Appendix E OM-2287

APPENDIX E
Praxairs Pipeline Operating and

Maintenance Manual
Operating and Maintenance Manual
Regulated
Hydrogen Gas
Pipelines
OM-2287
Operating and Maintenance Manual
Regulated Hydrogen
Gas Pipelines
OM-2287
Issued: November 1995

Revised: October 2007
Praxair, Inc.
Technical Communications
P.O. Box 44
Tonawanda, NY 14151-0044
USA
OM-2287
www.praxair.com
info@praxair.com
Phone:
800-PRAXAIR
800-772-9247
716-879-2472
Fax:
800-772-9985
716-879-2146
Copyright 1998, 2007 Praxair Technology, Inc.

All rights reserved
Printed in the USA.
10/2007
Regulated Hydrogen Gas Pipelines
NOTICES
Business Confidential: This document contains confidential and proprietary information of
Praxair, Inc. and is provided in confidence and solely for use in conjunction with the
Operating and Maintenance Manual for Regulated Hydrogen Gas Pipelines. This
documentation may not be reproduced or its contents disclosed to third parties without
the prior written consent of Praxair, Inc.
Disclaimers: All information referred to and/or included in this documentation is current as of
the original issue date. Praxair, Inc., makes no warranty or representation with respect
to the accuracy of the information or with respect to the suitability of the use of such
information outside Praxair, Inc., nor does Praxair, Inc., assume responsibility for any
injury or damage which may result, directly or indirectly, from the use of such
information.
This documentation could include technical inaccuracies or typographical errors.
Changes are made periodically to the information herein; these changes will be
incorporated in subsequent revisions. Praxair, Inc., reserves the right to make
improvements and/or changes to the product(s) and/or programs described in this
document at any time and without notice.
Trademarks: Praxair and the Flowing Airstream design are trademarks or registered
trademarks of Praxair Technology, Inc., in the United States and/or other countries.
Other trademarks used herein are trademarks or registered trademarks of their
respective owners.
OM-2287
Issued: Nov 1995, Revised: Oct 2007
Page iii of xxii
Page iv of xxii
OM-2287
TABLE OF CONTENTS
NOTICES .................................................................................................................................. iii
CHAPTER 1 SCOPE AND PURPOSE ................................................................................. 1
CHAPTER 2 REPORTING REQUIREMENTS ...................................................................... 2
2.1
2.2
2.2.1
2.2.2
2.3
2.4
2.5
Incident Reporting...................................................................................................... 2
Safety-Related Conditions Reporting ......................................................................... 2
Conditions That Must Be Reported ............................................................................ 2
Filing a Safety-Related Condition Report ................................................................... 3
Annual Report............................................................................................................ 3
Other Reports ............................................................................................................ 3
DOT Reporting Addresses ......................................................................................... 3
CHAPTER 3 CUSTOMER NOTIFICATIONS ........................................................................ 5

CHAPTER 4 NORMAL OPERATIONS ................................................................................. 6
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Operations and Maintenance Manual Review ............................................................ 6

Availability of Pipeline Records .................................................................................. 6
Pipeline Startup and Shutdown .................................................................................. 6
Procedure Review and Update .................................................................................. 7
Safety Precautions for Excavated Trenches .............................................................. 7
Pipe-type and Bottle-type Holders ............................................................................. 7
Report of a Gas Odor Inside a Building...................................................................... 7
CHAPTER 5 ABNORMAL OPERATING CONDITIONS ...................................................... 8

5.1
5.2
5.3
5.4
Task-specific AOCs ................................................................................................... 8

Generic AOCs ........................................................................................................... 8
AOC Follow-up .......................................................................................................... 9
Notifying Personnel of an AOC .................................................................................. 9
CHAPTER 6 CLASS LOCATIONS ..................................................................................... 10

6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
Definitions ................................................................................................................ 10
Class Locations Units .............................................................................................. 10
Class 1 Location ...................................................................................................... 10
Class 2 Location ...................................................................................................... 10
Class 3 Location ...................................................................................................... 10
Class 4 Location ...................................................................................................... 10
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Page v of xxii
Table of Contents
6.2
6.3
Class Location Studies ............................................................................................ 10

MAOP Change Due to Class Locator Change ......................................................... 11
CHAPTER 7 CONTINUING SURVEILLANCE .................................................................... 13

CHAPTER 8 DAMAGE PREVENTION PROGRAM ........................................................... 14
CHAPTER 9 EMERGENCY MANUALS ............................................................................. 15
CHAPTER 10 PUBLIC EDUCATION ................................................................................. 16
CHAPTER 11 FAILURE INVESTIGATION ......................................................................... 17
CHAPTER 12 MAXIMUM ALLOWABLE OPERATING PRESSURES.............................. 18
CHAPTER 13 PRESSURE TESTING ................................................................................ 19
CHAPTER 14 UPRATING PIPELINE MAOP .................................................................. 20
CHAPTER 15 ODORIZATION OF GAS ............................................................................. 21
CHAPTER 16 TAPPING PIPELINES UNDER PRESSURE .............................................. 22
CHAPTER 17 PIPELINE BLOWDOWN, PURGING, OR RE-PRESSURIZATION ........... 23
CHAPTER 18 MAINTENANCE PROCEDURES ................................................................ 24
CHAPTER 19 RIGHT-OF-WAY PATROLS AND LEAK SURVEYS ................................. 25
19.1
19.1.1
19.1.2
19.1.3
19.1.4
19.2
19.2.1
19.2.2
19.2.3
19.2.4
19.2.5
19.2.6
Right-of-Way Patrols................................................................................................ 25
ROW Patrol Schedule .............................................................................................. 25
Pipeline Cover ......................................................................................................... 25
Construction Activity along ROW ............................................................................. 26
Casing Vent Stacks ................................................................................................. 26
Leak Surveys ........................................................................................................... 26
Scheduled Leak Surveys ......................................................................................... 26
Unscheduled Leak Surveys ..................................................................................... 27
Visual Inspection for Underground Piping Leaks ...................................................... 27
Aboveground Piping Leak Detection ........................................................................ 27
Leaks Detected in non-Praxair Pipelines ................................................................. 28
Detection Report Form ............................................................................................ 28
Page vi of xxii
OM-2287
CHAPTER 20 PIPELINE MARKERS ................................................................................. 29

CHAPTER 21 RECORDKEEPING ..................................................................................... 30
CHAPTER 22 FIELD REPAIR PROCEDURES ................................................................. 31
22.1
22.2
22.3
22.4
22.5
Immediate Response to Pipeline Damage ............................................................... 31

Repair of Imperfections and Damage....................................................................... 31
Permanent Field Repair of Welds ............................................................................ 31
Permanent Field Repair of Leaks............................................................................. 32
Testing of Repairs.................................................................................................... 32
CHAPTER 23 PIPELINE ABANDONMENT/DEACTIVATION ........................................... 33

23.1
23.2
23.3
Discontinuance of Service ....................................................................................... 33

Deactivated Pipelines .............................................................................................. 33
Abandonment of a Pipeline ...................................................................................... 34
CHAPTER 24 COMPRESSOR STATION PROCEDURES ................................................ 35

24.1
24.2
24.3
Compressor Operating Procedures ......................................................................... 35

Compressor Maintenance Procedures ..................................................................... 35
Compressor Building Requirements ........................................................................ 36
CHAPTER 25 PRESSURE LIMITING AND REGULATOR STATION PROCEDURES ..... 37

25.1
25.2
25.3
Pressure Limiting Valve Inspections ........................................................................ 37

Meter/Regulator Station Inspections ........................................................................ 37
Security and Safety Requirements........................................................................... 38
CHAPTER 26 VALVE INSPECTIONS ................................................................................ 39

26.1
26.2
26.3
Mainline Isolation Valves ......................................................................................... 39

Check Valves........................................................................................................... 39
Vaults ...................................................................................................................... 39
CHAPTER 27 PREVENTION OF ACCIDENTAL IGNITION ............................................... 40

CHAPTER 28 WELDING AND WELD DEFECT REMOVAL ............................................ 41
28.1
28.2
28.3
Praxair Maintenance Welding Standards ................................................................. 41

Weld Procedures ..................................................................................................... 41
Welder Qualifications ............................................................................................... 41
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Page vii of xxii
Table of Contents
28.4
28.5
28.6
28.7
Weld Preparation and Alignment ............................................................................. 42

Other Welding Requirements ................................................................................... 42
Inspection of Welds ................................................................................................. 42
Repair of Weld Defects ............................................................................................ 42
CHAPTER 29 NONDESTRUCTIVE TESTING PROCEDURES......................................... 43

CHAPTER 30 PLASTIC PIPE ............................................................................................ 44
CHAPTER 31 CATHODIC PROTECTION SYSTEMS ....................................................... 45
31.1
31.2
31.3
31.4
31.4.1
31.4.2
31.4.3
31.5
31.6
31.7
31.8
31.9
Cathodic Protection System Design and Installation ................................................ 45

Electrical Isolation .................................................................................................... 45
Coating Specifications ............................................................................................. 46
Cathodic Protection Criteria ..................................................................................... 47
-850 MV with Cathodic Protection Current Applied .................................................. 47
Negative Polarized Potential of -850 MV.................................................................. 48
100 MV Shift of Cathodic Polarization ...................................................................... 48
Cathodic Protection System Annual Inspection........................................................ 48
Rectifier Inspections ................................................................................................ 49
Stray Current and Interference Bonds...................................................................... 49
Cathodic Protection System Repair ......................................................................... 49
Cathodic Protection Records ................................................................................... 50
CHAPTER 32 CORROSION INSPECTIONS AND RESPONSE ........................................ 51

32.1
32.2
32.3
32.4
32.5
Aboveground Piping Inspections.............................................................................. 51

External Inspection of Exposed Pipe ....................................................................... 51
Inspection of Exposed Internal Pipe Surfaces .......................................................... 52
Investigation of Causes of Corrosion ....................................................................... 52
Prompt Repair of Corroded Pipe .............................................................................. 52
CHAPTER 33 UNDERWATER PIPELINE INSPECTIONS ................................................. 54

CHAPTER 34 LEAK INSPECTION AND RESPONSE....................................................... 55
34.1
34.1.1
34.1.2
Leak Classification and Action Criteria ..................................................................... 55

Leak Investigation .................................................................................................... 55
Leak Reporting ........................................................................................................ 56
Page viii of xxii
OM-2287
LIST OF TABLES
1
2
3
Right-of-Way Patrol Schedule .................................................................................. 25

Leakage Surveys ..................................................................................................... 27
Leak Classification ................................................................................................... 55
OM-2287
Page ix of xxii
Table of Contents
Page x of xxii
OM-2287
Regulated Hydrogen Gas Pipelines]
Protocol Cross-Reference to Operating Manual

Name of Operator: Praxair, Inc.
OP ID No.: 20044
HQ Address:
Praxair, Inc.
39 Old Ridgebury Road
Danbury, CT 06810
Unit ID No.: Contra-Costa Pipeline

System/Unit Name and Address:
Praxair, Inc.
841 Chevron Way,
Richmond, CA, 94801-2006
Co. Official:
James R. Ryan
Phone No.:
(815) 467-5412
Fax No.:
(815) 467-5643
Emergency Phone No.:
(815) 342-1121
Company System Maps (Copies for Region Files):
Activity Record ID No.:

Phone No.:
Fax No.:
Emergency Phone No.:
49 CFR PART 191

REPORTING PROCEDURES
.605(b)(4)
.605(a)
Procedures for gathering data for incident reporting:

191.5
Telephonically reporting incidents to NRC (800) 424-8802.
191.15(a)
30-day follow-up written report (Form 7100-2).
191.15(b)
Supplemental report (to 30-day follow-up).
191.23
191.25
Reporting safety-related condition (SRCR).

Filing the SRCR within 5 days of determination, but not later than 10 days
after discovery.
191.27
Offshore pipeline condition reports filed within 60 days after the
inspections.
Instructions to enable operation and maintenance personnel to recognize potential
Safety Related Conditions.
.605(d)
O&M Section 2.0
Local
emergency
manual
2.2
2.2.2
N/A
2.2.1
49 CFR PART 192
.13(c)
CUSTOMER NOTIFICATION PROCEDURES

.16
.605(a)
Procedures for notifying new customers, within 90 days, of their responsibility for
those selections of service lines not maintained by the operator.
NORMAL OPERATING and MAINTENANCE PROCEDURES
.605(a)
.605(b)(3)
.605(b)(5)
.605(b)(8)
.605(b)(9)
.605(b)(10)
.605(b)(11)
O&M Plan review and update procedure (1 per year/15 months).

Making construction records, maps, and operating history available to
appropriate operating personnel.
Start up and shut down of the pipeline to assure operation within MAOP
plus allowable buildup.
Periodically reviewing the work done by operators personnel to determine
the effectiveness and adequacy of the procedures used in normal
operation and maintenance and modifying the procedures when
deficiencies are found.
Taking adequate precautions in excavated trenches to protect personnel
from the hazards of unsafe accumulations of vapors or gas, and making
available when needed at the excavation, emergency rescue equipment,
including a breathing apparatus and a rescue harness and line.
Routine inspection and testing of pipe-type or bottle-type holders.
Responding promptly to a report of a gas odor inside or near a building,
unless the operators emergency procedure under 192.615(a)(3)
specifically apply to these reports. Amdt 192-93 pub. 9/15/03, eff.
10/15/03.
OM-2287
O&M Section 3.0

3.0
O&M Section 4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Page xi of xxii
49 CFR PART 191
.605(a)
ABNORMAL OPERATING PROCEDURES

.605(c)(1)
Procedures for responding to, investigating, and correcting the cause of:
(i)
(ii)
(iii)
Unintended closure of valves or shut downs.

Increase or decrease in pressure or flow rate outside of normal
operating limits.
Loss of communications.
(iv)
(v)
.605(c)(2)
.605(c)(3)
.605(c)(4)
.605(a)
O&M Section 5.0
The operation of any safety device.

Malfunction of a component, deviation from normal operations or
personnel error.
Checking variations from normal operation after abnormal operations
ended at sufficient critical locations.
Notifying the responsible operating personnel when notice of an abnormal
operation is received.
Periodically reviewing the response of operating personnel to determine
the effectiveness of the procedures and taking corrective action where
deficiencies are found.
CHANGE in CLASS LOCATION PROCEDURES
5.0, 5.1, 5.2

5.0, 5.1, 5.2
5.0, 5.1, 5.2
5.0, 5.1, 5.2
5.0, 5.1, 5.2
5.3
5.4
4.4
O&M Section 6.0
.609
Class location study.
6.2
.611
Confirmation or revision of MAOP.
6.3
.613(a)
Procedures for surveillance and required actions relating to change in

class location, failures, leakage history, corrosion, substantial changes in
CP requirements, and unusual operating and maintenance conditions.
Procedures requiring MAOP to be reduced, or other actions to be taken, if
a segment of pipeline is in unsatisfactory condition.
.613
CONTINUING SURVEILLANCE PROCEDURES
.613(b)
.605(a)
DAMAGE PREVENTION PROGRAM PROCEDURES

.614
Participation in a qualified one-call program, or if available, a company

program that complies with the following:
(1) Identify persons who engage in excavating.
(2) Provide notification to the public in the One Call area.
(3) Provide means for receiving and recording notifications of pending
excavations.
(4) Provide notification of pending excavations to the members.
(5) Provide means of temporary marking for the pipeline in the vicinity of
the excavations.
(6) Provides for follow-up inspection of the pipeline where there is reason
to believe the pipeline could be damaged.
(i) Inspection must be done to verify integrity of the pipeline.
(ii) After blasting, a leak survey must be conducted as part of the
inspection by the operator.
.615
EMERGENCY PROCEDURES
.615(a)(1)
.615(a)(2)
.615(a)(3)
Page xii of xxii
Gas detected inside a building.
(ii)
Fire located near a pipeline.
7.0
7.0
O&M Section 8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
8.0
O&M Section 9.0
Receiving, identifying, and classifying notices of events which require

immediate response by the operator.
Establish and maintain communication with appropriate public officials
regarding possible emergency.
Prompt response to each of the following emergencies:
(i)
O&M Section 7.0
Local emergency
manual all items
OM-2287
49 CFR PART 191

(iii)
.615(a)(4)
.615(a)(5)
.615(a)(6)
.615(a)(7)
.615(a)(8)
.615(a)(9)
.615(a)(10)
.615(b)(1)
.615(b)(2)
.615(b)(3)
.615(c)
.605(a)
Explosion near a pipeline.
(iv)
Natural disaster.
Availability of personnel, equipment, instruments, tools, and material
required at the scene of an Emergency.
Actions directed towards protecting people first, then property
Emergency shutdown or pressure reduction to minimize hazards to life or
property.
Making safe any actual or potential hazard to life or property.
Notifying appropriate public officials required at the emergency scene and
coordinating planned and actual responses with these officials.
Instructions for restoring service outages after the emergency has been
rendered safe.
Investigating accidents and failures as soon as possible after the
emergency.
Furnishing applicable portions of the emergency plan to supervisory
personnel who are responsible for emergency action.
Training appropriate employees as to the requirements of the emergency
plan and verifying effectiveness of training.
Reviewing activities following emergencies to determine if the procedures
were effective.
Establish and maintain liaison with appropriate public officials, such that
both the operator and public officials are aware of each others resources
and capabilities in dealing with gas emergencies.
Local emergency
manual all items
PUBLIC EDUCATION PROCEDURES

*
.616
.616(d)
.616(e)
.616(f)
.616(g)
.617
Public Awareness Program also in accordance with API RP 1162 (Amdt

192-99 pub. 5/19/05, eff. 06/20/05). The Clearinghouse recently reviewed
the procedure applicable to API 1162.
The operator's program must specifically include provisions to educate the
public, appropriate government organizations, and persons engaged in
excavation related activities on:
(1) Use of a one-call notification system prior to excavation and other
damage prevention activities;
(2) Possible hazards associated with unintended releases from a gas
pipeline facility;
(3) Physical indications that such a release may have occurred;
(4) Steps that should be taken for public safety in the event of a gas
pipeline release; and
(5) Procedures for reporting such an event.
The program must include activities to advise affected municipalities,
school districts, businesses, and residents of pipeline facility locations.
The program and the media used must be as comprehensive as
necessary to reach all areas in which the operator transports gas.
The program must be conducted in English and in other languages
commonly understood by a significant number and concentration of the
non-English speaking population in the operator's area.
FAILURE INVESTIGATION PROCEDURES
.617
.605(a)
Analyzing accidents and failures including laboratory analysis where

appropriate to determine cause and prevention of recurrence.
MAOP PROCEDURES
.619
O&M Section 10
Establishing MAOP so that it is commensurate with the class location.
PA Plan
submitted to
clearing house
PA Plan All
Items
O&M Section 11
11.0
O&M Section 12
12.0
MAOP cannot exceed the lowest of the following:

(a)(1)
Design pressure of the weakest element.
OM-2287
12.0
Page xiii of xxii
49 CFR PART 191

(a)(2)
(a)(3)
Test pressure divided by applicable factor.

The highest actual operating pressure to which the segment of
line was subjected during the 5 years preceding the applicable
date in second column, unless the segment was tested according
to .619(a)(2) after the applicable date in the third column or the
segment was uprated according to subpart K. Amdt 192-102 pub.
3/15/06, eff. 04/14/06. For gathering line related compliance
deadlines and additional gathering line requirements, refer
to Part 192 including this amendment.
Pipeline segment
-- Onshore gathering line that first became
subject to this part (other than 192.612) after
April 13, 2006.
-- Onshore transmission line that was a gathering
line not subject to this part before March 15,
2006.
Offshore gathering lines.
All other pipelines.
(a)(4)
(b)
*
(c)
.13(c)
.503
Pressure date
March 15, 2006, or
date line becomes
subject to this part,
whichever is later.
Test date
5 years preceding
applicable date in
second column.
July 1, 1976.
July 1, 1970.
July 1, 1971.
July 1, 1965.
Maximum safe pressure determined by operator.

Overpressure protective devices must be installed if .619(a)(4) is
applicable.
The requirements on pressure restrictions in this section do not
apply in the following instance. An operator may operate a
segment of pipeline found to be in satisfactory condition,
considering its operating and maintenance history, at the highest
actual operating pressure to which the segment was subjected
during the 5 years preceding the applicable date in the second
column of the table in paragraph (a)(3) of this section. An
operator must still comply with 192.611. Amdt 192-102 pub.
3/15/06, eff. 04/14/06. For gathering line related compliance
deadlines and additional gathering line requirements, refer to
Part 192 including this amendment.
PRESSURE TEST PROCEDURES
Pressure testing.
.13(c)
.553
.625(b)
*
.625(f)
.605(a)
Uprating.
ODORIZATION of GAS PROCEDURES
Odorized gas in Class 3 or 4 locations (if applicable) must be readily
detectable by person with normal sense of smell at 1/5 of the LEL.
Periodic gas sampling, using an instrument capable of determining the
percentage of gas in air at which the odor becomes readily detectable.
Amdt 192-93 pub.9/15/03, eff. 10/15/03.
TAPPING PIPELINES UNDER PRESSURE PROCEDURES
Hot taps must be made by a qualified crew. NDT testing is suggested
prior to tapping the pipe. Reference API RP 2201 for Best Practices.
PIPELINE PURGING PROCEDURES
.629
Purging of pipelines must be done to prevent entrapment of an explosive

mixture in the pipeline:
Page xiv of xxii
N/A
O&M Section 13
O&M Section 14
.627
.605(a)
12.0
13.0
UPRATING PROCEDURES
.605(a)
N/A all lines

have been
pressure tested
since applicable
dates
(a)
Lines containing air must be properly purged.
(b)
Lines containing gas must be properly purged.
14.0
O&M Section 15
15.0
N/A No
odorization
O&M Section 16
16.0
O&M Section 17
17.0
OM-2287
49 CFR PART 191
.605(a)
MAINTENANCE PROCEDURES
.703(b)
(c)
.605(b)
Each segment of pipeline that becomes unsafe must be replaced,

repaired, or removed from service.
Hazardous leaks must be repaired promptly.
TRANSMISSION LINES - PATROLLING & LEAKAGE SURVEY PROCEDURES

.705(a)
(b)
Patrolling ROW conditions.
1 and 2
At Highway and Railroad

Crossings
2/yr (7 months)
At All Other
Places
1/yr (15 months)
4/yr (4 months)
2/yr (7 months)
4/yr (4 months)
4/yr (4 months)
Leakage surveys 1 year/15 months.
LINE MARKER PROCEDURES

.707
Line markers installed and labeled as required.
.605(b)
RECORDKEEPING PROCEDURES
.709
.605(b)
.713(b)
19.1.1
19.2.1
19.2.1
O&M Section 20
20.0
O&M Section 21
Records must be maintained.

(a)
Repairs to the pipe life of system.
(b)
Repairs to other than pipe 5 years.
(c)
Operation (Sub L) and Maintenance (Sub M) patrols, surveys, tests

5 years or until next one.
FIELD REPAIR PROCEDURES
.713(a)
O&M Section 19
19.1
Leak detector equipment survey requirements for lines transporting unodorized gas
(a)
Class 3 locations - 7 months but at least twice each calendar
year.
(b)
Class 4 locations - 4 months but at least 4 times each calendar
year.
.605(b)
18.0
Maximum interval between patrols of lines:
Class Location
.706
O&M Section 18
Imperfections and Damages

Repairs of imperfections and damages on pipelines operating above 40%
SMYS.
(1)
Cut out a cylindrical piece of pipe and replace with pipe of design
strength.
(2)
Use of a reliable engineering method.
21.0
O&M Section 22
22.2
Reduce operating pressure to a safe level during the repair.

Permanent Field Repair of Welds
.715
Welds found to be unacceptable under 192.241(c) must be repaired by:

(a)
If feasible, taking the line out of service and repairing the weld in
accordance with the applicable requirements of 192.245.
(b)
If the line remains in service, the weld may be repaired in
accordance with 192.245 if:
(1)
The weld is not leaking.
(2)
The pressure is reduced to produce a stress that is 20% of
SMYS or less.
(3)
Grinding is limited so that inch of pipe weld remains.
(c)
If the weld cannot be repaired in accordance with (a) or (b) above,
a full encirclement welded split sleeve must be installed.
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22.3
22.3
22.3
Page xv of xxii
49 CFR PART 191
Permanent Field Repairs of Leaks

.717
Field repairs of leaks must be made as follows:

(a)
Replace by cutting out a cylinder and replace with pipe similar or of
greater design.
(b)(1) Install a full encirclement welded split sleeve of an appropriate
design unless the pipe is joined by mechanical couplings and
operates at less than 40% SMYS.
(b)(2) A leak due to a corrosion pit may be repaired by installing a bolt on
leak clamp.
(b)(3) For a corrosion pit leak, if a pipe is not more than 40,000 psi
SMYS, the pits may be repaired by fillet welding a steel plate.
The plate must have rounded corners and the same thickness or
greater than the pipe, and not more than D of the pipe size.
(b)(4) Submerged offshore pipe or pipe in inland navigable waterways
may be repaired with a mechanically applied full encirclement split
sleeve of appropriate design.
(b)(5) Apply reliable engineering method.
Testing of Repairs
Replacement pipe must be pressure tested to meet the requirements of a
new pipeline.
For lines of 6-inch diameter or larger and that operate at 20% of more of
SMYS, the repair must be nondestructively tested in accordance with
192.241(c).
.719(a)
(b)
.605(b)
ABANDONMENT or DEACTIVATION of FACILITIES PROCEDURES

.727(b)
(c)
(d)
(e)
(g)
.605(b)
Operator must disconnect both ends, purge, and seal each end before
abandonment or a period of deactivation where the pipeline is not being
maintained. Offshore abandoned pipelines must be filled with water or an
inert material, with the ends sealed.
Except for service lines, each inactive pipeline that is not being maintained
under Part 192 must be disconnected from all gas sources/supplies,
purged, and sealed at each end.
Whenever service to a customer is discontinued, do the procedures
indicate one of the following:
(1)
The valve that is closed to prevent the flow of gas to the customer
must be provided with a locking device or other means designed to
prevent the opening of the valve by persons other than those
authorized by the operator.
(2)
A mechanical device or fitting that will prevent the flow of gas must
be installed in the service line or in the meter assembly.
(3)
The customers piping must be physically disconnected from the
gas supply and the open pipe ends sealed.
If air is used for purging, the operator shall ensure that a combustible
mixture is not present after purging.
Operator must file reports upon abandoning underwater facilities crossing
navigable waterways, including offshore facilities.
COMPRESSOR STATION PROCEDURES
.605(b)(6)
.605(b)(7)
.731
.735
Page xvi of xxii
Maintenance procedures, including provisions for isolating units or

sections of pipe and for purging before returning to service.
Starting, operating, and shutdown procedures for gas compressor units.
Inspection and testing procedures for remote control shutdowns and
pressure relieving devices (1 per yr/15 months), prompt repair or
replacement.
(a) Storage of excess flammable or combustible materials at a safe
distance from the compressor buildings.
(b) Tank must be protected according to NFPA #30.
22.4
22.5
O&M Section 23
23.2
23.1
23.2, 23.3
23.3
O&M Section 24
24.2
24.1
24.2
N/A 24.3
OM-2287
49 CFR PART 191

.736
Compressor buildings in a compressor station must have fixed gas

detection and alarm systems (must be performance tested), unless:
$
50% of the upright side areas are permanently open, or
$
.605(b)
N/A 24.3
It is an unattended field compressor station of 1000 hp or less.
N/A 24.3
PRESSURE LIMITING and REGULATING STATION PROCEDURES
O&M Section 25
.739(a)
*
.605(b)
Inspection and testing procedures for pressure limiting stations, relief

devices, pressure regulating stations and equipment (1 per yr/15 months).
(1)
In good mechanical condition.
(2)
Adequate from the standpoint of capacity and reliability of operation
for the service in which it is employed.
(3)
Set to control or relieve at correct pressures consistent with
.201(a), except for .739(b). Amdt. 192-96 pub. 5/17/04, eff.10/8/04.
(4)
Properly installed and protected from dirt, liquids, other conditions
that may prevent proper oper.
.739(b)
For steel lines if MAOP is determined per .619(c) and the MAOP is 60 psi
(414 kPa) gage or more . . . Amdt. 192-96 pub. 5/17/04, eff.10/8/04.
If MAOP produces hoop
Then the pressure limit is:
stress that
Is greater than 72 percent of
MAOP plus 4 percent
SMYS
A pressure that will prevent unsafe operation
Is unknown as a percent of
of the pipeline considering its operating
SMYS
and maintenance history and MAOP
.743
Testing of Relief Devices
.743
(a)
Capacity must be consistent with .201(a) except for .739(b), and be
determined 1 per yr/15 mo. Amdt. 192-96 pub. 5/17/04, eff.
10/8/04.
.743
(b)
If calculated, capacities must be compared; annual review and
documentation are required. Amdt. 192-93 pub. 9/15/03, eff.
10/15/03.
.743
(c)
If insufficient capacity, new or additional devices must be installed
to provide required capacity. Amdt. 192-93 pub. 9/15/03, eff.
10/15/03.
VALVE AND VAULT MAINTENANCE PROCEDURES
.745
.745
.749
.605(b)
PREVENTION of ACCIDENTAL IGNITION PROCEDURES

.751
Reduce the hazard of fire or explosion by:

(a)
Removal of ignition sources in presence of gas and providing for a
fire extinguisher.
(b)
Prevent welding or cutting on a pipeline containing a combustible
mixture.
(c)
Post warning signs.
OM-2287
25.1
25.1
O&M Section 26
Valves
(a)
Inspect and partially operate each transmission valve that might be
required during an emergency (1 per yr/15 months).
(b)
Prompt remedial action required, or designate alternative valve.
Amdt. 192-93 pub. 9/15/03, eff. 10/15/03.
Vaults
Inspection of vaults greater than 200 cubic feet (1 per yr/15 months).
25.1, 25.2
26.1
N/A 26.3
O&M Section 27
27.0
Page xvii of xxii
49 CFR PART 191
.13(c)
WELDING AND WELD DEFECT REPAIR/REMOVAL PROCEDURES

*
.225
.227
(a)
(b)
(a)
(b)
.229
(a)
(b)
(c)
(d)
Welding procedures must be qualified under Section 5 of API

1104 (19th ed. 1999, 10/31/01 errata) or Section IX of ASME
Boiler and Pressure Code (2001 ed.) by destructive test. Amdt.
192-94 pub. 6/14/04, eff. 7/14/04.
Retention of welding procedure details and test.
Welders must be qualified by Section 6 of API 1104 (19th
ed.1999, 10/31/01 errata) or Section IX of ASME Boiler and
Pressure Code (2001 ed.) See exception in .227(b). Amdt.192-94
pub. 6/14/04, eff. 7/14/04.
Welders may be qualified under section I of Appendix C to weld
on lines that operate at < 20% SMYS.
To weld on compressor station piping and components, a welder
must successfully complete a destructive test.
Welder must have used welding process within the preceding 6
months.
A welder qualified under .227(a)
(1)
May not weld on pipe that operates at > 20% SMYS unless
within the preceding 6 calendar months the welder has had
one weld tested and found acceptable under the sections 6
or 9 of API Standard 1104; may maintain an ongoing
qualification status by performing welds tested and found
acceptable at least twice per year, not exceeding 7
months; may not requalify under an earlier referenced
edition. Amdt. 192-94 pub. 6/14/04, eff. 7/14/04.
(2)
May not weld on pipe that operates at < 20% SMYS unless
is tested in accordance with .229(c)(1) or requalifies under
.229(d)(1) or (d)(2).
Welders qualified under .227(b) may not weld unless:
28.2
28.3
28.3
28.3
.231
Requalified within 1 year/15 months, or

Within 7 months but at least twice per year had a
production weld pass a qualifying test.
Welding operation must be protected from weather.
.233
Miter joints (consider pipe alignment).
28.5
.235
.241
Welding preparation and joint alignment.

(a)
Visual inspection must be conducted by an individual qualified by
appropriate training and experience to ensure: Amdt. 192-94 pub.
6/14/04, eff. 7/14/04.
(1)
Compliance with the welding procedure.
(2)
Weld is acceptable in accordance with Section 9 of API
1104.
(b)
Welds on pipelines to be operated at 20% or more of SMYS must
be nondestructively tested in accordance with 192.243 except
welds that are visually inspected and approved by a qualified
welding inspector if:
(1)
The nominal pipe diameter is less than 6 inches, or
(2)
The pipeline is to operate at a pressure that produces a
hoop stress of less than 40% of SMYS and the welds are so
limited in number that nondestructive testing is impractical.
(c)
Acceptability based on visual inspection or NDT is determined
according to Section 9 of API 1104. If a girth weld is unacceptable
under Section 9 for a reason other than a crack, and if Appendix
A to API 1104 applies to the weld, the acceptability of the weld
may be further determined under that appendix. Amdt. 192-94
pub. 6/14/04, eff. 7/14/04.
28.4
(1)
(2)
O&M Section 28
.241
Page xviii of xxii
28.3
28.6
OM-2287
.13(c)
49 CFR PART 191

.245
Repair and Removal of Weld Defects:

(a)
Each weld that is unacceptable must be removed or repaired.
Except for offshore pipelines, a weld must be removed if it has a
crack that is more than 8% of the weld length.
(b)
Each weld that is repaired must have the defect removed down to
sound metal, and the segment to be repaired must be preheated if
conditions exist which would adversely affect the quality of the weld
repair. After repair, the weld must be inspected and found
acceptable.
(c)
Repair of a crack or any other defect in a previously repaired area
must be in accordance with a written weld repair procedure,
qualified under 192.225.
$
Sleeve Repair low hydrogen rod (Best Practices ref. API 1104
App. B, In Service Welding).
NONDESTRUCTIVE TESTING PROCEDURES
.243
(a)
(b)
28,5
O&M Section 29
Nondestructive testing of welds must be performed by any process,

other than trepanning, that clearly indicates defects that may affect
the integrity of the weld.
Nondestructive testing of welds must be performed:
(1)
22.3, 28.7
29.0
In accordance with a written procedure, and
(2)
(c)
(d)
By persons trained and qualified in the established

procedures and with the test equipment used.
Procedures established for proper interpretation of each
nondestructive test of a weld to ensure acceptability of the weld
under 192.241(c).
When nondestructive testing is required under 192.241(b), the
following percentage of each days field butt welds, selected at
random by the operator, must be nondestructively tested over the
entire circumference.
(1)
In Class 1 locations at least 10%.
(2)
29.0
29.0
In Class 2 locations at least 15%.
In Class 3 and 4 locations, at crossings of a major navigable

river, offshore, and within railroad or public highway rightsof-way, including tunnels, bridges, and overhead road
crossings, 100% unless impractical, then 90%.
Nondestructive testing must be impractical for each girth
weld not tested.
(4)
At pipeline tie-ins, 100%.
Except for a welder whose work is isolated from the principal
welding activity, a sample of each welders work for each day must
be nondestructively tested, when nondestructive testing is required
under 192.241(b).
Nondestructive testing the operator must retain, for the life of the
pipeline, a record showing by mile post, engineering station, or by
geographic feature, the number of welds nondestructively tested,
the number of welds rejected, and the disposition of the rejected
welds.
(3)
(e)
(f)
.273(b)
JOINING of PIPELINE MATERIALS

.281
29.0
O&M Section 30
Joining of plastic pipe:

$
Type of plastic used.
Proper markings in accordance with 192.63.
Manufacturer.
Type of joint used.
OM-2287
N/A 30.0 No
plastic pipe
allowed
Page xix of xxii
49 CFR PART 191

*
.283
.285
.287
.605(b)
Qualified joining procedures for plastic pipe must be in place Amdt. 19294 pub. 6/14/04, eff. 7/14/04.
Persons making joints with plastic pipe must be qualified Amdt. 192-94
pub. 6/14/04, eff. 7/14/04.
Persons inspecting plastic joints must be qualified Amdt. 192-94 pub.
6/14/04, eff. 7/14/04.
CORROSION CONTROL PROCEDURES
.453
Are corrosion procedures established for:

$
Design.
Operations.
Installation.
31.1
.463
Maintenance.
For pipelines installed after July 31, 1971, buried segments must
be externally coated, and
(b)
cathodically protected within one year after construction (see
exceptions in code).
(c)
Aluminum may not be installed in a buried or submerged pipeline if
exposed to an environment with a natural pH in excess of 8 (see
exceptions in code).
(a)
All effectively coated steel transmission pipelines installed prior to
August 1, 1971, must be cathodically protected.
(b)
If installed before August 1, 1971, cathodic protection must be
provided in areas of active corrosion for: bare or ineffectively
coated transmission lines, and bare or coated c/s, regulator sta,
and meter sta. piping.
Examination of buried pipeline when exposed: if corrosion is found, further
investigation is required.
Procedures must address the protective coating requirements of the
regulations. External coating on the steel pipe must meet the
requirements of this part.
Cathodic protection level according to Appendix D criteria.
.465
(a)
Pipe-to-soil monitoring (1 per yr/15 months).
31.5
(b)
Rectifier monitoring (6 per yr/2 months).
31.6
.455
.457
.459
.461
$
(a)
31.1
31.1
32.2
31.3
31.4
31.7
.467
Interference bond monitoring (as required).

Prompt remedial action to correct any deficiencies indicated by the
monitoring.
(e)
Electrical surveys (closely spaced pipe to soil) on bare/unprotected
lines, cathodically protect active corrosion areas (1 per 3 years/39
months) Amdt 192-93 pub.9/15/03, eff. 10/15/03.
Electrical isolation (include casings).
.469
Sufficient test stations to determine CP adequacy.
31.5
.471
Test lead maintenance.
31.8
.473
Interference currents.
31.7
.475
(a)
(b)
(c)
(d)
O&M Sections
31 & 32
.465
Page xx of xxii
Proper procedures for transporting corrosive gas?

Removed pipe must be inspected for internal corrosion. If found,
the adjacent pipe must be inspected to determine extent. Certain
pipe must be replaced. Steps must be taken to minimize internal
corrosion.
31.8
31.1
31.2
32.3, 32.5
OM-2287
49 CFR PART 191
.605(b)
.476
.477
.479
Systems designed to reduce internal corrosion. Amdt 192-(no number)

Pub. 4/23/07, eff. 5/23/07.
(a)
New construction.
(b)
Exceptions offshore pipeline and systems replaced before
5/23/07.
(c)
Evaluate impact of configuration changes to existing systems.
Internal corrosion control coupon (or other suit. Means) monitoring (2 per
yr/7 months).
(a)
Each exposed pipe must be cleaned and coated (see exceptions
under .479(c)).
Offshore splash zones and soil-to-air interfaces must be coated.
(b)
(c)
.481
*
.481
.481
.483
.485
.491
.605(b)
31.3
Coating material must be suitable.

Coating is not required where operator has proven that corrosion
will:
(1)
Only be a light surface oxide, or
N/A 31.3
(2)
Not affect safe operation before next scheduled inspection.
(a)
Atmospheric corrosion control monitoring (1 per 3 yrs/39 months
onshore; 1 per yr/15 months offshore).
(b)
Special attention required at soil/air interfaces, thermal insulation,
under disbonded coating, pipe supports, splash zones, deck
penetrations, spans over water Amdt 192-93 pub.9/15/03, eff.
10/15/03.
(c)
Protection must be provided if atmospheric corrosion is found (per
192.479) Amdt 192-93 pub.9/15/03, eff. 10/15/03.
Replacement and required pipe must be coated and cathodically
protected (see code for exceptions).
(a)
Procedures to replace pipe or reduce the MAOP if general
corrosion has reduced the wall thickness?
(b)
Procedures to replace/repair pipe or reduce MAOP if localized
corrosion has reduced wall thickness (unless reliable engineering
repair method exists)?
(c)
Procedures to use Rstreng or B-31G to determine remaining wall
strength?
Corrosion control maps and record retention (pipeline service life or 5
yrs).
32.1
32.5
31.9
UNDERWATER INSPECTION PROCEDURES GULF of MEXICO and INLETS

*
.612(a)
.612(b)
.612(c)
O&M Section 33
Operator must have a procedure prepared by August 10, 2005 to identify

pipelines in the Gulf of Mexico and its inlets in waters less than 15 feet
(4.6 meters) deep that are at risk of being an exposed underwater pipeline
or a hazard to navigation? Amdt. 192-98 pub. 8/10/04, eff. 9/9/04.
Operator must conduct appropriate periodic underwater inspections based
on the identified risk Amdt. 192-98 pub.8/10/04, eff. 9/9/04.
Do procedures require the operator to take action when the operator
discovers that a pipeline is exposed on the seabed, or constitutes a
hazard to navigation:
(1)
Promptly, within 24 hours, notify the National Response Center
of the location of the pipeline?
(2)
Promptly, but not later than 7 days after discovery, mark the
location of the pipeline in accordance with 33 CFR Part 64 at the
ends of the pipeline segment and at intervals of not over 500 yards
long, except that a pipeline segment less than 200 yards long
need only be marked at the center?
OM-2287
33.0
Page xxi of xxii
49 CFR PART 191
(3)
Page xxii of xxii
Place the pipeline so that the top of the pipe is 36 inches below
the seabed for normal excavation or 18 inches for rock
excavation within 6 months of discovery or not later than
November 1 of the following year if the 6 month period is later
than November 1 of the year the discovery is made? See code re:
engineering alternatives, PHMSA notification.
OM-2287
1
Protocol: .605
SCOPE AND PURPOSE

This Operating and Maintenance (OM) Manual is applicable to Praxair
pipelines transporting hydrogen gas that are regulated by 49 U.S.C.
60101 et seq. (the pipeline safety laws) and 49 U.S.C. 5101 et seq. (the
hazardous material transportation laws).
The numbers shown in parentheses identify the subparts of 49 CFR 191
or 49 CFR 192 with which the paragraph or section of the manual
complies.
Praxair pipelines may also be required to comply with additional and/or
different state regulations in the states in which the pipelines operate.
These additional requirements are addressed in Addendum A for each
state.
OM-2287
Page 1 of 56
REPORTING REQUIREMENTS
2.1
Incident Reporting
Protocol: 191.5
Incident reporting is explained in the local Emergency Plan at each

location.
2.2
Safety-related Conditions Reporting
2.2.1
Conditions That Must Be Reported
Protocol: 191.23
As defined in the Department of Transportation (DOT) Code Part 191,

paragraph 191.23, a report of a safety-related condition shall be filed in
the following cases:
A pipeline (that operates at 20 percent specified minimum yield
strength [SMYS] or more) has general corrosion that has reduced the
wall thickness to less than that required for the maximum allowable
operating pressure (MAOP) and/or has localized corrosion pitting to a
degree where leakage might result.
A pipeline has experienced unintended movement or abnormal
loading by an environmental condition (such as an earthquake,
landslide, or flood) that impairs its serviceability.
A pipeline (that operates at 20 percent SMYS or more) has any
material defect or physical damage that impairs its serviceability.
A pipeline experiences any malfunction or operating error that causes
the pressure to exceed the MAOP of the pipeline.
A pipeline experiences a leak that constitutes an emergency.
A pipeline experiences any safety-related condition that would lead to
an imminent hazard and cause a 20 percent or more reduction in
operating pressure or shutdown of pipeline operation.
Reports of safety-related conditions are not required under this
paragraph when:
An incident results from the condition before the deadline for filing the
safety-related condition report.
The condition exists on a pipeline that is more than 220 yards from
any building intended for human occupancy or outdoor place of
Page 2 of 56
OM-2287
assembly, except that reports are required for conditions within the
right-of-way of an active railroad, paved road, street, or highway.
The condition is corrected by repair or replacement in accordance
with applicable safety standards before the deadline for filing the
safety-related condition report.
2.2.2
Filing a Safety-Related Condition Report
Protocol: 191.25
2.3
A report of any safety-related condition must be filed in writing within 5

working days (not including Saturday, Sunday, or federal holidays) after
the day a representative of the operator first determines that the condition
exists but no later than 10 working days after the day a representative of
the operator discovers the condition. The Pipeline Regulatory
Compliance Manager shall file all Safety-Related Condition Reports with
both the DOT and the applicable state agency, as required. Safetyrelated conditions shall be filed using the Safety-Related Condition Report
(Exhibit B).
Annual Report
Each year, the Pipeline Regulatory Compliance Manager shall submit
PHMSA Form 7100.2-1 Annual Report for Gas Transmission and
Gathering Systems to the Office of Pipeline Safety. The report shall be
submitted on or before March 15 of each year. Instructions for filling out
and submitting the report are available from the web site of the Office of
Pipeline Safety (OPS) (http://ops.dot.gov/). Copies of the report shall also
be submitted to the respective state agencies.
2.4
Other Reports
Various other reports and submittals to government agencies may be
required, as specified in other compliance programs (Integrity
Management Program, Operator Qualification Program, and Public
Awareness Program) or at the request of the regulating agency. All such
reports and submittals shall be made by or at the direction of the Pipeline
Regulatory Compliance Manager to the DOT and to the respective state
agencies at the addresses shown in the respective appendices of each
state.
2.5
DOT Reporting Addresses

Incidents must be reported by telephone at the earliest practicable
moment following the incident, to the National Response Center (1-800424-8802). Incident reporting is explained in more detail in the local
Emergency Plan at each location.
OM-2287
Page 3 of 56
Annual reports (PHMSA Form 7100.2-1) may be filed electronically with

the Office of Pipeline Safety at the OPS web site (http://ops.dot.gov)
through the On-line Data Entry System (ODES). The ODES also
contains copies of all reports submitted since 2001. The Pipeline
Regulatory Compliance Manager submits these entries and maintains the
password for access to Praxairs entries in the ODES.
Completed forms may be submitted by mail to:
DOT/PHMSA Office of Pipeline Safety
Information Resources Manager
400 7th Street SW, Room 2103, PHP-10
Washington, DC 20590
Completed forms may be faxed to the Information Resources Manager at:
202-366-4566.
Page 4 of 56
OM-2287
3
Protocol: .16
CUSTOMER NOTIFICATIONS
Praxair pipelines supply industrial customers exclusively. The pipelines
connect directly into customer process piping and do not pass through
service piping. The contracts with Praxairs customers clearly identify
where Praxairs responsibilities end and the customers responsibilities
begin. No notifications are made to customers beyond those made in the
supply contracts.
OM-2287
Page 5 of 56
NORMAL OPERATIONS
4.1
Operations and Maintenance Manual Review
Protocol: .605(a)
4.2
Availability of Pipeline Records
Protocol: .605(b)(3)
4.3
This OM Manual shall be reviewed at least once each calendar year, not
to exceed 15 months, by the Pipeline Manager or Facility Manager. The
Manager shall identify updates to reflect changes in operating and
maintenance practices, addition or removal of equipment with special
requirements, etc. The Manager shall also consult with the Pipeline
Regulatory Compliance Manager to ensure that the OM Manual is
updated as required by possible regulatory changes. When changes are
necessary, the Pipeline Regulatory Compliance Manager shall initiate a
Management of Change (MOC) to ensure review and communications
about the updates, as necessary.
Most pipeline records and documentation, including as-built drawings,

project books, inspection records, and other records are maintained in the
file rooms and file cabinets at the local office of each pipeline. Each local
office and these pipeline records and documentation are available and
accessible to all pipeline personnel 24 hours per day. In several
locations, pipeline personnel also have laptop computers with appropriate
hardware to provide wireless access to the Praxair wide area network.
The wide area network enables the pipeline personnel to connect to the
Praxair Pipeline Asset Control System (PACS), the DigTrack web site for
One-Call management, and to the other systems and databases that
provide relevant information or records.
Pipeline Startup and Shutdown
Instructions for normal operation of all pipelines and compressors (where

installed) are contained in the Standard Operating Procedure (SOP) Book
located in the local control room of each pipeline. The SOP Book
contains procedures for startup, shutdown, and other normal operational
pipeline activities. The procedures are written so that when properly
executed they will not allow pipeline pressure to exceed the MAOP of any
pipeline segment.
Instructions for the normal operations of remotely located pipeline
compressors, including startup and shutdown, are located at the
compressor facility.
Procedures for compressor isolation are documented using the Praxair
Hazardous Energy Control Procedure.
Page 6 of 56
OM-2287
4.4
Procedure Review and Update
Protocol: .605(b)(8),
.605(c)(4)
Praxair periodically reviews and updates its procedures for both normal
and abnormal operating conditions to ensure that they are effective and
adequate. The Pipeline Management Team, which includes
representatives from various pipeline groups like Operations,
Maintenance, Engineering, Corrosion Protection, Regulatory Compliance,
and Safety, meet periodically to review pipeline operations and consider
changes to procedures or equipment, as warranted. This group also
looks at new technologies to decide how those technologies will be
applied by Praxair.
Personnel are also periodically observed performing procedures to
confirm that the procedures, as written, achieve the desired results safely
and effectively.
The Praxair Safety Observation System (SOS) allows Praxair employees
at all levels, to report safety-related actions by themselves and others.
The SOS Cards may be signed or anonymous, and all SOS cards are fed
into both local and safety management for action, as appropriate.
When procedure shortcomings are identified through any of these
reviews, the procedure is revised, as required, and personnel using the
procedure are trained on how to use the new or revised procedure.
4.5
Safety Precautions for Excavated Trenches
When purging or working on flammable gas pipelines, measures shall be

taken to ensure positive ventilation in confined areas, and periodic
atmospheric test taken according to the Hazardous Work Permit (HWP)
procedures to detect any oxygen deficiency in the work area.
When needed at an excavation site, Praxair shall provide emergency
rescue equipment, including a breathing apparatus and a rescue harness
and line. These shall be provided by a rescue services contractor hired
for the situation. Such an excavation shall be treated as a confined space
and the Praxair Confined Space Entry procedures shall be applied.
These are explained in the Worldwide S&ES Manual database in section
2.04.
4.6
Pipe-type and Bottle-type Holders
4.7
Praxair does not use pipe-type or bottle-type holders in its operations.
Report of a Gas Odor Inside a Building
This response is addressed in the local Emergency Plan at each location.
OM-2287
Page 7 of 56
ABNORMAL OPERATING CONDITIONS

An abnormal operating condition (AOC) is defined as a condition that may
indicate a malfunction of a component or deviation from normal
operations that may:
Indicate a condition exceeding design limits
Result in a hazard(s) to persons, property, or the environment
AOCs include:
Unintended closure of valves or shutdown
Increase or decrease of pressure
Loss of communications
Operation of any safety device
Malfunction of a component, deviation from normal operations, or
personnel error
5.1
Task-specific AOCs
Protocol: .605(c)(1)
5.2
Generic AOCs
Page 8 of 56
For each of Praxairs covered tasks, various possible AOCs could occur
during execution of the task, including or in addition to the AOCs listed
above. These AOCs are described in the procedures related to each
covered task and in the task training modules in the Praxair Operator
Qualifications Program, including how to recognize and react to the
AOCs. The tests and performance evaluations for each module are used
to verify that the individuals who perform covered tasks can recognize
and properly react to AOCs that they might encounter during the
performance of a covered task.
In addition to task-specific AOCs, generic AOCs may be encountered at

any time a person is working at pipeline facilities, without regard to the
covered task being performed. The Praxair Operator Qualification
Program includes a training and qualification verification module that
covers generic AOCs that all Praxair personnel must complete to perform
pipeline tasks. Contractor qualifications to recognize and react to generic
AOCs must also be verified before they may perform work, through one of
the equivalent verification methods described in
P-15-496, Operator Qualification (OQ) Manual.
OM-2287
5.3
AOC Follow-up
5.4
After an AOC appears to have been restored to the normal condition,

Praxair personnel will continue to observe pipeline parameters related to
or providing indication of the abnormal condition. Close monitoring of
these parameters will continue as long as necessary, until operating
personnel are satisfied that pipeline operations are completely stable and
normal.
Notifying Personnel of an AOC
When an AOC occurs, the personnel responding to the AOC are required
to notify others who may be affected by the AOC, except to the extent
that they could put themselves or others in harms way. Thus, control
room personnel are made aware of field operations each day and are
expected to notify field personnel when an AOC occurs in the vicinity
where they are working or that could affect them in some way.
Likewise, field personnel are expected to notify control room personnel
about AOCs occurring in the field so that they can begin appropriate
response activities. Both field and operating personnel are expected to
notify management about the occurrence of AOCs as well.
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CLASS LOCATIONS
6.1
Definitions
6.1.1
Class Location Units

A class location unit is an onshore area that extends 220 yards on either
side of the centerline of any continuous 1-mile (1.6 kilometers) of pipeline.
6.1.2
Class 1 Location
A Class 1 location is defined as any class location unit that is an offshore
area or any class location unit that has 10 or fewer buildings intended for
human occupancy.
6.1.3
Class 2 Location
A Class 2 location is defined as any class location unit that has more than
10 but fewer than 46 buildings intended for human occupancy.
6.1.4
Class 3 Location
A Class 3 location is defined as any class location unit that has 46 or
more buildings intended for human occupancy, or an area where the
pipeline lies within 100 yards of either a building or a small well-defined
outside area such as a playground, recreational area, outdoor theatre, or
other place of public assembly that is occupied by 20 or more persons on
at least 5 days a week for 10 weeks in any 12-month period (days and
weeks need not be consecutive).
6.1.5
Class 4 Location
A Class 4 location is defined as any class location unit where buildings
with four or more stories above ground are prevalent. A Class 4 location
ends 220 yards from the nearest building with four or more stories above
ground.
6.2
Class Location Studies
Protocol: .609
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Class locations for a pipeline segment shall be determined during the

engineering and construction processes. Additional Class Location
Studies shall be conducted periodically, as warranted by conditions along
the pipeline right-of-way (ROW). ROW conditions, including evidence of
construction, are monitored as part of the regularly scheduled ROW
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inspections. New construction along the ROW is reported on the ROW

Inspection Report.
A Class Location Study shall be conducted when it appears from the
ROW inspection reports or other unscheduled observations, that
population densities or land uses along the ROW have changed
significantly.
Class location studies shall determine:
The present class location for the segment involved.
The design, construction, and testing procedures followed in the
original construction and a comparison of these procedures with those
required for the present class location by the applicable provisions of
this part.
The physical condition of the segment to the extent it can be
ascertained from available records.
The operating and maintenance history of the segment.
The maximum actual operating pressure and the corresponding
operating hoop stress, taking pressure gradient into account, for the
segment of pipeline involved.
The actual area affected by the population density increase and
physical barriers or other factors that may limit further expansion of
the more densely populated area.
Class Location Studies are conducted by the Pipeline Regulatory
Compliance Manager or a designee, using the PACS RiskFrame-HCA
application. Results of the study are integrated into the PACS GIS
database.
6.3
Protocol: .611
MAOP Change Due to Class Location Change

The class of a pipeline segment is one of the factors considered when
determining the MAOP of the segment. When the class of a location
changes, the MAOP shall be reviewed to confirm that it is commensurate
for the new class location. If the current MAOP of a segment is not
commensurate for the new class location, one of the following steps must
be taken.
Perform a pressure test of the segment to qualify it to operate at the
new MAOP.
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Reduce the MAOP of the segment to meet the new Class location.
Replace the pipe with piping that meets the new MAOP requirement.
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CONTINUING SURVEILLANCE
Protocol: .613(a),
.613(b)
Praxair has many regularly scheduled inspections of its pipeline

facilities, including ROW patrols, leak surveys, equipment inspections,
and cathodic protection system surveys. These inspections are
performed by both Praxair personnel and qualified contractors, all of
whom may report observations about pipeline conditions, not only related
to the specific inspection or survey being performed, but also related to
any other condition that may warrant further investigation. Such
conditions, when observed, are reported on the appropriate inspection
forms and survey reports. A pipeline management representative reviews
every inspection report to ensure that appropriate responses are being
made to deficiencies that are reported and integrates information from the
various inspections and surveys to identify trends, problem areas, or
potential deficiencies that may be likely to occur.
Personnel are also trained to observe and report unusual pipeline
conditions they may observe during routine work they may be performing
along the pipeline. These observations are discussed during a morning
meeting of the pipeline personnel and the pipeline management.
Whenever anomalous conditions are discovered, the pipeline
management shall promptly review and assess them to ensure that they
do not jeopardize pipeline integrity. When necessary, they may conduct
additional inspections to confirm conditions (wall thickness
measurements, RSTRENG calculations, indirect inspections, etc.).
When a pipe segment is discovered to be in unsatisfactory condition,
appropriate repairs shall be scheduled and made on a timely basis, or the
segment shall be phased out of service. If the segment cannot be
reconditioned or taken out of service, the MAOP shall be lowered to an
appropriate pressure according to 192.619.
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DAMAGE PREVENTION PROGRAM
Protocol: .614
Every Praxair pipeline participates in the One-Call Systems in the states

in which the pipelines operate. Each location has, or is connected with, a
response center that is manned 24 hours per day with staff qualified to
receive requests for pipeline identification and probing/locating. The
telephone number of the respective response center is shown on our
pipeline markers.
Praxair technicians or Praxairs qualified contractors locate and mark
Praxair pipelines with temporary markers, as required by the local OneCall regulations. Technicians do on-site inspections of locations that are
in close proximity to a pipeline or about which insufficient information has
been provided to determine how close construction activities will be to a
pipeline. When a Praxair pipeline is adjacent to the activity or is exposed,
a technician observes the activity to conclusion to ensure the integrity of
the pipeline.
Praxair annually notifies, by mail, residents along our pipeline ROWs of
the product our pipeline transports, how to identify a pipeline leak, what to
do if one occurs, and where to call. Additional information about other
Praxair notifications to the public and various contractors is described in
the Praxair Public Awareness Program.
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Protocol: .615
EMERGENCY MANUALS
The local emergency manuals describe how personnel should respond to
emergencies that might be encountered in the course of pipeline
operations and maintenance. In particular, the manuals explain
notification of other emergency responders, Praxair management, and
government authorities, and steps to follow to manage the scene of the
emergency. Some AOCs may trigger emergency response activities, as
explained in the emergency manuals.
The emergency manuals also explain how personnel shall respond to
various possible natural disasters or threats by third parties to pipeline
integrity.
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10
PUBLIC EDUCATION
Protocol: .616
Page 16 of 56
Praxair has an extensive public awareness and education program that

complies with API RP 1162. Refer to the Praxair Public Awareness
Program.
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11
Protocol: .617
FAILURE INVESTIGATION
All pipeline or pipeline component failures or leaks shall be investigated to
determine cause. The investigation shall follow the Praxair Root Cause
Analysis (RCA) process to identify probable causes and contributory
conditions. The RCA shall also provide recommendations to prevent
reoccurrence.
The root cause analysis procedures and forms can be found in the
Praxair NAIG Operations Procedures database as SOP-010, Root Cause
Analysis Program. Completed RCAs shall be entered in the RCA
database. The subject databases are located on all Praxair Lotus Notes
servers. The RCA short form may be used to document an RCA,
provided it allows for documentation of all of the relevant factors about the
root cause; however, additional documentation will have to be attached to
ensure that all of the documentation requirements have been covered.
If any section of leaking or corroded pipe has been replaced to repair
corrosion or a leak, the pipe section that was removed shall be analyzed
by the Praxair Metallurgical Lab or by a suitably qualified outside lab to
identify conditions that may have caused or contributed to the corrosion
or leak. These findings shall be considered as part of the RCA. Samples
of failed pipe or pipeline components may also be provided to state or
federal regulating agencies, on their request, for further investigation.
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12
MAXIMUM ALLOWABLE OPERATING

PRESSURES
No segment of a steel pipeline shall be operated at a pressure that
exceeds the lower of the following:
Protocol: .619(a)(1)
The design pressure (as defined in Subparts C & D of Part 192) of the
weakest element of the pipeline. The term elements refers to pipe,
valves, fittings, and other components that may be exposed to the
maximum allowable operation pressure.
Protocol: .619
The formula for calculating the design pressure of pipe is explained in

192.105. For this calculation, the design factor F is applied to take
into account the class location of the pipe. Details about the design
factor for class locations may be found in 192.111.
The design pressures for other components are specified by the
manufacturer.
The pressure obtained by dividing the pressure to which the pipeline

is tested after construction by a factor of 1.5 (assuming Class 3 or 4
locations). Exceptions to this factor are noted in 192.619.
Protocol: .619(a)(4),
.619(b)
The maximum pressure considered safe by the Pipelines and

Metering Engineering Department or by the Region Operations
Department. Note that when MAOP is selected based on the
maximum pressure considered safe, pipeline safety devices must be
installed and set to prevent exceeding the selected MAOP.
Changes to the class of a pipeline location or changes to the condition of

the pipe or components of a pipe segment may require changes to the
MAOP. These circumstances are explained in various places in this
manual.
If it is desired to increase the MAOP of a pipe segment, the increase must
be conducted according to a written plan that follows the requirements of
49 CFR 192 Subpart K. Refer to Chapter 14 of this manual.
Page 18 of 56
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Protocol: .503
PRESSURE TESTING
All pressure tests shall be performed according to Praxair procedure T-1,
Procedure for Field Pneumatic Testing, or Praxair procedure T-6,
Hydrostatic Testing of Pipelines. The most current versions of these
procedures may be found on the Praxair Standards Technology
database.
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14
UPRATING PIPELINE MAOP
Protocol: .553
Any increase in the MAOP of a pipeline segment shall be performed in

accordance with 49 CFR 192, Subpart K Uprating. Subpart K includes
the following requirements:
Develop and follow a written plan that ensures that all Subpart K
requirements will be met.
Review the design, operating, and maintenance history and previous
testing of the segment of pipeline, and determine whether the
proposed increase is safe and consistent with the requirements of
Subpart K.
Make any repairs, replacements, or alterations in the segment of
pipeline that are necessary for safe operation at the increased
pressure.
Increase pressure in pre-determined increments.
Hold the pressure constant after each pressure increase, and inspect
the pipeline for leaks.
Repair any potentially hazardous leaks before increasing pressure
further, and monitor leaks that are not potentially hazardous.
Subpart K has additional requirements and specifications for MAOP
increases based on pipeline material of construction, internal stresses
that will be encountered, class location, and other factors. All of these
must be considered when preparing the written plan for the pressure
increase.
All records of MAOP uprating shall be kept for the life of the pipeline.
Page 20 of 56
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ODORIZATION OF GAS
Protocol: .625(b),
.625(f)
All Praxair regulated pipelines transport hydrogen gas is used as a

feedstock for industrial manufacturing processes; therefore, odorization is
not required.
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16
TAPPING PIPELINES UNDER PRESSURE
Protocol: .627
Page 22 of 56
Praxair safety procedures do not permit hot-tapping pipelines that contain

hydrogen at any pressure. Any connection made to a Praxair hydrogen
pipeline must be made under the control of a Praxair HWP, with the
effected line purged out of service and depressurized.
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PIPELINE BLOWDOWN, PURGING, OR

RE-PRESSURIZATION
Any hydrogen pipeline blowdown, purging, or re-pressurization activities
shall be performed according to Praxair SOP-214, Hazardous Gas
Pipeline Job Plan Template and the Praxair Safety & Health Manual
Database, section 2.2.1, Hazardous Work Permit procedures.
Protocol: .629(a)
When purging a hydrogen pipeline out of service, the line shall be purged
using nitrogen or other inert gas. The purge vent shall be sampled with
appropriate analytical equipment to determine that all hydrogen has been
purged.
Protocol: .629(b)
When purging a hydrogen pipeline into service, the pipeline shall first be
purged using nitrogen or other inert gas to remove all air from it. The
purge vent shall be sampled with appropriate analytical equipment to
determine that all of the air has been purged. After all of the air has been
purged, the pipeline shall be purged with hydrogen gas. The purge vent
shall be sampled with appropriate analytical equipment to determine
when hydrogen purity has been restored, after which the pipeline may be
raised to the normal operating pressure and put back into service.
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18
MAINTENANCE PROCEDURES
Protocol: .703(b)
Praxair inspects and monitors its hydrogen pipelines on a frequent and

on-going basis to ensure that they are in good condition for the intended
service. Whenever anomalous conditions are discovered, the pipeline
management shall promptly review and assess them to ensure that they
do not jeopardize pipeline integrity. When necessary, they may conduct
additional inspections to confirm conditions (wall thickness
measurements, RSTRENG calculations, indirect inspections, etc.).
When a pipe segment is discovered to be in unsatisfactory condition,
appropriate repairs shall be scheduled and made on a timely basis, or the
segment shall be phased out of service. If the segment cannot be
reconditioned or taken out of service, the MAOP shall be lowered to an
appropriate pressure according to 192.619. Any segment found to be
unsafe shall be repaired immediately or taken out of service.
Protocol: .703(c)
When a hazardous Class 1 leak occurs, Praxair shall take immediate

action to take the affected pipeline segment out of service until
appropriate repairs can be made. Praxair personnel shall make the area
of the hazardous leak safe until the pipeline has been taken out of service
and the leak area is no longer hazardous. Refer to Chapter 34, Leak
Inspections and Response, and the local Emergency Plan for more
details about responses to hazardous leaks.
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RIGHT-OF-WAY PATROLS AND LEAK

SURVEYS
19.1
Right-of-Way Patrols
Each pipeline location shall maintain a pipeline patrol program to observe
surface conditions on the pipeline right-of-way (ROW). During these
surveys, the ROW shall be observed for leaks, construction activity,
vandalism, missing or damaged markers or casing vents, and any other
factors affecting the safe operation of the pipeline system.
Protocol: .705(a)
Pipeline patrols and findings are recorded using the Pipeline Patrol Log
(Exhibit F). Logs are maintained in the files of the local pipeline office.
When a pipeline patrol reveals the need for repairs or other remedial
action, such requirements shall be documented and managed with a D7i
Work Order.
9.1.1
ROW Patrol Schedule

The schedule shown in Table 1 shall apply:
Protocol: .705(b)
Table 1
Right-of-Way Patrol Schedule
Class
Location
1 and 2
19.1.2
At Highways and Railroad

Crossings
At All Other Places
Twice per calendar year, not to

exceed 7 months
Once per calendar year, not to

exceed 15 months
Four times per calendar year, not to

exceed 4 months
Twice per calendar year, not

to exceed 7 months
Four times per calendar year, not to

exceed 4 months
Four times per calendar year,

not to exceed 4 months
Pipeline Cover
Each pipeline location shall monitor all segments of the underground
pipeline system for acceptable cover during normal pipeline patrolling.
During the patrol, if personnel see any indication of major changes in the
cover over the pipelines at road crossings, ditches, or cross-country
terrain, they shall take the following action:
Determine whether the cover has deteriorated to an unacceptable
level.
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Inspect the line, where possible, for line movement.

If the cover has deteriorated to an unacceptable level or the pipeline is
exposed, provide temporary protection such as markers, barriers, and
supports or shoring until the cover can be permanently restored.
19.1.3
Construction Activity along ROW

Any construction or other unusual activity noted around Praxair pipelines
during patrols shall be reported on a Construction Activity Report (refer to
Exhibit G). Construction Activity Reports are maintained in the files of the
local pipeline office. Copies are also submitted to the Pipeline Regulatory
Compliance Manager, who evaluates the need for a Class Location Study
of the pipeline segments near the construction site and the impact of the
construction on risk and integrity assessments of the Integrity
Management Program.
19.1.4
Casing Vent Stacks

Casing vent stacks are used at all locations where the pipeline is installed
in a casing to relieve pressure in the casing in the event of a leak in the
pipe within the casing. A pipeline marker shall be installed on the pipeline
vent stack. Casing vents shall be inspected for damage during the
pipeline ROW patrols. Findings shall be reported on the Patrol Log. If
repairs or other remedial action are required, such requirements shall be
documented and managed with a D7i Work Order.
Casing vent atmospheres shall be sampled with leak detection equipment
during leak surveys to check for leaks of the piping inside the casing.
Leak survey procedures and documentation are explained in section
19.2, Leak Surveys.
19.2
Leak Surveys
19.2.1
Scheduled Leak Surveys
Protocol: .706
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Each pipeline location shall conduct leakage surveys on its hydrogen

pipelines at the minimum intervals shown in the Table 2. Leak surveys in
Class 3 and 4 locations shall be performed using calibrated leak detection
equipment. Leak detection equipment is typically used in Class 1 and 2
locations as well.
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Table 2
Leakage Surveys
Class
Location
Frequency
1 and 2
Once per calendar year, not to exceed 15 months
Twice per calendar year, not to exceed 7 months
Four times per calendar year, not to exceed 4 months
Leak surveys may be conducted by qualified Praxair personnel or by

qualified contractors, depending on local staffing. Leak surveys shall be
documented using a suitable format. Leak surveys that are performed at
the same time as a ROW patrol may be documented on the Patrol Log.
Leak surveys conducted by contractors shall be documented with a
written report submitted by the contractor. After the appropriate
emergency response, any leak discovered shall be documented on the
Leak Detection Report.
19.2.2
Unscheduled Leak Surveys
Protocol: .614(6)(ii)
19.2.3
Whenever blasting has occurred in close proximity to a Praxair pipeline or

whenever some other activity has occurred on or near the pipeline that
might have jeopardized pipeline integrity, a leak detection survey, with
leak detection instruments, will be performed on that section of the
pipeline.
Visual Inspection for Underground Piping Leaks

A visual leak inspection is conducted by inspecting the pipeline ROW for
any of the following conditions:
Vegetation changes (dead grass or plants)
Noise
Bare spots in ground
Gas bubbling in water
Observations of any of these conditions will warrant a subsequent
inspection of the area using leak detection equipment capable of
detecting hydrogen. Visual leak inspections are conducted as part of the
regularly scheduled ROW inspections.
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19.2.4
Aboveground Piping Leak Detection

In addition to the required leak surveys using calibrated leak detection
equipment, aboveground piping may also be checked for leaks using a
soapy water solution or other foam-forming solution. Pipeline casings
and areas where vegetation around the pipeline may not be adequate to
indicate the presence of a leak shall be inspected by sampling the
atmosphere at ground surface openings and casing vents.
19.2.5
Leaks Detected in non-Praxair Pipelines

If, during a survey, indications of leakage are found to originate from a
nearby pipeline not owned or operated by Praxair, prompt action shall be
taken as necessary to protect life and property. The operator of the
leaking pipeline shall be notified of the approximate location of the leak;
and if an emergency condition exists, local emergency responders shall
be notified of the leak.
19.2.6
Detection Report Form

Any pipeline leak or failure shall be reported on the Leakage Detection
Report Form (Exhibit A).
Section 1 of the form shall be completed by operating location personnel
at the time the leak is reported. The Pipeline Manager or a designee
shall be accountable to complete the report as more information is
gathered about the leak. If the leak or failure was defined as a Grade 1
leak, a copy of the report shall be attached to a Plant Incident Report and
forwarded to the appropriate personnel.
Page 28 of 56
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20
Protocol: .707
PIPELINE MARKERS
Signs and markers have been installed to identify the location of the
pipeline to reduce the possibility of damage or interference.
Generally, pipeline markers shall be located such that a person can stand
at one marker and see the next marker where possible. Markers shall be
installed at all valve and meter stations; road, railroad, and water
crossings; and on all casing vent stacks.
All markers shall carry the word Warning followed by the words
Hydrogen Pipeline. The marker shall include the name, Praxair, and the
telephone number at which Praxair personnel can be reached 24 hours
per day. Lettering shall be at least 1-inch tall with a stroke width of not
less than inch.
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21
RECORDKEEPING
Protocol: .709
All pipeline construction and maintenance records shall be kept for the life
of the pipeline. These include the date, location, and description of
repairs to both pipe and pipeline components. All surveys, inspections,
tests, and patrols shall also be kept for the life of the pipeline.
Records shall be kept in the files of the local pipeline office and/or in any
of Praxairs computerized systems, including DataStream D7i CMMS,
PACS GIS system, the DOT Regulated Pipelines Sharewaves site, or file
folders on either of these servers:
\\usatonas2\deptdata\SPET\Pipeline Management\Integrity Management Program
\\usadeets1\Compliance Documents\Integrity Management
Page 30 of 56
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22
FIELD REPAIR PROCEDURES
22.1
Immediate Response to Pipeline Damage

Whenever a leak, imperfection, or other damage is discovered on a
pipeline that impairs the pipelines serviceability, Praxair shall take
immediate, temporary steps, as necessary, to protect the public. Praxair
shall make permanent repairs as soon as it is feasible to do so.
Temporary steps may include cordoning off the area of the defect,
temporarily taking the pipeline out of service, temporarily lowering the
MAOP, or other steps as the situation warrants.
22.2
Repair of Imperfections and Damage
Protocol: .713(a)(1, 2)
An imperfection or other damage may be repaired by cutting out a

cylindrical piece of pipe that includes the damaged area and replacing it
with pipe of equal or greater design strength or by installing a Clock
Spring or similar engineered repair system.
Imperfections or damage in submerged pipelines may also be repaired by
installing a Clock Spring or similar engineered repair system.
Protocol: .713(b)
Before making any repair to an in-service pipeline segment, the situation

shall be evaluated to determine a safe operating pressure at which the
repair can be made, and the pipeline pressure shall be maintained at or
below that pressure until the repairs have been completed. This provision
applies only to engineered repair systems (wraps) or bolt-on split sleeves.
Praxair does not permit welding on lines under pressure or lines
containing hazardous or flammable gases.
For the proper protection of the repaired pipeline, the pipe shall be
adequately coated according to Praxair Standard EN-49.
22.3
Permanent Field Repair of Welds
Protocol: .715(b)
Defective welds in Praxair pipelines may only be repaired with the

pipeline purged out of service.
Protocol: .245(b),
.715(a)
A weld that is unacceptable according to section 9.0 of API Standard

1104 can be repaired by removing the defect down to clean metal and
where appropriate, preheating the segment before rewelding. After
rewelding, the repaired weld must be inspected. Repaired welds that fail
inspection must be completely removed.
Protocol: .245(a)
A cracked weld may only be repaired if the crack is shorter than 8 percent
of the weld length.
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Protocol: .715(c)
22.4
If the defective weld cannot be repaired as described, it may be repaired

by installing a full encirclement welded split sleeve of appropriate design
over the defective weld.
Permanent Field Repair of Leaks
Protocol: .717(a)(b)
(1, 2, 5)
A leak may be repaired by cutting out a cylindrical piece of pipe that

includes the leak, and replacing it with pipe of equal or greater design
strength, or by installing a Clock Spring or similar engineered repair
system. Leaks may also be repaired by installing a full encirclement
welded split sleeve of appropriate design over the leak area. If the leak is
due to a corrosion pit, it may be repaired by installing a bolt-on leak
clamp.
Leaks in submerged pipelines may be repaired by installing a

mechanically applied full encirclement split sleeve of appropriate design
over the leak.
Before making any repair to an in-service pipeline segment, the situation
shall be evaluated to determine a safe operating pressure at which the
repair can be made, and the pipeline pressure shall be maintained at or
below that pressure until the repairs have been completed. This provision
applies only to engineered repair systems (wraps) or bolt-on split sleeves.
Praxair does not permit welding on lines under pressure or lines
containing hazardous or flammable gases.
22.5
Praxair does not allow the use of fillet-welded patches, no matter what the
MAOP stress levels to the pipe segment may be. For the proper
protection of the repaired pipeline, the pipe shall be adequately coated
according to Praxair Standard EN-49.
Testing of Repairs
Protocol: .719(a)
All replacement pipe must be pressure tested to the same pressure that
would be required for a new pipeline installed in the same location. The
replacement pipe may be tested before installation.
Pressure testing shall be done according to Praxair T-1 or T-6
procedures.
Protocol: .719(b)
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All repairs made by welding shall be nondestructively tested. These

include welds made to repair defective or cracked welds, welds made to
install a full-encirclement split sleeve, and tie-in welds of new pipe
segments that were pressure tested prior to installation. Nondestructive
testing shall be in compliance with API 1104, section 8 - Procedures for
Nondestructive Testing. Test acceptability shall be in accordance with
API 1104, section 9, or API 1104, Appendix A, for girth welds with
repaired weld defects other than cracks.
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23
PIPELINE ABANDONMENT/DEACTIVATION
23.1
Discontinuance of Service
Protocol:
.727(d)
When service is discontinued to a customer, one of the following actions

shall be taken:
A valve that fully isolates the customers piping from the Praxair
pipeline shall be locked and tagged shut. Only specifically authorized
Praxair personnel may unlock or open the valve.
A flange blind or similar mechanical device or fitting that prevents the
flow of gas to the customer shall be installed in the meter station or
other location at or upstream of the customers piping.
The customer piping shall be physically disconnected from the Praxair
piping, and the open ends of the pipe shall be sealed.
23.2
Deactivated Pipelines
Deactivation refers to the cessation of use of a pipeline for some period of
time. Because a pipeline is a valuable piece of property, a deactivated
pipeline shall be maintained so that it may be restored to service.
The decision to deactivate a pipeline must consider ROW concerns,
associated costs, safety, future use by Praxair, and possible sale for use
by others. The Pipeline Manager will secure Business Management and
Operations Management agreement on all deactivation decisions. Upon
receipt of authorization to deactivate a pipeline facility or section thereof,
it shall be the responsibility of the local pipeline location to execute
deactivation procedures.
Protocol: .727(e)
Pipeline segments that are to be deactivated shall be purged with an

inert gas and tested as necessary to confirm that they do not contain
a flammable gas mixture.
Customer supply connections shall be closed and locked or
disconnected (refer to section 23.1).
Protocol: .727(c)
Pipeline segments shall be physically disconnected from all sources

and supplies of product, including connecting pipelines, crossover
piping, meter station control piping, and other apparatus.
All disconnected piping ends or other openings shall be sealed with
blind flanges, welded caps, or other sealing devices as appropriate for
the connection.
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Automatic mainline block valves shall be locked open and shall be

metal tagged open.
Pipeline markers and casing vents shall not be removed.
The deactivated segments shall remain included in the local One-Call
System, and Praxair shall continue to respond to One-Call locate
requests on the segments as though they are still in service.
The deactivated segments shall be removed from compliance with
Part 192.
Additional conditions that are found in a particular lease, license or
easement covering that section of line regarding deactivation shall be
adhered to.
All records for executing the deactivation plan shall be maintained in
the files of the local pipeline office.
23.3
Abandonment of a Pipeline
If there is no further need for a pipeline and Praxair desires to cease all
maintenance of the pipeline, the following considerations apply:
Protocol: .727(e)
Pipeline segments that are to be abandoned shall be purged with an

inert gas and tested as necessary to confirm that they do not contain
a flammable gas mixture.
All connections to in-service piping shall be removed.
All aboveground elements and components shall be removed.
ROW owners shall be notified that the line will no longer be operated.
Corporate rules for abandonment shall be adhered to.
Additional abandonment actions shall be taken as stipulated by
applicable right-of-way agreements or by state or local laws or
regulations.
Protocol: .727(g)
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For pipeline segments that cross navigable waterways, reports

documenting the location and abandonment shall be filed with the
National Pipeline Mapping System in accordance with the Standard
for Pipeline and Liquefied Natural Gas Operator Submissions and to
applicable state agencies.
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24
COMPRESSOR STATION PROCEDURES
24.1
Compressor Operating Procedures
Procedures for compressor operations, including startup, shutdown,

emergency shutdown, and other compressor-related actions that can be
performed remotely from a control center are maintained at each control
center.
Procedures for local compressor operations, including startup, shutdown,

emergency shutdown, and other compressor-related actions that can be
performed locally and procedures for compressor maintenance are
maintained at the local compressor control station or at the plant facility
from which compressor operators are dispatched.
24.2
Compressor Maintenance Procedures
Compressor isolation shall be performed according to a procedure written

specifically for the compressor. Isolation procedures shall include steps
for purging hydrogen from compressor components and adjoining piping
with inert gas, before opening any part of the compressor. Isolation
procedures shall include steps to purge air from an isolated compressor
with inert gas before returning the unit to service.
Protocol: .731
Compressor remote shutdown devices shall be tested once per calendar

year, not to exceed 15 months. Local compressor emergency shutdown
devices shall also be tested once per calendar year, not to exceed 15
months. Shutdown devices that do not function properly shall be
replaced promptly.
Compressor pressure relief valves shall be tested once per calendar year,
not to exceed 15 months, as described in section 25.1, Pressure Limiting
Valve Inspections.
The capacity calculations for each compressor pressure relief valve are
reviewed once each calendar year, not to exceed 15 months, to confirm
that the valve capacity is sufficient for the pressures and flows to which it
is exposed. Any valve found to have insufficient capacity shall be
replaced immediately with a valve that has sufficient capacity for the
location at which it is installed. Capacity calculations and reviews are
performed and documented by the Pipelines and Metering Engineering
Department.
The tests shall be documented in the D7i Computerized Maintenance
Management System.
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24.3
Compressor Building Requirements
Protocol: .735(a, b),

.736
Page 36 of 56
None of Praxairs pipeline compressors are inside compressor buildings

or other structures. No flammable or combustible material is stored
around any compressor.
OM-2287
25
PRESSURE LIMITING AND REGULATOR

STATION PROCEDURES
25.1
Pressure Limiting Valve Inspections
All pipeline pressure limiting valves and safety relief valves shall be set to
prevent pipeline pressure from exceeding the MAOP of the protected
segment by more than 10 percent.
Protocol: .739(a)(1, 2, 4)
All pressure limiting valves and safety relief valves shall be inspected,
tested, and adjusted by a certified testing facility, once each calendar
year, not to exceed 15 months. Valves to be tested and their set
pressures are listed in the Overpressure Protection List.
Protocol: .739(b)
None of the MAOPs of Praxair pipeline segments produce stresses

exceeding 72 percent of SMYS.
The testing facility shall submit a test report for each valve tested. The
report lists the test date, repairs made, and the as-left set pressure.
Copies of all test reports shall be kept in the files of the local pipeline
office.
Protocol: .743(a, b, c)
25.2
The capacity calculations for each pressure limiting device shall be

reviewed once each calendar year, not to exceed 15 months, to confirm
that the valve capacity is sufficient for the pressures and flows to which it
is exposed. Any valve found to have insufficient capacity shall be
replaced immediately with a valve that has sufficient capacity for the
location at which it is installed. Capacity calculations and reviews are
performed and documented by the Pipelines and Metering Engineering
Department.
Meter/Regulator Station Inspections
Protocol: .739(a)
(1, 2, 3, 4)
Regulator valves have been installed at critical locations on all Praxair

pipelines to maintain the proper operating pressure of the respective line
sections and to meet customer requirements. Meter/Regulator Station
Inspections shall be conducted at least once each calendar year, not to
exceed 15 months, but these inspections are typically conducted
quarterly. Each inspection of a meter or regulating station shall be
documented on the Meter/Regulator Station Inspection Report (Exhibit
H). The completed reports shall be kept in the files of the local pipeline
office.
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When an inspection reveals the need for repairs or other remedial action,
such requirements shall be documented and managed with a D7i Work
Order.
25.3
Security and Safety Requirements

An exterior chain link fence shall enclose each meter/regulator station
with gates locked when the site is unattended. Warning signs for
potential hazards, where appropriate, shall be posted; e.g., noise, no cell
phones, no pagers, or other portable electrical devices, No Smoking, will
be conspicuously displayed at the station. Proper Personal Protective
Equipment Required signs will also be posted, i.e., Flame Retardant
Clothing, Hardhats, etc.
Page 38 of 56
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26
VALVE INSPECTIONS
26.1
Mainline Isolation Valves

Any Praxair pipeline system equipped with mainline isolation valves shall
have these valves installed in locations readily accessible for
maintenance and emergency operation.
Protocol: .745(a, b)
Each isolation valve that might be required to operate in an emergency

must be partially operated at least once each calendar year (not to
exceed 15 months) and promptly repaired if defective. The inspection
shall include visual and operational checks. Isolation valve inspections
shall be documented on the Valve Exercising Log, which shall be kept in
the files of the local pipeline office.
When the inspection reveals the need for repairs or other remedial action,
Order.
26.2
Check Valves
Each Praxair pipeline contains check valves that are installed to prevent
backflow of customer materials into the pipeline network.
Proper functioning of check valves shall be verified by an operational test,
or the valves shall be removed for inspection and repair or replacement.
It is recognized that some of these check valves cannot be inspected
unless a customer outage occurs. An agreement between the customer
and the sales department must take place. Check valve function tests
are typically performed at five-year intervals, operations permitting.
Inspection results, including valve tag number and/or location, date of
inspection, method of inspection, results of inspection, remedial action
taken, and remarks shall be documented on the Check Valve Inspection
Log. A separate log shall be maintained for each check valve. All Check
Valve Inspection Logs shall be kept in the files of the local pipeline office.
Order.
26.3
Protocol: .749
Vaults
The Praxair pipeline systems do not have any vaults.
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27
PREVENTION OF ACCIDENTAL IGNITION

All construction, maintenance, and repair work to or near Praxair
pipelines shall be carried out in accordance with the rules of Praxairs
HWP procedures.
Where a hazardous amount of gas is being vented or the presence of
flammable gas constitutes a hazard of fire or explosion:
Protocol: .751(a)
All potential source of ignition shall be removed from the area.
Protocol: .751(a)
A fire extinguisher shall be provided.
Protocol: .751(c)
Warning signs shall be posted around the area.

The atmosphere shall be monitored with flammable gas detection
equipment.
Protocol: .751(b)
No welding or cutting shall be permitted on any pipeline segment or

component containing a combustible mixture of flammable gas and air.
Activities that might otherwise present a risk of accidental ignition may be
restricted to designated areas, as necessary, to ensure safe completion
of the job.
Page 40 of 56
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28
WELDING AND WELD DEFECT REMOVAL
28.1
Praxair Maintenance Welding Standards

All welding of Praxair pipelines shall be in accordance with Praxair
Standard W-39, Field Welding of Cross Country Pipelines in compliance
with ANSI/ASME B31.8 Code, and the Praxair Gas Transmission Design
Manual.
W-39 is based on ASME Gas Transmission and Distribution Piping
Systems, ASME Boiler and Pressure Vessel Code Welding and Brazing
Qualifications, section IX, and API 1104 Welding of Pipelines and Related
Facilities. In some cases, the applicable Praxair standards apply
additional and/or more restrictive requirements than the ASME or API
standards and must be followed for all welding to be done on Praxair
pipelines.
Welding shall only be performed on a pipeline that has been
depressurized and purged under an HWP.
28.2
Weld Procedures
28.3
All pipeline welding must be performed by a qualified welder according to

a welding procedure qualified under API 1104, section 5 or ASME Boiler
and Pressure Vessel Code, section IX, as specified in W-39, section 4.1.
Test welds produced for weld procedure qualification shall be
destructively tested, as specified in these standards. The procedure
specification and the procedure test records shall be kept for the life of
the pipelines on which it was used.
Welder Qualifications
Protocol: .227(a),
.229(a, b)
Welders shall be qualified to perform the welding procedure specified for

the work being performed (refer to section 28.2). Welder qualification
shall be according to either API 1104, section 6, or ASME Boiler and
Pressure Vessel Code, section IX, as specified in W-39, section 4.2,
including destructive testing of weld samples produced by the welder
using the procedure for which qualification is sought. For the qualification
to remain valid, the welder must have performed the specified procedure
in the last six months. Welders performing welds on compressor piping
or components shall also be qualified according to these requirements.
Protocol: .227(b),
.229(c, d)
Welder qualifications achieved according to Part 192, Appendix C, shall

not be accepted, even when welding pipe that will operate at stresses
less than 20 percent SMYS.
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Welders shall also have met the requirements of the Praxair Operator
Qualification Program.
The welder shall present copies of his certifying paperwork. If that
paperwork is more than six months old, records of having performed the
weld procedure in the last six months must also be presented. The
required records shall be presented before starting work.
28.4
Weld Preparation and Alignment

Weld preparation and alignment shall be as specified in W-39, sections
6.1 and 6.2.
Protocol: .235
28.5
Other Welding Requirements
Protocol: .231
All welding operations must be protected from the weather.
Protocol: .233
Miter joints are not permitted on underground piping (See Gas

Transmission Design Manual (GTE-9) section 9.9.6.7 Fabrication and
Fit-up Procedures).
Additional welding requirements are specified in the Gas Transmission
Design Manual (GTE-9) and in W-39, section 6.
Protocol: .245(*)
28.6
Inspection of Welds
Weld inspection procedures shall be as specified in W-39, section 7.0.
Protocol: .241
28.7
All of the welding rods specified for pipeline welding are low hydrogen
rods.
Repair of Weld Defects

Defective welds may only be repaired with the pipeline purged out of
service.
Protocol: .245(c)
Repairs shall be made in accordance with API 1104, section 10.0, at the
contractors expense. If a repair is unacceptable, the weld shall be
removed. Any weld with a crack that exceeds 8 percent of the weld
length shall be removed.
Additional information about repairs of weld defects may be found in
section 22.3.
Page 42 of 56
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29
NONDESTRUCTIVE TESTING
PROCEDURES
Protocol: .243(a), (b)(1),

(c)
Nondestructive tests of welds shall be performed according to a written

test procedure that complies with the testing standards of the American
Society for Nondestructive Testing (ASNT). The test applied shall be one
that clearly indicates defects that may affect the integrity of the weld. The
written procedure shall describe how to perform the test and how to
interpret the results of the test.
Nondestructive testing shall be performed by a technician holding ASNT

TC1A Level 2 certification to perform the procedure who is also trained in
the use of the tools and equipment required to perform the nondestructive
test procedure.
Weld acceptability shall be in accordance with API 1104, section 9.
Protocol: .243(d)
When nondestructive testing is required, the following percentages of butt

welds shall be randomly selected for inspection:
10 percent of welds in Class 1 locations
15 percent of welds in Class 2 locations
100 percent of the welds in Class 3 and 4 locations, at major or
navigable river crossings, offshore, and within railroad or public
highway ROW, including tunnels, bridges, and overhead road
crossings 100 percent unless impractical, then 90 percent.
Nondestructive testing must be impractical for each girth weld not
tested.
All tie-in welds not subjected to a pressure proof test shall be examined.
Protocol: .243(e)
When nondestructive testing is required, a sample of each welders work

shall be tested each day.
Protocol: .243(f)
A record of nondestructive testing shall show by mile post, engineering

station, or geographic feature the number of welds nondestructively
tested, the number of welds found to be defective, and the disposition of
the defective welds.
These nondestructive test records shall be kept for the life of the pipeline.
They will be stored in the local facility file room.
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30
PLASTIC PIPE
Protocol: .281, .283,

.285, .287
Page 44 of 56
Praxair does not currently permit the use of plastic pipe for hazardous gas
service.
OM-2287
31
CATHODIC PROTECTION SYSTEMS
31.1
Cathodic Protection System Design and

Installation
Cathodic protection systems for Praxair pipelines shall be designed and
installed according to the Praxair Gas Transmission Design Manual,
section GTE-14. The Cathodic Protection System shall include sufficient
test stations to measure its condition and capability to protect the pipeline.
Protocol: .453
The system may be designed and installed by Praxair or by a reputable

Cathodic Protection contractor. In either case, the design and installation
shall comply with NACE RP-0169 and RP-0177.
Protocol: .455(a, b),
.457, .465(e)
All buried pipelines shall be externally coated, and a cathodic protection

system shall be installed and in operation within one year of completion of
construction.
Protocol: .455(c)
Materials suitable for pipeline construction are listed in Gas Transmission

Engineering Guideline, GTE-7. Aluminum, copper, or plastic may not be
used as a pipeline material.
31.2
Protocol: .467
Electrical Isolation
Each buried or submerged pipeline shall be electrically isolated from
other foreign underground structures and casings except where system
design allows mutual cathodic protection. All aboveground piping shall be
properly grounded.
Insulating devices shall be installed where electrical isolation of a portion
of a pipeline is necessary to facilitate the application of corrosion control.
Insulating devices may not be installed in any area where a combustible
atmosphere is anticipated.
Pipelines shall be electrically isolated from metallic casings. Where
isolation is impractical, the existing cathodic protection current shall be
adjusted, as necessary, to ensure cathodic protection of the carrier pipe
despite the shorted casing.
Underground piping shall be electrically isolated by means of insulated
flanges, physical separation of at least 12 inches from other piping or by
dielectric shielding. The proper installation of insulating flanges is shown
in Praxair Engineering Standards EN-39 and EN-49.
Pipeline segments near electrical transmission line tower footings shall be
protected against fault currents.
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Lightning arrestors shall be installed to provide alternate electrical paths

around insulating flanges, where necessary, to protect against possible
lightning strikes or to protect against possible AC power surges.
31.3
Coating Specifications
Protocol: .461, .479
Coatings shall meet the following criteria:

Be applied on a properly prepared surface
Have sufficient adhesion to the metal surface to effectively resist
underfilm migration of moisture
Be sufficiently ductile to resist cracking
Have sufficient strength to resist damage from handling and soil stress
Have properties compatible with any supplemental cathodic protection
Coatings that are inherently electrically insulating must also have low
moisture absorption and high electrical resistance.
Coatings shall be inspected just before lowering the pipe into the ditch
and backfilling, and any coating damage that could affect the corrosion
control capability of the coating shall be repaired.
Coatings shall be protected from any trench conditions (rocks, debris,
etc.) or damage from supporting blocks that could cause damage to the
coating.
Installation techniques such as boring, driving, pulling, etc., shall be
performed in a manner that minimizes coating damage.
Protocol: .479(a)
All aboveground pipelines shall be cleaned and either coated or jacketed

with a material suitable for the prevention of atmospheric corrosion,
including soil-to-air interfaces.
Information about external coating types and capabilities for buried
pipelines are explained in detail in the Gas Transmission Design Manual
GTE-13 Coatings for Underground Pipelines. Information about
coatings for aboveground piping may be found in Praxair Standard
EN-34, Painting of Industrial Gas Plants.
Page 46 of 56
OM-2287
31.4
Protocol: .463
Cathodic Protection Criteria

Corrosion control can be achieved at various levels of cathodic
polarization, depending on the environmental conditions. However, in the
absence of specific data that demonstrates achievement of adequate
cathodic protection, one or more of the following shall apply:
-850 MV with cathodic protection current applied
Negative polarized potential of 850 MV
100 MV shift of cathodic polarization
On rectified systems, IR drop will be measured by cycling the rectifier or
by use of coupons. For magnesium anode systems or rectified systems,
IR drop may be measured by using dual-coupon test stations. One
coupon is connected to the pipeline and used to measure the level of
cathodic protection current applied. The second coupon is left
unconnected to the pipeline to measure the native soil potential.
Momentary interruption of the protected coupon will indicate the level of
polarization, either by having a reading higher than -850 MV or by having
a greater than 100 MV shift to the native potential measured at the
unconnected coupon.
31.4.1
-850 MV with Cathodic Protection Current Applied

This refers to a negative cathodic potential of at least 850 MV (relative to
a saturated copper-copper sulfate reference electrode) with the cathodic
protection applied and consideration given to electrolytic voltage drop
errors.
This potential is measured with the reference electrode contacting the
electrolyte. Voltage drops, other than those across the structure to
electrolyte boundary, must be considered for valid interpretation of this
voltage measurement.
Consideration of electrolytic voltage drop errors is understood to mean
the application of sound engineering practice in determining the
significance of voltage drops by methods such as:
Measuring or calculating the voltage drops
Reviewing the historical performance of the cathodic protection
system
Evaluating the physical and electrical characteristics of the pipe and
its environment
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When appropriate, other standard reference electrodes may be

substituted for the saturated copper/copper sulfate reference electrode
with proper voltage conversion to copper/copper sulfate reference
equivalent.
31.4.2
Negative Polarized Potential of 850 MV

This refers to a negative polarized potential of at least -850 MV relative to
a saturated copper-copper sulfate reference electrode.
This potential is to be measured with the cathodic protection current
interrupted. Care must be taken to record this Instant Off potential before
significant depolarization occurs. It is very important that all current
sources affecting the survey area be interrupted for this measurement.
When appropriate, other standard reference electrodes may be
substituted for the saturated copper/copper sulfate reference electrode
with proper voltage conversion to copper/copper sulfate reference
equivalent.
31.4.3
100 MV Shift of Cathodic Polarization

This refers to a minimum of 100 MV of cathodic polarization between the
structure surface and a stable reference electrode contacting the
electrolyte.
This criterion requires two voltage measurements. One measurement is
the polarized potential described above. The other measurement is the
depolarized potentials taken after the cathodic protection current sources
have been de-energized (or disconnected) and the structure allowed
sufficient time to depolarize.
The difference between both measurements is the cathodic polarization.
This difference must be at least 100 MV.
The formation or decay of polarization can be measured to satisfy this
criterion, that is, the voltage measurements may be performed in either
order.
31.5
Cathodic Protection System Annual Inspection
Protocol: .465(a), .469
Page 48 of 56
Each cathodic protection system shall be tested at least once each

calendar year, not to exceed 15 months. The inspection shall include
measurement of pipe to soil potentials and tests for shorted casings. Test
leads shall also be inspected as part of the survey to ensure proper
functioning and to ensure that there are a sufficient number of test leads
to determine the adequacy of the Cathodic Protection System being
inspected.
OM-2287
Test meters and half-cells shall be calibrated, as required, to ensure that

tests and measurements are accurate and repeatable. These calibration
results shall be recorded as part of the report for which they were
performed.
When the survey indicates a shorted casing, the report will also indicate
whether the short is metallic or non-metallic. If a metallic short is
indicated, it shall be repaired. If a non-metallic short is identified, the
casing shall be inspected with leak-detection equipment at least twice
each calendar year, not to exceed 7 months.
Cathodic Protection Survey results shall be reported on a Cathodic
Protection Survey Report that includes readings taken at each test
station, repairs, or other remediation required, and any other notable
conditions observed.
31.6
Rectifier Inspections
Protocol: .465(b)
31.7
Rectifier stations shall be inspected six times each calendar year (not to
exceed 2 months) as part of the normal pipeline patrol to ensure that
they are operating properly and have not been damaged. Inspection
results shall be reported on the appropriate Exhibit C Report Form.
Stray Currents and Interference Bonds
Protocol: .465(c)
Critical interference bonds shall be inspected at least six times per

calendar year, not to exceed 2 months. All other bonds shall be
monitored, as required, to ensure proper operation of the bond. Bond
inspections are typically performed in conjunction with rectifier
inspections.
Protocol: .473
In addition to the regularly scheduled inspections, which include tests to

check for potential stray currents, Praxair corrosion specialists shall
participate in corrosion control committees, where they exist, to resolve
potential interference problems with operators of other pipelines or other
underground structures
31.8
Cathodic Protection System Repair
Protocol: .465(d), .471
such repairs shall be made promptly, and repair requirements and results
shall be documented and managed with a D7i Work Order. Repairs may
include the following, as appropriate for the problems found:
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The application or repair of a protective coating

The installation of anodes
The application of impressed current (via rectifier)
Electrical isolation from adjacent pipelines or structures
The control of stray currents from other systems
31.9
Cathodic Protection Records
Protocol: .491
Page 50 of 56
Each pipeline location shall maintain Cathodic Protection maps to show

cathodically protected piping, cathodic protected facilities, and
neighboring structures bonded to the Cathodic Protection System.
Records of each test, survey, and inspection required by this section shall
also be maintained in the files of the local pipeline office. The records
shall identify the pipeline system, site location, date of test, and results,
findings, or remarks. All records shall be kept for as long as the pipeline
is in service.
OM-2287
32
CORROSION INSPECTIONS AND

RESPONSE
32.1
Aboveground Piping Inspections
Protocol: .481
Each aboveground pipeline and soil/air interface shall be visually

inspected for corrosion at least once every 3 calendar years, not to
exceed 39 months. The inspection shall cover the following items:
Painting/coating condition on external pipe surfaces
Soil-to-air interfaces
Thermal insulation
Under disbonded coating
Pipe supports
Splash zones
Deck penetrations
Spans over water
Soil/air interfaces shall be given special attention for corrosion prevention.
Inspections reports shall be maintained in the files of the local pipeline
office.
32.2
Protocol: .459
External Inspection of Exposed Pipe

Whenever a portion of an underground pipeline is exposed, the exposed
portion shall be examined for evidence of external corrosion and
deteriorating coating. Inspection results shall be reported using the
Exposed Pipe Inspection Report. Exposed pipe shall be photographed,
as required, to document all corrosion or defects found.
If evidence of external corrosion is found, the area must be cleaned, and
the actual wall thickness shall be determined using an ultrasonic
thickness gauge. The RSTRENG or B31G calculation method shall be
applied to determine the strength of the remaining wall.
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32.3
Inspection of Exposed Internal Pipe Surfaces
Protocol: .475, .477
Praxair hydrogen pipelines transport very high-purity dry hydrogen gas,

which does not contain significant amounts of corrosive compounds.
Internal corrosion is not anticipated, nor has evidence of internal
corrosion ever been found. As a result, Praxair pipelines do not require
coupons for monitoring internal corrosion.
Protocol: .475(b)
If during the process of pipeline maintenance or capital project work the

internal surfaces of a pipeline segment are exposed or a pipeline
segment is removed, the internal walls of the section of pipeline that was
removed and the ends of the pipeline still in the ground shall be inspected
for internal corrosion. Inspection results shall be reported on the Exposed
Pipe Inspection Report.
Protocol: .475(b)
If there is any evidence of internal corrosion, the pipeline sections still in

the ground shall be inspected as necessary to determine the extent of the
corrosion. The RSTRENG or B31G calculation method must be applied
to determine the strength of the remaining wall.
32.4
Investigation of Causes of Corrosion

Whenever any form of corrosion of a pipeline segment is discovered, an
RCA must be performed to determine the causes of the corrosion and to
identify corrective measures to prevent further corrosion from the
identified causes (refer to Chapter 11, Failure Investigation).
32.5
Prompt Repair of Corroded Pipe
Protocol: .475(b), .485
When a corrosion inspection reveals the need for repairs or other

remedial action, such repairs shall be made promptly. If RSTRENG or
B31G calculations reveal that the strength of the remaining pipe wall is
insufficient for the current MAOP of the segment and the segment will not
or cannot be repaired promptly, the MAOP of the segment shall be
reduced to a pressure suitable for the strength of the remaining wall.
Protocol: .483
Repairs to corroded underground and aboveground pipe shall be made

by cutting out and replacing the corroded pipe segment with pipe that
meets the requirements for new pipe installed in the same location, or the
pipe shall be repaired by installation of an engineered repair system that
can permanently restore the serviceability of the pipe. Repaired or
replacement pipe shall also be appropriately coated and cathodically
protected. Refer to section 22, Field Repair Procedures, for more
information about repairs.
Page 52 of 56
OM-2287

Protocol: .481(c)
Aboveground or buried pipe that is not severely corroded enough to

require replacement or repair shall be cleaned and recoated with a
coating material suitable for the installation location and conditions.
Repair requirements and results shall be documented and managed with
a D7i Work Order.
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33
UNDERWATER PIPELINE INSPECTIONS
Periodically, underwater pipeline surveys are conducted to ensure that

pipelines in navigable waters have adequate cover and do not leak.
Protocol: .612(c)
If it is discovered that a pipeline is exposed or constitutes a hazard to

navigation, the National Response Center (NRC) will be notified within 24
hours. Reporting to the NRC is explained in the local Emergency Plan.
Also, within 7 days, the exposed segments of the pipeline shall be
marked in accordance with 33 CFR 64 (mark the ends of the exposed
segments and at intervals not more than 500 yards along the exposed
segments). Corrective action to rebury the exposed segments or to apply
an engineered solution to provide the same level of protection as burial
shall be completed within 6 months.
An accredited underwater pipeline contractor shall be hired to perform the
survey and submit a findings report that will be kept in the files of the local
pipeline office.
Operation of the cathodic protection equipment, which is installed to
protect the integrity of the underwater pipeline, will be tested.
The contractor performing the inspection shall provide a report of findings,
including depth of cover.
Page 54 of 56
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34
LEAK INSPECTION AND RESPONSE
34.1
Leak Classification and Action Criteria

Pipeline leaks are classified into three grades, as shown in Table 3.
Table 3
Leak Classification
Grade
Definition
Grade 1
A leak that represents an existing hazard to persons or property and requires

immediate repair or continuous action until conditions are no longer hazardous.
Grade 2
A leak that is recognized as being non-hazardous at the time of detection but

justifies scheduled repair based on probable future hazards.
Grade 3
A leak that is non-hazardous at the time of detection and can reasonably be

expected to remain non-hazardous.
If a leak or failure is classified as a Grade 1 leak, the local pipeline

personnel shall immediately initiate the emergency plan specified in the
Emergency Plan. A Leakage Detection Report shall be completed as
soon as practical.
In certain circumstances, a leak may also be classified as an
incident, as defined in 49 CFR 191. Incidents must be
reported as soon as practicable. Reporting requirements are
explained in the local Emergency Plan.
If the leak is not considered to be an emergency, it should be classified as
a Grade 2 or 3. A Leak Detection Report shall be completed, and a work
order shall be entered into the D7i Maintenance Management System for
a scheduled repair. The priority of the work request and scheduled repair
shall be based on the severity of the leak and probable future hazard, as
described under the definition of a Grade 2 leak. Leaks that are classified
as a Grade 2 or 3 will be monitored until the leak has been repaired.
34.1.1
Leak Investigation
All leaks shall be investigated to determine cause. The leak investigation
shall follow the Praxair RCA process to identify probable causes and
contributory conditions. The RCA shall also provide recommendations to
prevent reoccurrence.
If any section of leaking or corroded pipe has been replaced to repair the
leak, the pipe section that was removed shall be analyzed by the Praxair
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Metallurgical Lab or by a suitably qualified outside lab to identify

conditions that may have caused or contributed to the leak.
34.1.2
Leak Reporting
All pipeline leaks will be reported to Pipeline and Metering Engineering.
The Leak Detection Report, which includes the preliminary findings of the
failure investigation, shall be included.
A copy of the Leak Detection Report, including details of the incident and
the final failure investigation, will be kept in the files of the local pipeline
office. A copy of the report shall also be submitted to the Pipeline
Regulatory Compliance Manager, who will submit reports as required to
federal and state government agencies.
Page 56 of 56
OM-2287
INDEX
100 MV Shift of Cathodic Polarization 48
-850 MV with Cathodic Protection Current
Applied 47
A
Abandonment of a Pipeline 34
Abnormal Operating Conditions 8
AOC Follow-up 9
Generic AOCs 8
Notifying Personnel of an AOC 9
Task-specific AOCs 8
Aboveground Piping Inspections 51
Aboveground Piping Leak Detection 27
Annual Report 3
AOC Follow-up 9
Availability of Pipeline Records 6
C
Casing Vent Stacks 26
Cathodic Protection Criteria 47
100 MV Shift of Cathodic Polarization 48
-850 MV with Cathodic Protection Current
Applied 47
Negative Polarized Potential of -850 MV 48
Cathodic Protection Records 50
48
Installation 45
Cathodic Protection System Repair 49
Cathodic Protection Systems 45
Cathodic Protection Criteria 47
Cathodic Protection Records 50
48
Installation 45
Cathodic Protection System Repair 49
Coating Specifications 46
Electrical Isolation 45
Rectifier Inspections 49
Stray Current and Interference Bonds 49
Check Valves 39
Class 1 Location 10
Class 2 Location 10
Class 3 Location 10
Class 4 Location 10
Class Location Studies 10
OM-2287
Class Locations 10
Class Location Studies 10
Definitions 10
MAOP Change Due to Class Locator Change
11
Class Locations Units 10
Coating Specifications 46
Compressor Building Requirements 36
Compressor Maintenance Procedures 35
Compressor Operating Procedures 35
Compressor Station Procedures 35
Compressor Building Requirements 36
Compressor Maintenance Procedures 35
Compressor Operating Procedures 35
Conditions That Must Be Reported 2
Construction Activity along ROW 26
Continuing Surveillance 13
Corrosion Inspections and Response 51
Aboveground Piping Inspections 51
External Inspection of Exposed Pipe 51
Inspection of Exposed Internal Pipe Surfaces
52
Investigation of Causes of Corrosion 52
Prompt Repair of Corroded Pipe 52
Customer Notifications 5
D
Damage Prevention Program 14
Deactivated Pipelines 33
Definitions 10
Class 1 Location 10
Class 2 Location 10
Class 3 Location 10
Class 4 Location 10
Class Locations Units 10
Detection Report Form 28
Discontinuance of Service 33
DOT Reporting Addresses 3
E
Electrical Isolation 45
Emergency Manuals 15
External Inspection of Exposed Pipe 51
Failure Investigation 17
Field Repair Procedures 31
Immediate Response to Pipeline Damage 31
Permanent Field Repair of Leaks 32
Permanent Field Repair of Welds 31
Page I-1 of 3
Index
Repair of Imperfections and Damage 31
Testing of Repairs 32
F
Filing a Safety-Related Condition Report 3
G
Generic AOCs 8
I
Immediate Response to Pipeline Damage 31
Incident Reporting 2
Inspection of Exposed Internal Pipe Surfaces 52
Inspection of Welds 42
Investigation of Causes of Corrosion 52
L
Leak Classification and Action Criteria 55
Leak Investigation 55
Leak Reporting 56
Leak Inspection and Response 55
Leak Classification and Action Criteria 55
Leak Investigation 55
Leak Reporting 56
Leak Surveys 26
Aboveground Piping Leak Detection 27
Detection Report Form 28
Leaks Detected in non-Praxair Pipelines 28
Scheduled Leak Surveys 26
Unscheduled Leak Surveys 27
Visual Inspection for Underground Piping
Leaks 27
Leaks Detected in non-Praxair Pipelines 28
M
Mainline Isolation Valves 39
Maintenance Procedures 24
MAOP Change Due to Class Locator Change 11
Maximum Allowable Operating Pressures 18
Meter/Regulator Station Inspections 37
N
Negative Polarized Potential of -850 MV 48
Nondestructive Testing Procedures 43
Normal Operations 6
Availability of Pipeline Records 6
Operations and Maintenance Manual
Review 6
Pipeline Startup and Shutdown 6
Pipe-type and Bottle-type Holders 7
Procedure Review and Update 7
Page I-2 of 3
Report of a Gas Odor Inside a Building 7

Safety Precautions for Excavated Trenches 7
Notices iii
Notifying Personnel of an AOC 9
o
Odorization of Gas 21
Operations and Maintenance Manual Review 6
Other Reports 3
Other Welding Requirements 42
P
Permanent Field Repair of Leaks 32
Permanent Field Repair of Welds 31
Pipeline Abandonment/Deactivation 33
Abandonment of a Pipeline 34
Deactivated Pipelines 33
Discontinuance of Service 33
Pipeline Blowdown, Purging, or RePressurization 23
Pipeline Cover 25
Pipeline Markers 29
Pipeline Startup and Shutdown 6
Pipe-type and Bottle-type Holders 7
Plastic Pipe 44
Praxair Maintenance Welding Standards 41
Pressure Limiting and Regulator Station
Procedures 37
Meter/Regulator Station Inspections 37
Pressure Limiting Valve Inspections 37
Security and Safety Requirements 38
Pressure Limiting Valve Inspections 37
Pressure Testing 19
Prevention of Accidental Ignition 40
Procedure Review and Update 7
Prompt Repair of Corroded Pipe 52
Public Education 16
R
Recordkeeping 30
Rectifier Inspections 49
Repair of Imperfections and Damage 31
Repair of Weld Defects 42
Report of a Gas Odor Inside a Building 7
Reporting Requirements 2
Annual Report 3
DOT Reporting Addresses 3
Incident Reporting 2
Other Reports 3
Safety-Related Conditions Reporting 2
Right-of-Way Patrols 25
Casing Vent Stacks 26
OM-2287

Construction Activity along ROW 26
Pipeline Cover 25
ROW Patrol Schedule 25
Right-of-Way Patrols and Leak Surveys 25
Leak Surveys 26
Right-of-Way Patrols 25
ROW Patrol Schedule 25
S
Safety Precautions for Excavated Trenches 7
Safety-Related Conditions Reporting 2
Conditions That Must Be Reported 2
Filing a Safety-Related Condition Report 3
Scheduled Leak Surveys 26
Scope and Purpose 1
Security and Safety Requirements 38
Stray Current and Interference Bonds 49
T
Tapping Pipelines Under Pressure 22
Task-specific AOCs 8
Testing of Repairs 32
U
Underwater Pipeline Inspections 54
Unscheduled Leak Surveys 27
Uprating Pipeline MAOP 20
V
Valve Inspections 39
Check Valves 39
Mainline Isolation Valves 39
Vaults 39
Vaults 39
Visual Inspection for Underground Piping Leaks
27
W
Weld Preparation and Alignment 42
Weld Procedures 41
Welder Qualifications 41
Welding and Weld Defect Removal 41
Inspection of Welds 42
Other Welding Requirements 42
Praxair Maintenance Welding Standards 41
Repair of Weld Defects 42
Weld Preparation and Alignment 42
Weld Procedures 41
Welder Qualifications 41
OM-2287
Page I-3 of 3

Appendix E OM-2287

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Appendix E OM-2287

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APPENDIX E

Praxairs Pipeline Operating and

Operating and Maintenance Manual

Operating and Maintenance Manual

Issued: November 1995

Copyright 1998, 2007 Praxair Technology, Inc.

Regulated Hydrogen Gas Pipelines

Page iii of xxii

Regulated Hydrogen Gas Pipelines

CHAPTER 3 CUSTOMER NOTIFICATIONS ........................................................................ 5

Operations and Maintenance Manual Review ............................................................ 6

CHAPTER 5 ABNORMAL OPERATING CONDITIONS ...................................................... 8

Task-specific AOCs ................................................................................................... 8

CHAPTER 6 CLASS LOCATIONS ..................................................................................... 10

Class Location Studies ............................................................................................ 10

CHAPTER 7 CONTINUING SURVEILLANCE .................................................................... 13

Regulated Hydrogen Gas Pipelines

CHAPTER 20 PIPELINE MARKERS ................................................................................. 29

Immediate Response to Pipeline Damage ............................................................... 31

CHAPTER 23 PIPELINE ABANDONMENT/DEACTIVATION ........................................... 33

Discontinuance of Service ....................................................................................... 33

CHAPTER 24 COMPRESSOR STATION PROCEDURES ................................................ 35

Compressor Operating Procedures ......................................................................... 35

CHAPTER 25 PRESSURE LIMITING AND REGULATOR STATION PROCEDURES ..... 37

Pressure Limiting Valve Inspections ........................................................................ 37

CHAPTER 26 VALVE INSPECTIONS ................................................................................ 39

Mainline Isolation Valves ......................................................................................... 39

CHAPTER 27 PREVENTION OF ACCIDENTAL IGNITION ............................................... 40

Praxair Maintenance Welding Standards ................................................................. 41

Page vii of xxii

Weld Preparation and Alignment ............................................................................. 42

CHAPTER 29 NONDESTRUCTIVE TESTING PROCEDURES......................................... 43

Cathodic Protection System Design and Installation ................................................ 45

CHAPTER 32 CORROSION INSPECTIONS AND RESPONSE ........................................ 51

Aboveground Piping Inspections.............................................................................. 51

CHAPTER 33 UNDERWATER PIPELINE INSPECTIONS ................................................. 54

Leak Classification and Action Criteria ..................................................................... 55

Page viii of xxii

Regulated Hydrogen Gas Pipelines

Right-of-Way Patrol Schedule .................................................................................. 25

Regulated Hydrogen Gas Pipelines]

Protocol Cross-Reference to Operating Manual

Unit ID No.: Contra-Costa Pipeline

Activity Record ID No.:

49 CFR PART 191

Procedures for gathering data for incident reporting:

Telephonically reporting incidents to NRC (800) 424-8802.

30-day follow-up written report (Form 7100-2).

Supplemental report (to 30-day follow-up).

Reporting safety-related condition (SRCR).

O&M Section 2.0

49 CFR PART 192

CUSTOMER NOTIFICATION PROCEDURES

O&M Plan review and update procedure (1 per year/15 months).

O&M Section 3.0

Protocol Cross-Reference to Operating Manual

49 CFR PART 191

ABNORMAL OPERATING PROCEDURES

Unintended closure of valves or shut downs.

O&M Section 5.0

The operation of any safety device.

5.0, 5.1, 5.2

Class location study.

Confirmation or revision of MAOP.