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Con Edison Case Study: Recent Plastic Fusion Orders

Con Edison Case Study: Recent Plastic Fusion Orders. Lauren Toczylowski Section Manager, Gas Quality Assurance. Agenda. Con Edison Distribution Overview Plastic Fusion Remediation Plan New NY State requirements Tracking & Traceability approach Ongoing Fusion Inspections

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Con Edison Case Study: Recent Plastic Fusion Orders

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  1. Con Edison Case Study: Recent Plastic Fusion Orders Lauren Toczylowski Section Manager, Gas Quality Assurance

  2. Agenda • Con Edison Distribution Overview • Plastic Fusion Remediation Plan • New NY State requirements • Tracking & Traceability approach • Ongoing Fusion Inspections • Required Enhancements • Tracking & Traceability approach • Other Plastic Joint Enhancements • Ongoing Tracking & Traceability Projects

  3. Con Edison Distribution Overview • Distributes natural gas to 1.1 million customers in Manhattan, the Bronx, Queens, and Westchester County • ~ 4,300 miles of gas mains and ~384,000 services transport about 225 billion cubic feet a year • Most of our customers use gas for cooking and ~221,000 also use gas for residential heating

  4. Con Edison Distribution Overview

  5. Organizational Structure

  6. Fusion Compliance Requirements History • September 29, 2014: Con Edison, and other NY LDCs required to submit a remediation plan • October 31, 2014: Con Edison, and other NY LDCs, submitted plans to be completed within one year • November 17, 2014: Con Edison’s original plan deployed, to be complete by November 1, 2015 • December 2014 – May 2015: Discussion with DPS Staff re: plan • May 15, 2015: PSC Orders Con Edison to submit revised plan. Also orders NY LCDs to: • Peer check 100% of all new fuses being installed • Visually inspect all fuses exposed during the course of normal business • August 2015: Excavations under new plan begin

  7. Plastic Fusion Remediation Plan

  8. Overview of Plastic Fusion Sampling Plan • Population: ~805,000 fuses installed in 2002-2014 • Conduct statistical approach to identify samples to be inspected • Fuses/fusers were not previously documented, but segments were mapped • A sub-set of pipe segments were randomly selected • Fuses were then mapped and labeled for each segment selected • Statistician’s analysis includes strata for each type of segment (main or service), geographic areas (Bronx, Queens, Manhattan, Westchester), and each type of fuse (butt fuse, electrofusion and sidewall tee) • 200 fuses will be inspected to determine whether additional sampling is needed to develop a remediation plan

  9. Inspection Form: Visual Inspection & Destructive Test

  10. Field Documentation • Tag sample to indicate: • Location (house address & borough) • Size of pipe • Date removed • Supervisor name • Piping Retrieval Information Form • Filled out for each sample length

  11. Inspection/Testing Photos & Videos

  12. Manual Data Conversion for PSC Reporting

  13. Multiple Documents & Files for One Fuse • Hand written forms • Pipe tags • Visual Inspection Results Data • Destructive Test Results Data • Multiple Photos • Video file • Spreadsheet entries • Letters to PSC

  14. Solution: Integrated Mobile Data Capture • Application deployed on ruggedized smart phones and tablet computers • Real-time data transfer from field to office to field • Centralized repository with robust reporting capability • Cloud computing/ hosted options

  15. In The Field

  16. Automated PSC Reporting

  17. New Fuse Peer Inspection & Exposed Fuses Visual Inspections NY State May 15th Order

  18. Con Ed Preparation for Additional Inspections • Needed to train and qualify additional employees/contractors to perform visual inspections • Developed and deployed additional training • Used a Written Evaluation (equivalent to NGA CT#52) developed by Con Edison • Qualified additional employees and contractors to perform visual inspections of plastic joints

  19. Field Documentation Identifying PE Plastic Joiner and Inspector • Plastic joints are identified on as-constructed drawings • Fuser and Peer Inspector are signing the pipe • Each plastic joint is documented • Data captured: • Job information (M&S plate #, Ticket/Leak #, Location , Layout #) • Plastic Joiner employee/ID # • Peer Inspector employee/ID # • Date Plastic Joint made • Joint Type ( Butt Fusion, Electrofusion, Mechanical Joint)

  20. Peer Check of All New Fuses

  21. Fuse-to-Fuser Application

  22. Fuse-to-Fuser Application

  23. Other Plastic Joining Enhancements

  24. Ongoing Enhancements in Plastic Joining • Annual OQ: block requalification with 3rd party evaluators • Online OQ system: eLearning, online testing and QR codes • Level 1/Level 2 inspections of new fuses • Remediation Options for visually unacceptable fuses • Elimination of the Sidewinder • Enhanced QA/QC Programs • NTSB Recommendations for Specification Improvements • R&D Projects: • Heat Fusion Processes • GPS Devices

  25. Butt Fusion Remediation Sleeve

  26. PE Repair Patch

  27. Additional QC: Fusion Inspections • Created a separate GQC group • Hired a 3rd party inspection contractor • Fusion inspectors in the field, making process observations • Field visits where ongoing fusions are taking place • All GQC inspectors are fusion qualified • Level 1/ Level 2 Fusion Inspections

  28. Analyzing Inspection Results • Large amount of data around fusion inspections and quality • Analyzing and reporting on results • Common issues identified and addressed: • Damaged Butt Fusion Plates (replacement program) • Alignment of Electrofusion (new tools identified) • Scraping of Pipe Surface (1” past fusion area)

  29. Tracking & Traceability R&D • IT Roadmap Project: analyzing GIS and WMS solutions • Trimble R&D Project: • Handheld Trimble and smart device connections • Testing in areas with Urban Canyons and Tree Canopy issues • Comparing usability with other smart device applications

  30. Thank You Any Questions?

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