipe off the ground.

3. The Owner/Contractor shall inspect the coating on the underside of the pipe while suspended from the sling and before lowering into the trench. Damage to the coating shall be repaired before placing the pipe into the trench.

Section 16. Pipe Joints and Fittings

1. No screw joints other than those referenced in Section 25 Installation of 1-¼” and 2” Services, and shown on Drawing D.S. 10.0, D.S. 10.15, D.S. 12.0, and D.S. 54.0 shall be used on any part of the underground system.

2. Individual lengths of steel pipe and appurtenant fittings such as bends, tees, crosses, drips, etc., shall be jointed together by welding, or by the use of mechanical compression couplings.

a) Mechanical compression fittings or couplings installed underground on 2” and smaller pipe shall be of a boltless compression type for gas with armored gaskets.

b) Mechanical compression fittings or couplings installed underground on 3” pipe and larger shall be bolted type with armored gaskets.

c) All welding fittings used underground such as ells, tees, crosses, reducers, Etc., shall be standard fittings in accordance with the provisions of the “Standard For Steel Butt Welding Fittings”: ANSI B-16.9, latest edition.

3. Odd degree bends shall be fabricated by the Owner/Contractor by cutting and beveling the Standard fitting. Bending of pipe is not permitted on the main system.

4. PE pipe must be joined by either the heat fusion method (butt, socket, or electro fusion) or by a mechanical coupling. Each joining procedure and each person making joints must be qualified. Butt fusion is not allowed for coil pipe.

Section 17. Pipe Joint Assembly

1. Mechanical Compression Coupling Assembly (Bolt Type) for Steel Pipe.

a) Clean exterior surface of each pipe for a distance of 6 to 8 inches back from the end. Remove oil, dirt, loose scale, and rust.


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b) Slip follower rings over pipe ends and slide back over cleaned area.

c) Wipe non-insulating gaskets clean and, except in freezing weather, immerse in soapy water. Slide gaskets over pipe ends, and then push back about five (5) inches. In freezing weather, parts shall be kept warm prior to installation so that they will “flow” readily into their seats. Insulating gaskets and parts shall be installed dry and shall be dry at time of coating.

d) Clean coupling middle ring, paying particular attention to flares on ends where the gasket will seat. Then slip middle ring over one end until centered.

e) Insert plain end of pipe into middle ring. Where required, retract pipe slightly and center middle ring over gap.

f) In non-freezing weather, except where insulating parts are involved, lubricate pipe and flares of middle rings with soapy water. Slide gaskets and followers into place making sure gaskets are pushed under middle ring flare all the way around. In freezing weather, brush parts clean and assemble dry.

g) Insert bolts and install nuts with rounded surface toward the follower ring.

h) Tighten bolts progressively, drawing up on opposite sides a little at a time. Return to retighten until all bolts have a uniform tightness. During tightening, strike the follower rings occasionally with a hammer to make sure they are properly seating.

i) Check the torque on all bolts so they are at “Required Torque” according to the following table:

Coupling Size Required Torque Bolt Diameter Torque

3” to 16” 5/8” 75 ft. lbs.

2. 1-¼” and 2” Mechanical Compression Coupling Assembly for Steel Pipe.

a) Couplings must be installed so that the coupling is centered over the ends of the pipe and the ends of the pipe must be no further than ¼” apart. The pipe shall be entered the full distance into compression fittings such as ells and valves.

b) Compression nut must be wrench tightened. A 24” wrench is required for 2” couplings. An 18” wrench is required for 1-¼” couplings. In each case, a pull of about 75 pounds is required to the end of the wrench when tightened.

3. Mechanical Compression Coupling Assembly for Plastic Pipe.

a) See Drawing D.S. 56.0 in Part 28


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Section 18. Welding

1. Qualification of welders shall be done by PGW alone in accordance with the latest requirements of the Department of Transportation, Office of Pipeline Safety Part 192, Sub-Part E, “Welding of Steel in Pipelines” using API Standard 1104, latest edition.

2. In addition, all welding shall be shielded metal arc welding and shall comply with PGW “Standard Procedure” Specifications Arc Welding of Gas Pipe and fittings”. Drawing D.S. 20.1, or an acceptable qualified equal.

3. All welds on the underground piping system shall be subject to radiographic examination. PGW may require 100% radiographic inspection based on system operating pressure, size of pipe or experience with the Owner/Contractor. All welds that PGW requires to be radiographed will be at the Owner/Contractor’s expense.

a) PGW shall approve or reject the weld on the basis of radiographic quality contained in latest edition of API-1104 Code.

b) The Owner/Contractor must repair all rejected welds.

Section 19. Bending of Pipe

1. All bent pipe shall conform to Section 192.313 of Part 192 “Minimum Federal Safety Standards” which is quoted in part as follows:

a) A bend may not impair the serviceability of the pipe.

b) A bend on pipe that is 12 inches or more in nominal diameter must not deflect the pipe more than one and one-half degrees in any length of pipe equal to the diameter.

c) For pipe more than four inches in nominal diameter, the difference between the maximum and minimum diameter at a bend may not be more than two and one-half percent of the nominal diameter.

d) Each circumferential weld of steel pipe that is subjected to stress during bending must be non-destructively tested.

e) On pipe containing a longitudinal weld, the longitudinal seam must be as near as practicable to the neutral axis of the bend.

2. Proper bending equipment is required, and the temperature of the coating must be such, the Engineer’s experience indicates that there will be no damage to the coating.

3. All mechanically bent pipe shall be hydrostatically tested at 100 psi and this test shall be held for a period of time sufficient to indicate to the PGW Engineer that


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the pipe is not leaking. No additional payment is required for this testing. IS THIS CORRECT?

Section 20. Plastic Fusion Procedures – GENERAL

1. General Requirement

a) Skillful application of the qualified joining processes and the use of approved materials and equipment in good condition are needed to achieve sound fusion joints in plastic piping. Joints shall be made in conformance to a qualified procedure and by personnel who have been qualified as described in this Section.

b) Fusion equipment should be maintained as described in Section 20 Plastic Fusion Procedures – GENERAL, PART V - “Maintenance of FusionEquipment.”

2. Qualification of Fusion Operators and Instructor

a) PGW shall alone qualify Owner/Contractor personnel to make heat fusion connections.

b) Any underground piping system not installed by a PGW qualified fusion operator will not be considered acceptable to PGW.

c) PGW shall designate the person responsible for the training and qualification of instructors. A listing of qualified instructors along with pertinent training information shall be maintained.

d) PGW shall maintain a file of qualified Owner/Contractor operators trained by PGW instructors. In addition, for the purpose of field identification, qualified Contractor operators shall carry an identification card furnished by PGW, which shows qualification status.

e) The destructive test described in Section 20 - PART III. EVALUATION OF FUSION JOINTS - shall be used to determine whether an operator or instructor is qualified to perform a particular process.

f) Documented evidence of fusion operator qualification shall be maintained as long as the operator remains active. The proficiency of qualified operators shall be verified by test or field observation once each calendar year. Test verification shall consist of making and testing joints. Changes in procedures, material, and equipment should be discussed at the time of verification. Any operator whose proficiency has not been verified during the calendar year must be re-qualified.

g) Any operator who has made 3 joints, or 3 percent of the joints made on any one job, whichever is greater, which are found to be unacceptable by testing must also be re-qualified.

3. Training


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a) Operators shall be trained and qualified by the type of joint to be made such as:

(i) Butt fusion

(ii) Tapping tee Electro fusion

(iii) Branch saddle connections (Electro fusion)

b) Training will require the making and testing of representative types of joints pertinent the qualification. In addition, initial operator’s training shall include an orientation to become familiar with and have explained.

(i) Fusion equipment and techniques

(ii) Test procedure

(iii) Maintenance of equipment

c) An operator’s skill shall be evaluated by the appropriate destructive tests. Tests performed and results observed shall be recorded and maintained.

4. Operator Identification

a) On projects where two or more qualified operators are making a joint, each operator shall identify his work with his Company Fusion Permit number. An approved china marker should be used to mark the Driscopipe fusion.

5. There are two types of fusion joints. Please note for saddle fusion joints only electro fusion ones are allowed.


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SADDLE FUSION JOINT

Good melt pattern on pipeBead formed completelyaround fitting

BUTT FUSION JOINT

No gaps or voids No misalignmentof pipe ends

Uniform double melt beadrolled back on both sides

Properly prepared surface

PART I. BUTT FUSION

1. Equipment

a) The McElroy plastic fusion unit will be the basic unit used for butt fusing plastic pipe; however, the Rigid (Connectra) butt fusion machine could be used also. Basically, all Fusion units, regardless of the manufactures, consist of the following:

(i) A joiner with appropriate adapters for holding the pipe and butt fitting to be fused is axial alignment.

(ii) A facer for preparing both pipe ends simultaneously.

(iii) A thermostatically controlled flat faced, coated, heating pipe to bring the pipe ends to be joined up to fusion temperature.


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b) Also, a generator with adequate power capacity (minimum 4,000 watts, 120 volt AC only) is needed for pipe sizes up to 8 inches.

2. Major Considerations

a) Some major points to consider when making a butt fusion joint are:

(i) Proper heater plate temperature.

(ii) Clamps securely closed.

(iii) Proper face off on both ends.

(iv) Proper melt.

♦ Pipe ends in firm contact with heater plate.

♦ No pressure applied. Hold pipe steady.

♦ Proper amount of melt on pipe ends.

b) Removal of heater plate.

(i) When you retract the operating handle, one pipe end will come away from heater plate first. Bump the heater plate directly away from the other pipe end, the stationary clamp end, and lift plate straight out.

c) Joining.

(i) Adequate pressure to produce double rolled back bead.

(ii) Hold pipe steady with pressure for at least ten or more seconds or until bead feels hard.

(iii) Leave pipe in clamps until joint hardens and finger can remain comfortably on bead.

3. Heating Plate Temperature – (Preheat)

a) Preheat heating plate to 425 degrees F.

b) Allow sufficient time for heating iron to heat uniformly prior to using. Normally this is five minutes after the temperature is indicated on the dial. Check heater plate with templilsticks for correct surface temperature at beginning of job. Do not use templilsticks in the area where fusion will occur. This area must be kept clean.

c) The temperature of heating iron should not exceed 450 degrees F.

4. Joining Procedures

a) Pipe End Preparation – Facing. The following steps shall be followed in a butt fusion joint:

(i) With a clean cotton cloth or paper towel, wipe the inside and outside of pipe to be joined. Make sure all foreign matter is removed.


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(Polyester-type material is not to be used because it could stick to the heater plate.)

(ii) Place correct inserts in the fusion unit alignment clamps.

(iii) Position the facer between the alignment clamps and lock into position.

(iv) Place the pipe in the alignment clamps with enough pipe extending through the clamps toward the facing device so that the distance between the face off stops and the facing device is greater than the amount to be trimmed off the pipe ends. With the clamps loose, reduce this distance to the minimum necessary to trim off to insure complete face off by moving the operating handle on the movable clamp approximately 1 inch. As each space becomes properly adjusted, lock the alignment clamp. Butt fusion of coil pipe is not allowed. If using coil pipe use electro fusion or mechanical couplings.

(v) While operating facing tool, apply pressure on the operating handle to move the pipe ends into the cutter blade. Maintain this pressure until the facing device hits the face off stops and the facer runs free.

(vi) Shut off facer and wait till it stops rotating before reversing the direction of the pipe joiner operating handle to move the pipe ends away from the facing device. Remove the facing device and remove pipe cuttings without touching the pipe ends. Visually inspect to see that complete face off has been obtained around the circumference of both pipe ends.

(vii) Bring the pipe ends together to check for alignment (“high-low”) and to see that they meet squarely and completely for proper joining. If alignment is unsatisfactory, repeat steps (iii) through (vi).

(NOTE: It is important that good axial alignment of the full length of the pipe joint be maintained with the pipe joiner. When working with the larger skids, etc. for this purpose; otherwise, the weight of the pipe may cause misalignment. It may be necessary to reposition pipe.)

b) Joining Materials - The following steps shall be followed when butt fusing:

(i) Wipe heater plate off with a clean non-synthetic cloth or paper towel.

(ii) Insert the heater plate between the pipe ends, bring the pipe ends bring the pipe ends firmly in contact with the heater plate with a quick snap action and hold that position until proper amount of melt is indicated. Do not apply pressure. As the material heats, it softens and expands and will form the melt bead on the outside of the pipe adjacent to the heater plate. Proper melt is obtained when this bead height (1/16”-1/8” for 2”, 1/8”-3/16” for 3” and 3/16”-¼” for 4”-8”) is observed around the entire circumference of the pipe.


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(iii) Move the properly melted pipe ends away from the heater plate and remove the heater plate with a quick snapping action.

(NOTE: If melted material is pulled off of pipe ends, stop the procedure, allow pipe to cool, face off and repeat the procedure.)

(iv) Bring the melted ends rapidly together with firm, steady, adequate pressure to form the double rollback bead. Maintain that pressure until the bead feels hard and is cool enough to hold your hand on it.

(NOTE: Do not delay between steps (iii) and (iv) by looking for a place to set the heater plate. Remove plate, bring melted ends together immediately, and then put down the heater plate.)

5. Handling Pipe after butt fusion joint is made

a) Before removing the butt fused pipe from the joiner, the fusion joint should be cool enough so that you can hold your hand on it. After it has cooled to this point, the joint has developed sufficient strength for careful handling and it may be removed from the joiner. However, care should be taken to avoid twisting or excessive bending of the pipe at the joint for five to ten minutes. Butt fused pipe should not be placed in the ditch until the last joint has cooled for ten minutes.

6. Inspection of Joint

a) After the joint has cooled enough to be removed from the joiner, the entire circumference of the fused joint is to be inspected for a uniform non-porous bead and proper alignment. The joint will have the appearance of a double bead. If the following conditions are observed, the fusion must be cut out and made over:

(i) Insufficient melt bead

(ii) Inadequate roll back

(iii) Improper alignment

(iv) Any other condition that doesn’t appear to be acceptable

7. Cold Weather Considerations

a) The preceding procedure works at chill temperatures down to zero degrees. (Chill temperature is the chilling temperature experienced from the combination of wind and temperature. See following table.) At lower temperatures, some special precautions are necessary to assure satisfactory joining. (See below) Consult with your supervisor if chill temperatures are below zero degrees.

(i) Raise the heating plate temperature 25 degrees to compensate for greater heat losses from the plate.

(ii) Do not use the heater unplugged from the generator.


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(iii) Make sure the joiner and pipe facer operate freely. If necessary, change to cold weather lubricants.

(iv) Provide the shelter from the wind.

WIND CHILL TEMPERATURE TABLE

Wind Velocity

Actual Thermometer Reading, F

MPH 30 20 10 0 -10 -20

Equivalent Chill Temperature

0 30 20 10 0 -10 -20

5 27 16 6 -5 -15 -26

10 16 4 -9 -21 -33 -46

15 9 -5 -18 -36 -45

20 4 -10 -25 -39

25 0 -15 -29

PART II. SADDLE FUSION

A. Saddle Fusion - Tapping Tee 1. Equipment

a) The Central Electro fuse unit for 2” tapping tees, branch saddles and smaller saddle fittings on all main sizes through 8” IPS is the only approved unit for use in the Distribution Department.

2. Some Major Considerations

a) There are four main steps in making a service tap with a tapping tee:

(i) Electro fuse saddle tee to main.


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(ii) Add service line.

(iii) Pressure test.

(iv) Make tap.

♦ Step (ii) should be done before step (i) when butt fusing 2” and larger services to the outlet of the service tee. If the tee is saddle fused to the main before fusing the service to the tee, the main interferes with the operation of the fusion joiner in making the butt joint.

3. Joining Tapping Tee to the Main with Electro fusion

a) With a clean cloth, remove dirt and loose substances from intended fusion area on pipe surface.

b) With the fitting still in the bag, position the fitting on the pipe and trace the area to be fused using a “non-oil based “marker.

c) Scrape the area to be fused. Do not touch Fusion area on the pipe or fitting with hands or allow scraped area to become re-contaminated. Paint scrapers are not allowed. Only rotary type scrapers are to be utilized.

d) Remove fitting from bag and place on fusion area of pipe.

e) Slide Central’s under carriage saddle clamp or top load clamp into place.

f) Attach leads

g) Press start

h) Remove leads, break-over one of the fusion pins and write the clamping time on the fitting, noting the appropriate removal time.

i) Remove clamp once clamping time has passed. Wait for appropriate cooling time before tapping.

B. Saddle Fusion - Branch Saddles

1. Some Major Considerations

a) The procedure for making a branch connection includes the following:

(i) Prepare the main and fitting for fusion


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(ii) Electro fuse the branch fitting to the main

(iii) Pressure test the branch assembly

(iv) Connect the branch line

(v) Tap the main.

2. Joining Branching Saddles

a) The procedure for installing Branching Saddles is the same as placing Tapping Tees on mains. See Section 1-C under Saddle Fusion for correct procedure for joining with the Central equipment.


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CENTRAL PLASTICS ELECTROFUSION TABLE

Fittings (assume IPS Unless

otherwise stated)

Fusion Time (Seconds)

Cooling Time in Clamped Position

(Minutes)

Total Cooling Time Before Pressure/Tap

(Minutes)

Total Cooling Time Before

Rough Handling ( Minutes)

Tapping Tees

1 ¼"" x 1" 45 10 20 30 2" x ¾" 90 10 20 30 2" x 1" 90 10 20 30 3" x ¾" 90 10 20 30 4" x ¾" 90 10 20 30 4" x 1" 90 10 20 30 6" x 1" 90 10 20 30

2” x 1 ¼ “ 120 10 25 30 2” x 2” 120 10 25 30

3” x 1 ¼” 120 10 25 30 3” x 2” 120 10 25 30 4” x 2” 120 10 25 30 6” x 2” 120 10 25 30 8” x 2” 100 10 25 30

Reducers

1” IPS x 1” CTS 30 5 15 30

Couplings ¾” 30 5 15 30

1” CTS 25 5 15 30 1 1/4 45 10 20 30

2” 45 10 20 30 3” 180 15 30 35 4” 200 20 40 45 6” 500 20 40 45 8” 500 20 40 45

Branch Saddles

2” x 2” 120 10 25 30 3” x 3” 120 10 25 30 4” x 2” 120 10 25 30 6” x 2” 120 10 25 30 8” x 2” 100 10 25 30 4” x 4” 50 10 20 30 6” x 4” 150 15 30 30

PART III. EVALUATION OF FUSION JOINTS

1. Introduction

a) To qualify to make plastic pipe fusions, a joiner must make five fusions that successfully pass both visual and destructive testing.


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2. Destructive Testing Butt Fusion Joints

a) Test specimens are prepared by cutting a butt fusion joint into strips approximately 10” long x 1” wide. Only one test is to be made on any single strip. Each test specimen must be completely cooled prior to testing. Failure of the joint will be indicated by any visual evidence of splitting, cracking, breaking or tearing.

b) The following test is to be conducted.

(i) Root Bend

♦ The test strip is to be bent in a vise until the outside pipe walls are in continuous contact. The joint should be in the bend.

3. Destructive Testing Electro fusion Joints

a) Cut test saddles into pipe ring strips approximately 1” wide starting on one side until the entire saddle has been cut out (minimum of 3 sections).

b) The following test is to be conducted:

(i) Bond Strength

♦ After visual examination for voids or unbounded areas, place pipe portion of ¾” ring strip in vise and flatten. There should be no separation of the saddle component and the pipe.

4. Destructive Testing Electro fusion Coupling

a) Root bend – same as Paragraph 2.b)(i)) Root Bend above.

5. Minimum Testing

a) The minimum number of test joints required to qualify an operator for fusion joining is as follows:

(i) Butt Fusion Joints

♦ 1 – 2” pipe to pipe

♦ 1 – 4” pipe to pipe

♦ 1 – 6” or 8” pipe to pipe

♦ (ii) Electro fusion Joints

♦ 1 – 1¼” Coupling

♦ 1 – 2” x 1” tapping tee


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PART IV. FIELD JOINT INSPECTION

1. Inspections

a) A visual inspection shall be made of every fusion joint. Any joint of questionable appearance shall be cut out and redone. PGW reserves the right of final acceptance. See Section 28 - Pressure Test for Leaks.

2. Heat Fusion Qualification Guide

a) Phillips Heat Fusion Qualification Guide is to be used for reference for acceptable appearance of butt and saddle fusion joints.

PART V. MAINTENANCE OF FUSION EQUIPMENT

1. Fusion Unit

a) This tool is designed to butt fuse pipe on true centerline. To maintain the close tolerance of manufacturing, the equipment must be kept clean and lubricated.

(i) Clean the machine with soap and water wash as needed.

(ii) Remove oily dirt build-up from the guide rods using a solvent. Then wipe guide rods clean.

(iii) Lubricate guide rod bushings with SAE 30 wt. Motor oil through the oil hole covers on the movable jaw.

(iv) Occasionally add a drop of oil to pivot pins and shafts.

(v) Remove dirt from jaw and insert serrations and clamp knob eyebolts.

(vi) All clamp knobs are equipped with thrust bearings to reduce the friction and improve the efficiency of the clamping screw. These bearings should be kept clean by washing in solvent. They should be lubricated with light machine oil. These bearings must be replaced if they become inoperative.

2. Facer Assembly

a) The facer is powered by a Milwaukee drill motor and should have the same care as a fine electric drill. Motors can be serviced by a local Milwaukee dealer.

CAUTION: THE MOTOR IS NOT EXPLOSION PROOF.

(i) Keep the inside of the facer guides clean and free of oil and dirt build-up.


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(ii) The facer is packed with high temperature grease at assembly. This grease should be good for the life of the unit.

(iii) Inspect the blades and sharpen or replace if necessary.

3. Heater Assembly

a) The flat plate heater assembly contains four heater cartridges, a thermo switch, and an internal temperature indicator. The temperature is set at the correct surface temperature requested by the customer. The temperature indicated on the thermometer will normally read higher than the actual surface temperature. The only purpose of the temperature indicator (thermometer) is to alert the operator concerning drastic temperature changes due to faulty thermo switch, elements, power source, etc. HEATER PLATE SHOULD BE CHECKED PERIODICALLY WITH TEMPLILSTICKS FOR CORRECT SURFACE TEMPERATURE. Do not use templilsticks in the area where fusion will occur. This area must be kept clean.

4. Temperature Adjustment

a) Unplug the heater. If lowering the temperature, allow the heater to cool to a temperature below the desired new setting.

b) Remove the pipe plug in the cover plate using a 5/16” hex wrench.

c) Loosen the small thermo switch lock screw using a small narrow blade screwdriver.

d) Using a medium sized screwdriver, turn the adjustment screw the proper direction and number of turns to achieve the desired setting. TO RAISE TEMPERATURE; TURN SCREW COUNTER CLOCKWISE (LEFT TO LOWER TEMPERATURE, TURN SCREW CLOCKWISE (RIGHT). One complete revolution (360) in either direction will change temperature approximately 1000 F.

e) Plug the heater in and allow it to stabilize at the new setting. Further adjustment may be required.

f) After the new temperature is set, unplug the heater, tighten the lock screw, and replace the pipe plug.

5. The heater surface is coated with an anti-stick coating. To prevent excessive build-up of plastic pipe residue on the heater (loss of surface temperature and pipe sticking may result), the heater must be cleaned with a clean, non-synthetic cloth after every joint. Be careful no to remove the coating. Plastic which sticks to the heater is best removed by a clean, non-synthetic clothe or paper towel.

6. The heater plate should be stored in its rack when not in actual use and care should be taken to keep the surface clean.


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Section 21. Valves and Housing for Valves

1. Valves shall be installed on all underground services not less than 5’ (if physically possible) outside the building wall. Any deviation from this requirement shall be reviewed and if found acceptable, approved in writing by PGW.

2. Valves installed on 2” and smaller steel and plastic services shall be the compression end coupling type, weld end or fused. Valves installed on 3” and larger steel services, shall be steel weld end type only. Valves on 3” and larger Plastic services shall be butt or electric fusion only.

3. Inverted gas stopcocks shall be installed on 1-¼” and 2” services as shown by Drawing D.S. 10.2, D.S. 12.2, and D.S. 54.2.

4. Lubricated plug valves shall be installed on all 3” to 8” steel services as shown by Drawing D.S. 30.3.

5. Polyethylene plug valves shall be installed on all 3” to 8” plastic services as directed by PGW.

6. The PGW’s Distribution Department Planning Section will specify valve design for 12” and larger steel services.

7. Refer to Drawing D.S. 10.15, D.S. 10.16, D.S. 10.17 and D.S. 54.5 for installation of valves on residential services which terminate outside the building to accommodate outside meter sets.

8. All main valves shall be steel weld end plug or butt or electric fusion plastic plug valves.

Section 22. Trenching, Installation and Backfilling of the Underground System

1. The underground system consists of pipe, joints, fittings, drip pots, valves, boxes, corrosion control devices, and all other appurtenances pertaining thereto.

2. The trench bottom in suitable earth shall be excavated and graded so that the pipe will be supported for its entire length on undisturbed ditch bottom. Blocking shall not be used. The trench shall be free of ashes, cinders, welding rod, or other debris, which would tend to damage the pipe or pipe coating during or after lowering into the trench.

3. Excavated material consisting of ashes, cinders, building material or rock is condemned and shall not be used for backfill. PGW will have the final approval on the suitability of the excavated material as backfill.


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4. Where the excavation consists of condemned material, the Contractor shall excavate an additional six (6) inches in depth. This 6” extra excavation shall be backfilled with suitable fill and mechanically tamped.

5. In rocky areas, the ditch shall be padded with sand or suitable fill and the pipe shall be wrapped with 3/16” rock shield.

6. Backfill shall consist of selected material free from mud, frozen soil, organic material, rubbish, or other objectionable foreign substances. No rock, cinders, or building material shall be used for backfill. When tamping, the backfill shall be placed in layer according to applicable regulations, but in no case exceeding 12 inches in depth. Each layer shall be firmly tamped before the next layer is applied. The Owner/Contractor shall avoid damage to the gas main or other facilities during backfilling and tamping.

7. The trench shall be kept as dry as is practical until the pipe joints are assembled, tested, coated, and the pipe is anchored. Installed pipe and appurtenances shall be made watertight at the end of each day, and at all times when the Owner/Contractor is not actively working on that pipe.

8. Shoring and sheathing shall be used at the Contractor’s discretion in keeping with applicable regulations.

9. In general, the Owner/Contractor shall not be permitted to drag pipe. However, in special situations where foreign structures may make it extremely impractical to do otherwise, dragging of pipe may be permitted provided it is performed as follows:

a) The entire trench bottom over which the pipe is to be dragged shall be sand padded.

b) Following the dragging operation, the pipe shall be rotated to permit the underside of the pipe coating to be treated for coating faults with an electrical flaw detector. All coating faults shall be repaired.

10. All pipes shall be internally cleaned and blown clear prior to installation.

11. Tie rods shall be installed where required as described on Drawing D.S. 20.8

12. Plastic pipe shall be inspected for cuts, gauges, etc. Damaged plastic pipe shall be removed.

13. When sand is used to pad the trench and/or backfill the pipe zone, it shall meet the following specifications:

Property Test Method Specification Requirements

pH ASTM C-40 6 to 8 Chlorides ASTM C-40 less than 0.02% Moisture content ASTM C-40 0 to 8%


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Density (dry & rodded)

ASTM C-40 95 to 110 lbs./cu.ft.

Organic Impurities ASTM C-40-66 Must Pass ASTM C40-66 Organic Impurities Test

Sand Equivalent ASTM D-2419 20 minimum Compaction Characteristics

ASTM D-1557 When material is compacted to a relative compaction of 95% or greater as determined by ASTM D-1557, the material shall not slough when cross-trenched.

Graduation ASTM C-136 & ASTM C-117 Sieve Size Percent Passing (By

Weight) 3/8"< (9.5MM) 100 No. 4 (4.75MM) 100 No. 8 (2.36MM) 90-100 No. 16 (1.18MM) 88-100 No. 30 (600MM) 75-100 No. 50 (300MM) 50-70 No. 100 (150MM) 0-30

14. Valve boxes and drip boxes shall be set in position before backfilling starts, and their tops shall be adjusted to final grade. This valve and drip box setting and adjusting shall not be considered complete until the grading and paving work around them has been finished.

Section 23. Drip Pots, Drip Rods, and Drip Boxes

1. The number of low points or traps in the system shall be kept to an absolute minimum through careful study of other underground structures involved, and where necessary, through the digging of test holes ahead of the pipe laying operation. When possible, low points or traps shall be avoided by changing pipe grading plans. PGW shall have the right of approval or disapproval of the location of the drip.

2. All service pipes entering buildings shall be graded to slope from the building to the main pipe.

3. The completed system shall be graded so condensate will flow into drips.

4. Rod drips shall be installed at the low spot on all pressure mains 8” and larger.

5. Drips are not required on any piping to be used exclusively as a service.


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6. Details of drip rod assembly for steel mains and services are shown by Drawings D.S. 20.4 and D.S. 20.5.

Section 24. Termination of Piping from Underground Into Buildings or Outside Meter Sets

1. No gas piping (meter, riser, etc.) can be placed within a 36-inch horizontal measurement from:

a) An electric meter or other electrical equipment, such as an air conditioning compressor unit.

b) Combustion air or fresh air intakes.

c) Any ignition source.

d) Meters cannot be placed under a carport roof, awning or an overhang larger than a standard eave.

e) Meters may be installed under operable windows only when no other options exist.

2. Basements

a) Underground gas piping entering a basement shall be protected against corrosion through the foundation wall as described on Drawing D.S. 10.0. To prevent the entry of water or gas, the portion of the foundation wall which has been pierced to provide entrance for the gas pipe, shall be repaired as described on Drawing D.S. 10.9, Note 5.

3. Crawl Space

a) Underground gas piping entering a crawl space shall be encased in a continuous gas tight conduit from at least 6” outside the foundation wall to the point where it becomes exposed in a normally usable and accessible portion of the building. At the point where the conduit terminates in the building, the space between the conduit and gas piping shall be sealed to prevent the possible entrance of any gas leakage. The space between the conduit and foundation wall shall be sealed to prevent the entrance of water into the crawl space. Details of installation are shown on Drawings D.S. 10.8, D.S. 13.3 or D.S. 54.4.

4. Underground Under Building

a) When a steel service requires a bent riser to enter a building which contains no basement, no cellar, or no crawl space, it shall be constructed of coated pipe and continuously encased in a sleeve of polyethylene flexible tubing or steel pipe to a point where it becomes exposed in an occupied space in the building as shown on Drawing D.S. 10.8, D.S. 13.3. A plastic service requires a steel service adapter as shown on Drawing D.S. 54.4.


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5. Outside Risers or Meter Sets

a) Meters and piping must be protected from damage by vehicles by 4” diameter bollards per D.S. 53.6 spaced a maximum of 5 feet apart.

Section 25. Installation of 1-¼” and 2” Services

1. Services of 1-1/4” and 2” shall be installed according to Drawings D.S. 10.0, D.S. 10.15, D.S. 12.0, and D.S. 54.0. The location for service entry into building or its termination outside of the building wall and the location of the service connection to the main will be approved by PGW.

2. Individual lengths of service pipe shall be joined together using compression couplings or by welding.

3. The finished service shall be graded so that condensate will flow from the building toward the main. Should it be necessary to grade the service so the condensate will flow from the main toward the building, the installation shall be approved by PGW.

4. A full length of pipe shall extend out from the cellar. The threaded end of the pipe, which is to receive the house fittings, shall extend inside cellar wall per the applicable D.S. drawings.

a) The house fittings for 1-¼” and 2” low pressure steel services are shown on Drawing D.S. 12.4 and D.S. 12.5 respectively. House fittings for 1 ¼” and 2” high and intermediate pressure steel services are shown on Drawing D.S. 10.4 and D.S. 10.11. The house fittings for 1-¼” and 2” plastic services, all pressures are shown on Drawing D.S. 54.3.

5. Services that terminate outside the building require a sleeve as shown on Drawing D.S. 10.15, D.S. 10.16, D.S. 10.17 and D.S. 54.5.

6. The following standards shall apply when connecting services to mains:

a) 2” and 1 ¼” high and intermediate pressure steel services shall be connected to steel mains as shown on Drawing D.S. 10.1 Steel connections shall be made by welding the threadolet to the main and then drilling or cutting a hole in the main using an appropriate Mueller machine. For a 1-¼” service, the hole shall be 7/8”; and for a 2” service, the hole shall be 1-1/2”.

b) 1 ¼” and 2” low pressure steel services shall be connected to steel mains as shown on Drawing D.S. 12.1.

c) All pressure plastic services shall be connected to plastic and steel mains as shown on Drawing D.S. 54.1.


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Section 26. Installation of 3” and Larger Services

1. Three inch (3”) and larger services shall be installed per the trenching instructions Section 22- Trenching, Installation and Backfilling of the Underground System, of these specifications.

2. A standard welding tee or butt fusion tee shall be used for main connections 3” and larger. All other main connections must be reviewed and approved by PGW.

3. When a 3” and larger steel service requires a riser to enter a building, it shall be constructed according to Drawing D.S. 13.3.

4. Three inch (3”) and larger plastic services shall make the transition to steel a minimum of 5’ outside the building wall. The steel pipe shall be cathodically protected as directed by this specification book.

Section 27. Installation of Corrosion Control Devices

1. Where specified, bonding wires shall be installed across all 3” and larger non-Insulating mechanical compression couplings as shown on Drawing D.S. 13.6.

2. Insulating Flanges

a) After delivery to the job, insulating flanges shall be protected by the Owner/Contractor from all forms of dirt and moisture until finally coated. Wherever possible, they should be stored under cover until the day they are coated.

b) Insulating flanges should not be dismantled.

c) When welding near an insulating flange, grounding of the welding machine and the welding shall be on the same side of the flange. Never draw an arc across the insulating flange.

d) During welding, the temperature at the outside circumference of the insulating flange shall not become too hot to touch. When this temperature is approached, the welding shall stop until the insulating flange has cooled.

e) Insulating flanges should be electrically tested before being backfilled.

3. Thermite Welds

a) Thermite welds shall be used for connecting wires to steel mains and services according to the various standard drawings showing bonding wires and corrosion control test station.

b) Thermite welds shall be tested for bond when completed. The test shall consist of striking the weld with a three (3) pound caulking hammer. Any welds which break loose, shall be re-welded and re-tested.


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c) Before priming, and coating, all portions of the exposed wire, weld metal, and adjacent pipe shall be cleaned to a bright metal.

4. For Coating of Steel Mains – See APPENDIX A – Corrosion Control

Section 28. Pressure Test for Leaks

1. The Owner/Contractor shall perform two tests for leaks. The first test shall be a joint leak test. The second test shall be a time-pressure test. The Owner/Contractor shall provide and install the required pressure medium and/or recording gauges. If PGW is requested to perform the pressure test there will be a fee charged for this service, as determined on a case by case basis.

2. The time-pressure test shall be performed after the entire underground system is complete in every detail.

3. All test heads on steel mains shall be installed by welding.

4. The Owner/Contractor shall properly retain or block exposed pipe ends.

5. All main valves and service valve shall be in the open position for the duration of each of these tests.

6. Just prior to the soap suds or standup test, all drips shall be blown clear at 5 PSIG pressure. Any drips showing evidence any foreign matter or liquid shall be cleared.

a) Any defective material discovered by these tests shall be removed and good material substituted.

7. Joint Leak Test

a) The joint leak test shall consist of a soapsuds test.

b) The soapsuds test shall be performed before any joints are concealed from view by backfill or any other means.

c) Test Procedure

(i) Air pressure as measured on a standard spring gauge shall be raised to 90 PSIG for all steel and plastic mains, and all steel and plastic services. In the event that services are physically connected to a main at the time of testing, the entire installation may be tested at 90 PSIG.

(ii) With the pressure test applied at 90 PSIG on the piping system, the Contractor shall, in the presence of PGW, test with soapsuds every joint, fitting, weld, fusion, and valve, as well as any other part which PGW may designate.


35

(iii) This pressure test is passed only after every leak has been completely stopped by correcting its cause by a method satisfactory to PGW.

8. Time Pressure Test

a) PGW is to be notified by the Contractor before the start of the Time Pressure Test and before the Contractor removes the Time Pressure Test so that at PGW’s discretion, a PGW inspector can be present to witness this test.

b) Test Procedure

(i) With an approved recording gauge attached to the system, air pressure shall be raised to 90 PSIG for all steel and plastic mains, and all steel and plastic services. In the event that services are physically connected to a main at the time of testing, the entire installation may be tested at 90 PSIG. (If the piping system is a simple one line point to point installation and is 2” diameter or smaller, then the recording gauge requirement may be waived depending on the discretion of the PGW engineer. A pressure gauge still has to be used and witnessed by a PGW inspector for a minimum testing time of one hour.)

(ii) The rise in air pressure shall be plotted on the recording gauge chart and when the desired pressure has been reached, the means by which the pressure has been raised shall be disconnected from the system.

(iii) The time pressure test shall be considered as passed when a constant pressure of 90 PSIG has been plotted on the recording gauge chart for a period satisfactory to PGW but not to exceed 24 hours.

(iv) The release of air pressure shall be plotted on the recording gauge chart.

(v) If at any time there is a drop in pressure indicating a leak, the test shall be disconnected until the Owner/Contractor locates and corrects the cause of the leak. The time pressure test shall then be repeated until a constant pressure reading is recorded for a time satisfactory to PGW.

c) All valves shall be operated after the final time pressure test and then left in the closed position.

9. Leak Repair - Leaks located on any welds or fusion made by the Owner/Contractor shall be repaired to the satisfaction of PGW. Leaks located on material found to be defective shall also be repaired by the Owner/Contractor.

10. Testing By PGW. In addition to the two tests performed by the Owner/Contractor as described above, if PGW deems it appropriate, PGW may perform a final


36

pressure test before turning on gas into the system. The purpose of this test is to detect any damage to the underground system that may have occurred after the time-pressure test was performed by the Owner/Contractor. The Owner/Contractor will be required to make any necessary repairs.

11. Safety Requirements

a) The Owner/Contractor shall insure that every reasonable precaution is taken to protect his employees and the general public during any of the proceeding pressure tests.

b) The Owner/Contractor shall ensure that the test medium is disposed of in a manner that will minimize damage to the environment.

Section 29. Damage Prevention Standards

1. In most cases, more than one prevention material will be necessary for the protection of the plastic pipe. Refer to the following Drawings D.S. 53.0., 53.1, 53.2, 53.3, 53.4, 53.5, 53.6, and 53.7.

2. Installation of buried caution tape is to be used whenever plastic main is installed by direct burial method. Tape is to be placed approximately 1’ below grade.

3. The following list of material is available to help prevent such damage.


37

Product Description PGW Material

Code Paint – marking Yellow, inverted spray, 20 oz 10-63-0628

Marking flags 4"x5", yellow, caution flag, 18" pl. post 10-66-5301

Whisker flags 6", issued with nail, for asphalt or dirt 10-66-5300

7" Soil Disks 7" disk & stake for marking in soil 10-66-5299

Curb markers 2.5" disk glued onto curb, at the service 10-66-5298

Curb markers adhesive

adhesive, glue for curb markers 10-66-5296

Flexible marking post

Fiberglass flat post, 3 3/4" x 5'-2", with caution decal

10-66-5297

Triangular marking post

Yellow, plastic post, 5'6" to 7' , with caution decal 10-66-5307

Caution decal Adhesive backed, rectangular decal, to be attached to posts

10-66-3501

Tracer wire #8 AWG – 7 stranded wire with 45 mils of yellow PE-45 insulation with UL print

10-57-0898

Buried caution tape

Yellow caution tape, to be buried on top of plastic main or service.

10-66-6899

Electronic Ball Marker

Ball marker for marking main and service up to 5’ deep to be placed over tees and ells in open areas.

10-66-3505

Electronic Disk Marker

Disk marker for marking main and service up to 5’ deep to be placed over tees and ells in open areas.

10-66-3506

a) The use of this material should be clearly defined on all construction drawings and will be required to be used by crews during the installation of plastic pipe during certain conditions. PGW Distribution Planning Section will describe the location of these materials on construction drawings as warranted.

b) PGW will require that the Owner/Contractor install these materials, where required, during installation. Failure to install damage prevention materials could result in PGW not accepting the underground gas piping system

c) All Owner/Contractors are encouraged to supplement the protection of underground gas piping structures at their discretion.

d) Listed below are some examples of conditions, describing when to use this damage prevention material.

(i) The main and/or service are installed where there are no curb in the general vicinity, making “coordinate locating” difficult.

(ii) The main and/or service is installed other than parallel or perpendicular to existing curb lines or house lines.

(iii) The main and/or service are installed through a parking lot.


38

(iv) The main and/or service are installed before permanent curbs are placed.

(v) The main and/or service that varies in location without the use of plastic fittings such as 45 and 90 degree bends.

(vi) If the main and/or service is installed with less than 2’-6” of cover.

(vii) The main and/or service are installed in a joint trench with other utilities.

(viii) The service is installed in a private driveway.

4. Temporary as well as permanent damage prevention marking practices reduce damages. During new construction, after a new line is installed, facilities are most vulnerable to damage. It is recommended that good temporary marking practices be followed immediately after installation.


39

Section 30. Drawings and Standards

Index

D.S. 10.0 1-¼” and 2” Steel High and Intermediate Pressure Services – Composite

D.S. 10.1 1-1/4” and 2” High and Intermediate Pressure Service Connections to Steel Cast or Ductile Iron Mains

D.S. 10.2 1-¼” and 2” High and Intermediate Pressure Service Curb Valves

D.S. 10.3 1-¼” and 2” Steel High and Intermediate Pressure Services – - Magnesium Anode

D.S. 10.4 2” High and Intermediate Pressure Head of Service Fittings

D.S. 10.8 1-¼” and 2” High, Intermediate and Low Pressure Services Bent Riser

D.S. 10.9 2” thru 6” and Larger High, Intermediate and Low Pressure Services Straight Sleeve

D.S. 10.10 1-¼” High, Intermediate and Low Pressure Services Straight Sleeve

D.S. 10.11 1-¼” High and Intermediate Pressure Head of Service Fittings

D.S. 10.15 1-¼” and 2” High Intermediate and Low Pressure Services for Outdoor Meter Set – Composite

D.S. 10.16 1-¼” High Intermediate and Low Pressure Head of Service – Outdoor Meter Set

D.S. 10.17 2” High and Intermediate Pressure Head of Service – Outdoor Meter Set

D.S. 12.0 1-¼” and 2” Low Pressure Coated Service – Composite

D.S. 12.1 1-¼” and 2” Low Pressure Service Connections to Steel, Ductile Iron, and Cast Iron Main

D.S. 12.2 1-¼” and 2” Low Pressure Service Curb Valves

D.S. 12.4 1-¼” Low Pressure Head of Service Fitting

D.S. 12.5 2” Low Pressure Head of Service Fitting

D.S. 13.1 3” and Larger High, Intermediate and Low Pressure Steel Services Head of Service Fittings

D.S. 13.3 Installation of 3” and Larger Service Risers High, Intermediate and Low Pressure Steel Services

D.S. 13.6 Installation of Preformed Bond Wires on 3” and Larger Bolt Type Compression Couplings

D.S. 20.1 Standard Procedure Specifications for Arc Welding of Gas Pipe and Fittings

D.S. 20.5 Fittings for Cast Iron, Ductile Iron, and Steel Pot and Rod Drips

D.S. 23.1 Typical Magnesium Anode Installation


40

D.S. 23.3 Lily Pad Installation

D.S. 30.3 Installation of 3” to 8” Service Valves

D.S. 30.4 Field Coating of Valves in Manholes

D.S. 53.0 Damage Prevention Composite

D.S. 53.1 Damage Prevention Caution Tape Installation

D.S. 53.2 Damage Prevention Tracer Wire Installation

D.S. 53.3 Damage Prevention Ball and Disc Marker Installation

D.S. 53.4 Gas Main Post Marker

D.S. 53.5 Utility Marker

D.S. 53.6 Installation of Bollards

D.S. 53.7 Identification Markers

D.S. 54.0 Composite, 2” & Smaller Plastic Services, All Pressures

D.S. 54.1 Main Connection All Plastic Services, All Pressures

D.S. 54.2 Curb Valve All Plastic Services, All Pressures

D.S. 54.3 Head of Service All Plastic Services, All Pressures

D.S. 54.4 Service Riser or –Steel Sleeve through Crawl Space All Plastic Services, All Pressures

D.S. 54.5 Outdoor Meter Set All Plastic Services, All Pressures

D.S. 54.6 Field Coating of Main Connection on Steel, D.I. or C.I. Mains

D.S. 54.7 Composite – Installation of 2” – 8” IPS Plastic Mains Direct Burial & Insert

D.S. 55 3” or Larger Plastic Services

D.S. 56 Plastic Mains


A-1

APPENDIX A – Corrosion Control

COATING - PRITEC A-1 Coating of Steel Mains

A-1.1 All steel mains shall be completely coated. Individual lengths of pipe will be furnished with a mill applied coating. Pipe joints, fittings insulating flanges and irregular shapes shall be coated in the field.

A-1.1.1. Mill applied coating shall be Pritec.

A-1.1.2. Field coating material shall be Polyken 927 Primer, Polyken 930-35 tape, Roybond 747 Primer, Handy Caps, and Wax Tape and Primer.

A-1.2 The Contractor shall repair, at his expense, all damages to pipe coating which occur after delivery of pipe to site.

A-1.3 Where less than 6” clearance will exist between the steel main and a crossing structure, an insulation spacer to protect the coating shall be fabricated and installed as shown on Drawing D.S. 23.3. However, when the main is passing under an1 ¼” service, the required clearance is 3”.

A-1.4 The Contractor shall inspect the pipe coating in accordance with NACE Standard RP-02-74 Recommended Practices entitled “High Voltage Electrical Inspection of Pipe Coating Prior to Installation” with particular attention to the following:

A-1.4.1. Grounding

A-1.4.2. The ground wire shall be insulated for its entire length with an insulated ground clip on the end to be attached to a ground stake when operating the instrument.

A-1.4.3. The supervisor or foreman in charge of the field operation will notify workmen and other persons on the job site of the potential danger of coming in contact with the ground stake and he will see that the work area is kept clear.

A-1.4.4. It is the Contractor’s responsibility to provide an approved Holiday Detector for the project. Pritec and tape coating shall be inspected at 12,000 volts.

A-2 Transportation and Handling Coated Pipe


A-2

A-2.1 Coated pipe shall be handled with equipment such as wide reinforced canvas slings and wide padded skids designed to prevent damage to the pipe coating. All handling and hauling equipment shall be approved by PGW.

A-2.2 Stored pipe shall be supported by wooden timbers placed under the uncoated ends to keep the coated pipe off the ground.

A-2.3 The Contractor shall allow inspection of the coating on the underside of the pipe while suspended from the sling and before lowering into the trench. Damage shall be repaired before laying the pipe.

A-3 Ditching and Backfilling

A-3.1 The ditch bottom shall be free of rocks, welding rod or other debris, which would tend to damage the coating during or after laying the pipe.

A-3.2 In rocky areas, either the ditch shall be padded with sand or soft fill, or the pipe shall be wrapped with Rock-Stop as determined by PGW.

A-3.3 Placing of backfill over the pipe shall only be done after final inspection and acceptance of pipe coating.

A-3.4 Damage to pipe coating shall be avoided in backfilling.

A-3.5 Where backfill conditions may cause damage to the coating, PGW may elect to have loose backfill placed in the ditch and around the pipe to a height of 6” above the pipe. This backfill shall consist of fine soil and sand.

A-4 Coating of Weld Joints and Fabricated Fittings

A-4.1 Mechanically clean the weld and adjacent bare pipe as follows:

A-4.1.1. Remove all oil and grease on the surface of the expose metal, using suitable solvents and clean burlap.

A-4.1.2. Removal all other foreign materials and adhesive by power brushing and scraping.

A-4.1.3. Power brush (lightly) 6” of Pritec coating adjacent to weld joint or fitting

A-4.2 Prime pipe surface and coating to 6” beyond joint or fitting to be taped with Polyken 927 primer.

A-4.2.1. Apply primer immediately following joint cleaning.


A-3

A-4.2.2. The pipe surface shall be dry at the time the primer is applied. No primer shall be applied during rain or fog unless protected from the weather by a shelter approved by PGW.

A-4.2.3. Apply primer by hand-brushing in accordance with manufacturer’s instructions.

A-4.2.4. After application, the prime coat shall be uniform and free from runs, drip or bare spots. Such defects shall be eliminated either by retouching or by complete recleaning and repriming at the discretion of PGW.

A-4.2.5. Primer shall be dry before application of the tape.

A-4.2.6. Using a spiral wrap, apply a layer of the Polyken 930-35 tape (50% overlap) over entire primed area, using a tension of 10 to 20 pounds.

A-4.2.7. Apply a coat of primer over entire taped area.

A-4.2.8. Spiral wrap (opposite direction from first layer) a second layer of tape with 50% overlap.

A-5 Coating of Insulating Flanges, Bolt Type Couplings, Buried Valves and Irregular Shapes

A-5.1 Apply underground wax tape as follows

A-5.1.1. Wire brush the surface clean of loose mill scale, rust, paint and other foreign matter

A-5.1.2. Apply a thin film of wax tape primer.

A-5.1.3. Rub and press on primer firmly to displace moisture and to insure adhesion. Than wrap wax tape using a 1” overlap. While wrapping, press and mold the tape into conformity, insuring that there are no air pockets or voids so that the tape is in intimate contact with the surface.

A-5.1.4. Press and smooth out lap seams to insure that they are sealed.

A-5.1.5. Factory applied all-Clad coated couplings are exempt from A-5, however bolts are to be waxed taped.

A-6 Coating of Posi-Hold Couplings

A-6.1 Refer to Drawing D.S. 56.0.

A-7 Coating of Valves in Manholes


A-4

A-7.1 Refer to Drawing D.S. 30.4.

A-8 Coating of Service to Main Connection and Control and Pressure Test Piping 1-¼ and 2”

A-8.1 Remove 4” square area of Pritec coating from main to accommodate tee or threadolet connection.

A-8.2 Mechanically clean the tee and adjacent bare pipe as specified for weld joints in Paragraph A-4.1.

A-8.3 Apply primer as specified in Paragraph A-4.2.

A-8.4 Apply 4” x 4” section of tape over tee (hole cut to accommodate tee). Lap tape up onto tee ½”. Apply additional tape overlapping Pritec by 2”.

A-8.5 Beginning at base of tee, spiral wrap (1” tape - ½” overlap) remaining area of tee.

A-9 Coating of Thermite Welds

A-9.1 Remove 3-½”x 3-½” section of coating to accommodate cadweld mold.

A-9.2 Clean weld and adjacent pipe are using power brush, solvent and scraping tools.

A-9.3 Spray apply Royston Roybond 747 primer on weld and pipe area.

A-9.4 Apply Royston Handy Cap over weld and pipe area. Cap shall overlap adjacent coating by a minimum of ½”

A-10 Patching of Coating

A-10.1 Removal of Pritec

A-10.1.1. It is generally not necessary to remove coating for minor slits or other similar damage in which the polyethylene backing has not been separated or pulled away from the pipe surface.

A-10.1.2. Minor Damage

A.10.1.2.1. Apply primer and spiral wrap with 50% overlap to cover a minimum of 3” in all directions from the extremities of the damage. (Note: Spiral wrap requires the tape to pass completely around the periphery of the tape.)


A-5

A-10.1.3. Major Damage

A.10.1.3.1. To remove disbonded coating, cut the coating with a linoleum knife and remove from the pipe. Remove adhesive from expose pipe areas using power brush solvent and scraping tools. Apply primer and tape coating by spiral wrapping for a minimum distance of 3” from all extremities of the damage.

A-11 Coating Inspection

A-11.1 Coating of all pipes and fittings shall be tested by the Contractor before backfilling using an electrical flaw detector. All defects shall be patched by the Contractor and approved by PGW.

A-11.2 All coating defects discovered after backfilling and which, in the option of PGW, are detrimental to the effectiveness of the protective coating, shall be excavated and repaired.

A-11.3 The bond of field coating to the pipe shall be tested on occasions by PGW, by removing small sections of the coating from the pipe surface. The amount of coating removed shall be at the discretion of PGW. The pipe will be recoated according to Paragraph A-10.1.

A-11.4 At the directions of PGW, all uncoated pipe in the ditch shall be made free of physical contact with dirt or water to permit an electrical measurement.


A-6

(BLANK)


B-1

APPENDIX B - List of Suppliers Material mentioned in the Specification for Installing Underground Gas Piping”

may be purchased from the following suppliers.

1. Couplings and Fittings

a. Dresser Piping Specialties www.dressercouplings.com 41 Fisher Avenue Bradford, PA 16701 ph: (814) 362-9200 fax: (814) 362-9363

b. Deacon Industrial Supply Company, Inc.

165 Boroline Road P.O. Box 62485 King of Prussia, PA 19406 ph: (610) 265-5322 fax: (610) 265-6470

c. Mueller Company

www.muellercompany.com 500 West Eldorado Street Decatur, IL 62525 ph: (800) 798-3131 fax: (217) 425-7524

d. Perfection Corporation

www.perfectioncorp.com 222 Lake Street Madison, OH 44057-3189 ph: (800) 544-6344 fax: (440) 428-7325

2. Gas Boxes a. Bingham & Taylor

P.O. Box 939 Culpeper, VA 22701 ph: (540) 825-8334 fax: (540) 825-2173


http://www.dressercouplings.com/

http://www.muellercompany.com/

http://www.perfectioncorp.com/

B-2

b. C.P. Test Services – Valvco, Inc.

234 Sanford Avenue Kearny, NJ 07032 ph: (201) 998-9750 fax: (201) 991-0620

3. Primer, tape Coating, Anodes and Cathodic Protection Services

a. Corpro Companies, Inc. 610 Brandywine Parkway West Chester, PA 19380 ph: (610) 344-7002 fax: (610) 344-7092

b. Stuart Steel Protection Corp.

P.O. Box 476 S. Boundbrook, NJ 08880 ph: (732) 469-5544 fax: (732) 469-9270

4. Test Equipment, Gauges

a. Ametek, US Gauge Division 820 Pennsylvania Blvd. Feasterville, PA 19053 ph: (215) 355-6900 fax: (215) 258-2061

b. Bristol Babcock, Inc.

www.bristolbabcock.com 1100 Buckingham Street Watertown, CT 06795 ph: (860) 945-2200 fax: (860) 945-2278

c. Mercury Instruments, Inc. www.mercuryinstruments.com 3940 Virginia Avenue Cincinnati, OH 45227-3412 ph: (513) 272-1111 fax: (513) 272-0211


http://www.bristolbabcock.com/

http://www.mercuryinstruments.com/

B-3

5. Valves

a. Central Plastics Company www.centralplastics.com 1901 West Independance Street P. O. Box 3129 Shawnee, OK 74802-3129 ph: (405) 273-6302 fax: (405) 273-5993

b. Balon Corporation www.balon.com 3245 South Hattie Oklahoma City, OK 73129 ph: (405) 677-3321 fax: (405) 677-3917

c. Deacon Industrial Supply Co., Inc. 165 Boroline Road P.O. Box 62485 King of Prussia, PA 19406 ph: (610) 265-5322 fax: (610) 265-6470

d. Perfection Corporation www.perfectioncorp.com 222 Lake Street Madison, OH 44057-3189 ph: (800) 544-6344

6. Plastic Pipe and Fittings

a. Central Plastics Company www.centralplastics.com 1901 West Independence Street P. O. Box 3129 Shawnee, OK 74802-3129 ph: (405) 273-6302 fax: (405) 273-5993

b. Dresser Piping Specialties www.dressercouplings.com 41 Fisher Avenue Bradford, PA 16701 ph: (814) 362-9200 fax: (814) 362-9353


http://www.centralplastics.com/

http://www.balon.com/


http://www.centralplastics.com/

http://www.dressercouplings.com/

B-4

c. Inner-Tite Corp.

110 Industrial Drive Holden, MA 01520 ph: (508) 829-6361 fax: (508) 829-4469

d. Perfection Corporation

www.perfectioncorp.com 222 Lake Street Madison, OH 44057-3189 ph: (800) 544-6344 fax: (440) 428-7325

e. Performance Pipe, Div. Chevron Phillips Chemical Co.

2929 N. Central Exway Suite 300 Richardson, TX 75044 ph: (972) 783-2603 fax: (972) 783-2647

f. R.W. Lyall & Company, Inc. 2665 Research Drive P. O. Box 2259 Corona, CA 91718-2259 ph: (909) 270-1500 fax: (909) 270-1600



C-1

APPENDIX C – Notification Form Notification of Owner’s Responsibilities for Underground Gas Piping

(Insert Address) Subject: UNDERGROUND PIPING NOTIFICATION Dear Customer: The outside gas service line that provides your property with natural gas has come under new federal regulations. The regulation pertains to a portion of the underground piping downstream of PGW’s meters and therefore, is not owned by PGW. The piping is the property of the landowner at your address. Most property owners are not aware of their responsibilities concerning underground natural gas piping, therefore, the federal codes discussed herein require Local Gas Distribution Companies, such as PGW, to notify owners of their obligations to safely maintain such piping. PGW does not maintain piping downstream of PGW’s meters. Federal Pipeline Safety Regulations, Part 192, Section 192.16 which covers this requirement is attached to this notice. Please note there are four (4) basic requirements for maintaining your portion of underground piping:

1. Monitor for Corrosion (Steel Only)

2. Survey for leaks

3. Repair any unsafe conditions

4. Identify and locate the piping prior to any excavation By serving this letter, PGW meets the federal requirements to notify you. You, or the owner of the gas facility, must make arrangements to comply with federal safety standards in maintaining the underground piping on your property. PGW’s representatives will gladly answer any questions you have regarding this notice and will assist you in determining the extent and location of your gas piping system to which this notice refers, free of charge. PGW’s representative can be contacted at: Philadelphia Gas works C/o Corrosion Control Department 1800 N. Ninth Street Philadelphia, PA 19122 Telephone number (215) 684-6384 Fax number (215) 683-6853


C-2

Please fill out the attached form and return it in the enclosed postage paid envelope so that PGW can better assist you in the future Thank you for your anticipated cooperation in this matter. Sincerely,

Jeffrey Meyers, P.E. Director Distribution Planning

Attachments: Pipeline Safety Regulations Part 192.16 PGW Return Envelope (postage paid) cc: General Supervisor Corrosion Department PGW File No. 32.3.4.3-C


C-3

Notification of Owner’s Responsibilities for underground gas piping Subject: UNDERGROUND PIPING NOTIFICATION Customer Name ______________________________________________ Customer Address ____________________________________________ ____________________________________________ ____________________________________________ Do you own the above mentioned property: Yes ( ) No ( ) Please return this form even if you are not the property owner. Do you wish to see a PGW representative? Yes ( ) No ( )

1. To locate your pipeline? Yes ( ) No ( ) 2. To discuss this notice? Yes ( ) No ( )

Property owner’s Name ________________________________________ Property owner’s Mailing Address _______________________________ _______________________________ Property owners phone number _________________________________


C-4

Pipeline Safety Regulations Part 192.16 Customer Notification (a) This section applies to each operator of a service line who does not maintain the

customer’s buried piping up to the entry of the first building downstream, or, if the customer’s buried piping does not enter a building, up to the principal gas utilization equipment or the first fence (wall) that surrounds the equipment. For the purpose of this section, “ customer’s buried piping” does not include branch lines that serve yard lanterns, pool heaters or other types of secondary equipment. Also “ maintain” means monitor for corrosion as according to 192.465 if the customer’s buried piping is metallic, survey for leaks according to 192.723, and if an unsafe condition is found, shut off the flow of gas to advise the customer the need to repair the unsafe condition, or repair the unsafe condition.

(b) Each operator shall notify each customer once in writing the following information.

(1) The operator does not maintain the customer’s buried piping.

(2) If the customer’s buried piping is not maintained, it may be subject to the potential hazards of corrosion and leakage.

(3) Buried pipe should be –

(i) Periodically inspected for leak;

(ii) Periodically inspected for corrosion if the piping is metallic; and

(iii) Repaired if any unsafe condition is discovered.

(4) When excavating near buried gas piping, the piping should be located in advance, and the excavation done by hand.

(5) The operator ( if applicable), plumbers and heating Contractors can assist in locating, inspecting and repairing the customer’s buried piping.

(c) Each operator shall notify each customer not later than August 14, 1996, or 90 days after the customer first receives gas at a particular location, whichever is later.

(d) Each operator must make the following records available for inspection by the

Administrator or State agency participating under 49 U.S.C. 60105 or 60106

(1) A copy of the notice currently in use; and

(2) Evidence that notices have been sent to customers within the previous 3 years.


D-1

APPENDIX D - Joint Trenching Detail

Gas cable

phone electric

screening

sand

varies

N.T.S.

3"

12"

Joint Trench specificationswith gas,cable,electric and

phone

Note: Gas main is to be placed on the street side of the trench

sand 6"

PGW5/1/04

30"minimum

12"minimum

12"

Burial (caution)Tape

Tracer wire

8"

House SideStreet Side


D-2

(BLANK)


E-1

APPENDIX E – PA ACT 187 Summary of Responsible Party's Duties under

Underground Utility Line Protection Act - PA ACT 187 1. Facility Owner’s Duties

a) If you own or operate underground lines, including storm drains and traffic loops, you are required to be a member If you own or operate underground lines, including storm drains and traffic loops, you are required to be a member of POCS. Failure to become a member is in violation of PA Act 287 which is enforced by PA Department of Labor & Industry, PENNSAFE.

b) “Facility Owner" means the public utility or agency, political subdivision, municipality, authority, rural electric cooperative or other person or entity who or which owns or operates a line.

c) "Line" or "Facility" means an underground conductor or underground pipe or structure used in providing electric or communication service, or an underground pipe used in carrying or providing gas, oil or oil product, sewage, water or other service to one or more consumers or customers of such service and the appurtenances thereto regardless of whether such line or structure is located on land owned by a person or public agency or whether it is located within an easement or right-of-way. The term includes storm drainage and traffic loops.

d) For more detailed information refer to Act 287 of 1974, as amended by Act 187 of 1996

2. Contractor's Duties a) Request the location and type of underground facilities at each site by notifying

all Utilities through the One Call System no less than (3) not more than ten working days in advance.

b) Provide the One Call System specific information to identify site.

c) When performing work at multiple sites or over a large area take reasonable steps to work with facility owner(s); protect and preserve.

d) Exercise due care-take and take all reasonable steps to avoid injury to or otherwise interfere with all lines.

e) If facility Owner fails to respond to the Contractor's timely request within two (2) working days or notifies that the line cannot be marked within the timeframe. The Contractor may proceed with excavation at the end of three (3) working days provided he exercises due care.

f) To inform each operator employed by the Contractor at the site of such work of the information obtained.

g) Plan the excavation or demolition to avoid damage to or minimize interference with a facility owner's facility's). Temporary interruption of service shall be coordinated.


E-2

h) Provide support and mechanical protection for known facility owner's lines at the construction site.

i) Immediately alert the occupants of premises as to any emergency.

j) Use color white to mark a proposed excavation site when exact site information cannot be provided.

k) Re-notify the One Call System if a worksite was vacated for more than two (2) working days and removed its equipment.

3. Designer's Duties a) Request the line and facility information not less than 10 or more than 90

working days before final design is to be completed.

b) Show position; type name, address and telephone number of each facility owner's line of designated office.

c) Make reasonable effort to prepare the construction drawings to avoid damage, and maintain an 18" clearance of the facility owner's facility(s).

d) Provide the One Call System serial number and toll free number on drawings.

e) Advise any changes to the original proposed excavation.

f) For more information concerning PA One Call System, Inc. contact 1-800-248-1786 or visit their website www.paonecall.org.

Pennsylvania One Call System, Inc. Call Before You Dig! 1-800-242-1776


http://www.paonecall.org/

F-1

CHECKLIST for ONSITE INSPECTION for GAS TURN-ON

STEPS INSPECTION REQUIREMENT SEE REFERENCED SECTION

DATE PASS /

FAIL

1. National Fuel Gas Code

Section 01 Scope of Specifications. Exposed piping meets the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (1999).

2. DOT Part 192

Section 01 Scope of Specifications. System meets the requirements of Title 49, Code of Federal Regulations, Part 192.

3. Notify POCS Section 03 Pennsylvania Act 187

4. Submit Drawings Section 04.3 Submitted three (3) sets of drawing

5. Approved Drawings

Section 04.6 Received approval on the drawings for installation from PGW’s Distribution Department. A signed copy noting PGW’s approval at jobsite.

6. Notify PGW before work.

Notify the Distribution Department 5 (five) working days before starting the installation - Telephone (215) 684-6384

7. Proper Cover on pipe Section 07 Location and Depth

8. Proper Clearance Section 08 Distance from Other Structures

9. Proper Cathodic Control System

Section 10 Corrosion Control Requirements for Steel Pipe

10. Approved Materials Used

Pipe specifications are listed below. Be sure to check Appendix A of 49 CFR Part 192 for the current specifications and standards. API 5L - Steel pipe ASTM A53 - Steel pipe ASTM D2513 - Thermoplastic pipe and tubing SEE: Section 11 Materials – General Section 12 Pipe Sizes and Material Section 13 Pipe Lengths Section 14 Protective Pipe Coating

11. Approved Assembly of Pipe

Section 16 Pipe Joints and Fittings Section 17 Pipe Joint Assembly

PGW UNDERGROUND HOUSE PIPING MANUAL 3-23-07 CHECK LIST

F-2

12. Used PGW qualified & approved Welders

Section 18 Welding

13. Used PGW qualified & approved Fusion Operators

Section 20 Plastic Fusion Procedures – GENERAL

14. Installed Valves as required

Section 21 Valves and Housing for Valves

15. Installed Drips as required Section 23 Drip Pots, Drip Rods, and Drip Boxes

16. Proper Trenching & Backfilling

Section 22 Trenching, Installation and Backfilling of the Underground System

17. Installed proper “head of service” Fittings or Riser

Section 24 Termination of Piping from Underground Into Buildings or Outside Meter Sets

18. Leak Test – before backfilling

Section 28 Pressure Test for Leaks

19. Leak Test – Completed system

Section 28 Pressure Test for Leaks

20. Installed Damage Prevention systems

Section 29 Damage Prevention Standards

21. Post Construction Corrosion Survey

Section 10 Corrosion Control Requirements for Steel Pipe Section 27 Installation of Corrosion Control Devices

APPENDIX A – Corrosion Control

22. Communicate/Understand: PGW Turn-On procedure Gas Turn-On by: (circle one) PGW Contractor

Section 06 Turn-on of Gas

23. Exposed Piping System tagged OK.

24. Underground Piping System Tagged OK.

25. Gas Turned – On By:

26. PGW maps Updated

27. Underground System Letter sent to PGW

APPENDIX C – Notification Form

PGW UNDERGROUND HOUSE PIPING MANUAL 3-23-07 CHECK LIST

underground house piping specifications

Documents

recording gauge chart

electrical flaw detector

perfection corporation www

bead feels hard

including storm drains

corrosion control devices

philadelphia gas works

customers buried piping