Compliance verification activity type: Field Inspection
Team:
Regulated company: Westcoast Energy Inc., carrying on business as Spectra Energy Transmission
Operating company: Westcoast Energy Inc., carrying on business as Spectra Energy Transmission
Province(s) / Territory(s):
Discipline(s):
Related events:
Rationale and scope:
Construction Inspection of WEI High Pine Pipeline Project, South Loop (XG-W102-024-2016).
Compliance tool(s) used:
Facilities:
Facility Types
Life-cycle Phases
Regulatory requirements that apply to this activity:
Regulatory instrument number(s):
Observation 1 - Day #1 - Construction Office Inspection
Date & time of visit: 2017-09-27 15:30
Discipline: Integrity Management
Categories:
Facility:
Observations:
Following the orientations, the NEB inspectors commenced to review the Project’s welding and Non-Destructive Testing (NDT) procedures and welders qualification records.
Compliance tool used: No compliance tool used
Observation 2 - Day #2 - Construction Office Inspection
Date & time of visit: 2017-09-28 06:00
The NEB inspectors and the Westcoast representatives attended the Westcoast Inspectors’ Daily Meeting, at the Westcoast Project office located in Chetwynd, British Columbia, to discuss the activities completed the day before and to plan the work to be completed during the day.The NEB inspectors then attended the SMJV and Westcoast’s Daily Meeting also attended by the Westcoast Project Managers, again, to discuss the details of ongoing works and any associated safety and environmental concerns and items that need special assessments and investigations (i.e. hazards related to equipment, vehicles, weather conditions and work processes). The subjects included defects identified in a number of pipeline Fusion Bond Epoxy (FBE) coating that had cracked during cold bending process. Westcoast’s representatives confirmed that the cracking involved heavy pipe joints with abrasion resistant dual layer powder epoxy. They stated that an investigation was completed to determine the route cause, properly repair the defects and implement adequate measures to prevent re-ocurrence. The discussion also addressed the long term storage of High Performance Powder Coating (HPPC) applied on the Project’s NPS 42 pipes. It was determined, in consultation with Shawcor (the HPPC supplier), that the coating is suitable for outdoor storage for a period of 2-3 years. Therefore, outdoor storage is not considered an issue for the Project and for excess/unused pipes that would potentially remain after the Project. After the meetings, the NEB inspectors continued the review of the Project related welding, coating and Non-Destructive Testing (NDT) procedures on file, and met with the following Westcoast personnel:
Observation 3 - Day #2 - Field Inspection
Date & time of visit: 2017-09-28 12:10
1. Mainline Coating Site GPS Location: 55.84564, -122.13772The Project construction pipe is HPPC coated with a layer of polyethylene tape coating over the FBE coating. River and road crossings are coated with abrasion resistant dual layer powder epoxy. At the time of the inspection, a girth weld mechanical coating process was being completed. A multi-component liquid epoxy coating covered with an additional polyethylene jacket coating was being applied on each completed field weld. Each completed coating was tagged with the technician number, as per procedures, to ensure their traceability. Westcoast coating inspector was on site and he confirmed that the quality control included a mill test on every coating and a destructive peel tests at least once in every 50 coatings. The Westcoast coating inspector confirmed that holiday testing is performed on the pipeline segment three times. The first jeeping of all coatings (i.e. plant and field applied coatings), except the portions above supportive wooden skids, to find the existence of any holiday from transport and hauling; the second jeeping includes finished welds only; and the third jeeping during the lowering process to specifically verify the portions above supportive skids. The Westcoast representatives confirmed that the coating applicators were approved by both Westcoast and the coating manufacturer.NEB inspectors observed a sand blasted weld, some completed coated welds and some repaired coating.2. Non-destructive TestingGPS Location: 55.8506, -122.13509A crew from TEAM was conducting UT testing. NEB inspectors observed the completion of the testing of one weld and witnessed a field technician’s process for assessing potential defects to determine whether the welds would be tagged for repair or not. They verified the file of the last rejected girth weld (ID: S-HP-SL-ML-0389). The identified defect was a lack of fusion. The NDT technician explained how the rejection decision is made, based on both the requirements of CSA Z662-15 and Engineering Critical Assessment. He also stated that the calibration block are checked at least every hour, after repairs, anytime the crew move to new location, or following every ten welds. Relevant copies of CSA Z662-15 and the Westcoast procedure for mechanized UT testing of pipeline girth welds were on site, available to the testing technician.3. Mechanized Mainline Welding GPS Location: 55.85313, -122.13363Westcoast's welding inspector was present on site and he confirmed that welding parameters were being continually recorded and full circumferential welds were being visually inspected each day. The SMJV welding supervisor specified that welding parameters are taken daily; at least once for each welder and three times for the work completed by a welding crew (gang). Each weld is referenced and traced with the welders’ identification numbers. The welds were preheated and ground between passes as per the procedure requirements. The NEB inspectors noted that insulating sleeves were placed on the welds to slow down the cooling rate.During the discussion, it was determined that a pipe joint had broken earlier in the Project construction. The suspected causes include lack of fusion of the root pass due to low voltage and pipe mis-alignment. It was confirmed that a cut out was performed and sent for further analysis and investigation to determine the root cause. Further follow up is being conducted (Information Request IR1 issued to Westcoast). 4. Cold bending GPS Location: 55.87125, -122.12746 At the time of the inspection a SMJV work crew had completed the bending of the pipeline joint # 88 (15.3 mm wall thickness) to 4 degrees and 4.5 degrees overbend. The bending supervisor confirmed that, as per the Project’s specifications, the maximum bending angle for this HPPC coated joint is 15.3 degrees and 19 degrees for the standard 18 metres pipe joints. 5. Direct Pipe InstallationGPS Location: 55.79218, -122.18655 The Project includes an approximately 400 metres wetland crossing that is being completed using Direct Pipe installation with a maximum of 10.7 metres depth of cover below the thalweg of the Moberly River. At the time of the inspection a work crew of Inovative Pipeline Crossing (the company contracted by SMJV) was on site. A SMJV supervisor was also on site. No active pipe installation work was ongoing. It remained approximately 11 metres of pipe to be installed. 6. Crossover GPS Location: 55.79792, -122.18159 The Project includes a crossover replacement that will interconnect the new NPS 42 pipeline with both the Westcoast’s existing NPS 30 and NPS 36 pipelines in the same right of way at this location. At the time of the inspection, no active work was ongoing. 7. Steep Slope and Bent Pipeline Construction at Kilometre Post (KP) 17GPS Location: 55.75203, -122.20927The Project includes an uphill pipeline installation of approximately 35 degrees slope from KP 17 to KP 18. At the time of the inspection, the slope grading was completed. SMJV crews were drilling rocks for installation of explosives, as this method is used for excavation at many locations along the right of way.
Compliance tool used: Information Request (IR)
Regulatory requirement:
Relevant section(s):
Company action required:
Information Request IR1:Westcoast is required to provide the following information regarding the root pass of a girth weld that cracked during the handling process, before the completion of the hot and fill passes:1. Detailed description of the event, including but not limited to:a) when, how and what happened;b) the location and specifications of the pipeline portion; andc) identification of the girth weld. 2. Summary results and any supporting documents, including but not limited to photos, related to Westcoast’s investigation to determine:a) the root cause of the weld cracking;b) repair method of the cracked weld; andc) the measures implemented by Westcoast to prevent the occurrence of similar issues. 3. Did any weld (from five welds before, to five welds after the cracked welding) fail a non-destructive test (i.e. visual, ultrasound and/or Radiography)?If yes, provide the detail of each failed weld:a) summary of the welding anomalies;b) applicable rejection criteria; andc) recorded welding parameters (if any).
Due date: 2017-11-02
Date closed: 2017-11-03 Note: the date closed is the date that the inspector completed their review of the company corrective actions for adequacy and determined that no further actions are required.
Reason closed: Requirement met
Compliance achieved: Yes
Observation 4 - Day #3 - Construction Office Inspection
Date & time of visit: 2017-09-29 10:30
NEB inspectors followed-up to the NEB Inspection Officer Order RRW-001-2017 dated 13 September 2017, at the Chetwynd office. They requested that Westcoast provides the following additional information: 1) The company’s safe handling/hauling procedures2) Clarify if these procedures are specific (or apply) to large diameter pipe?3) Describe the training the company provide to workers on these procedures?4) Supervision from Westcoast regarding hauling /handling activity over SMJV bending crews.5) Inspector competency: the assessments, procedures or program that are implemented for the Project.Westcoast representatives provided the attached documents:
Identified non-compliances to company plans or procedures are non-compliances either to:
- the condition of an authorization document that requires the implementation of that plan or procedure; or
- the relevant section of the regulations that requires implementation of that plan or procedure including those sections that require implementation of plans or procedures as a part of a Program