Compliance Verification Activity Report: CV2223-103 - Trans Mountain Pipeline ULC

Overview

Compliance verification activity type: Field Inspection

Team:

• Inspector 2769
• Inspector 2279

Regulated company: Trans Mountain Pipeline ULC

Operating company: Kinder Morgan Canada Inc

Province(s) / Territory(s):

• British Columbia

Discipline(s):

• Integrity Management

Rationale and scope:

TMEP Inspection of Spread 5A, including the Coldwater River DPI

Compliance tool(s) used:

• None

Facility details

Facilities:

• TRANS MOUNTAIN EXPANSION PROJECT

Facility Types

• Pipeline
• Pipeline
• Pipeline right of way (ROW)

Life-cycle Phases

• Construction

Regulatory requirements

Regulatory requirements that apply to this activity:

• Canadian Energy Regulator Act (CERA)
• Canadian Energy Regulator Act (CERA)
• Onshore Pipeline Regulations (OPR) 2020-03-16
• Standards
• CSA Z662-19 - Oil and Gas Pipeline Systems

Additional Project-specific requirements or conditions:

Observations (no outstanding follow-up required)

Observation 1 - INSPECTION DRAFT REPORT

Date & time of visit: 2023-03-31 13:35

Discipline: Integrity Management

Categories:

• Pipeline
• Bends and Elbows
• Lower-In
• Backfilling
• HDD/Drilling
• Welding Operations
• Procedures

Facility:

• TRANS MOUNTAIN EXPANSION PROJECT (Pipeline)

Observations:

Review of documentation/records:

Welding:
Overall, the repair rate is to date 2.79%. TMEP mentioned that the most repairs occur on the HSC Girth Weld and heavier walls (+19 mm). TMEP provided some welding repair statistics (see picture “Welding activities Dashboard”).

WPS and WPDS:
TMEP provided the CER with actual welding activities WPS and WPDS for mainline welding and repairs.
CER IOs reviewed the following documents:

• TMEP-SA-WPS-02-14.7-HSC-RP-Rev 0 with the PQR TMEP-HSC-36-14.7-2-3 Revision 1 and TEMP-SA-WPDS-01-14.7-HSC-Rev 5 used for weld repairs.

• TMEP-SA-WPS-02-14.7-HSC Rev.5 and TMEP-WPDS-02-14.7-HSC Rev.5 used for the mainline welding in HSC areas.

• CER IOs also checked the Daily Weld Repair Inspection reports for an example of a repair executed, following the detection by UT/TOFD of an unacceptable flaw in the Girth Weld (Incomplete Fusion). TMEP provided the report TMEP-5A-T-697 for the first control of the Girth Weld (GW) and the report TMEP-5A-T-REP-036 indicating that after repair of the GW number TMEP-5A-T-1460, the repair (TMEP-5A-T-1460R) was accepted.

• TMEP provided its Lowering-In plan and CER IOs review the document and did not identify any issues.

• CER IOs reviewed the document and found that the grade material identified in STEP 2 & 3 of the plan was not used in the field (see picture “Backfilling grade material”). Instead, TEMP used the STEP 4 grade layer, which in fact is not a concern with respect to the location of the pipeline. For locations other than road crossing, the 95% proctor is not applicable. Therefore, the grade in STEP 4 is valid for STEP 2 & 3 according to TMEP.

• HDD daily reports,
• Rig certificates (as per page 15 of 36 of the document)
• Bore stability,
• Potential deviation from the plan,
• Buoyancy control plan,

• TMEP bending inspector mentioned that so far 36 bends were executed on spread 5A. He showed how bending is tracked in a dedicated database (see picture “Bending track sheet #1”). Overall, each bend has a unique identifier (a number TMEP-S5A-BEND-xxxx and a barcode) and all its characteristics are recorded in the database (NPS, Wall thickness, degree, bend type, min/max OD, ovality, number of pulls). Bend acceptance is also indicated.
• TMEP inspector also mentioned that the Bend acceptance is based on the criteria indicated in the Trans Mountain General Construction Procedure (TMEP-MP3120 – Section 9).
• CER IOs also checked the pipe marking (see picture “Pipe Marking.jpg’).

• CER IOs witnessed welding activities. Two welders and a welding inspector were on site.
• CER IOs requested the WPDS used for the welding (see pictures “WPDS #1” and “WPDS #2”). The welding inspector mentioned that WPDS #1 was the most used as the second is used for pipe joints of 11.8 mm wall thickness.
• The welding inspector mentioned that:
  • Pre-heat temperatures (Min 121 C for the first 3 manual passes – Root-Hot-First fill and 50 C for the rest of the passes) are obtained using a torch and controlled using temp sticks,
  • Interpass temperatures are also controlled with a temp stick,
  • The inspector also mentioned that the girth weld NDE is executed with no specific delay at this site,
• CER IOs verified the site welders’ certification list (see picture “Welders certification track sheet.jpg”) and the welders’ qualification records, which were digitalized (see picture “Welders Qualification records.jpg”.

• TMEP mentioned that 132 km out of 169 km of backfilling were completed so far,
• Observed TM contractor screening soil using Volcano brand screener and preparing sub-soil for back feeling. Screening loose soil free of rock, boulders, and other big/hard materials. The loose soil is placed in the bottom of the trench to cover the pipe. The site supervisor indicated that any rock falls during the lowering operation will be handpicked safely to avoid coating damage. 
• Observed the other soil used to fill the trench on top of the loose soil. 
• Precautions were taken to prevent damage to the leak detection (Hi-Fi) conduit and a pressure monitoring device was set to monitor any damage to the conduit.
• Observed muddy surface conditions and challenging terrain for the loader and vehicle movement. 
• The Hi-Fi is monitored for damage using a pressure gauge, in case of a leak, the pressure will fall (see picture “HiFi pressure monitoring.jpg”)

• The 48” bore drilling operation was completed for 263 m out of 853 m
• The maximum depth is 32 m,
• Pilot hole: 12.25", Reamer: 24", 36" and 48", Product line 36".
• Visited Cold Water river HDD site. After a safety briefing and safety orientation site supervisor gave the CER an operational overview. During our site visit, the rig was engaged in the reaming operation. After drilling the pilot hole, the hole was already reamed using 24" and 36" reamers. At present, the rig is reaming the hole with a 48" reamer. Apparently, there are no wellbore stability or fluid loss issues (see picture “HDD Site drilling.jpg”.
• Visited the drilling console. Driller was engaged in reaming operation at that time and gave us an operational overview regarding torque, drag, fluid monitoring, volume totalization, and penetration rate. The hole remained smooth and there was no overloading with cutting or excessive hydraulic pressure.
• The solid control system was in operation with two shale shakers and a centrifuge. The rig used gel mud for this reaming operation, and the return cuttings appear to be harder and separate smoothly at the surface (see picture “Drilling returns.jpg”).
• Inspect the drill bit and reamer on site. They are using an insert carbide drill bit and reamer due to the harder formation.
• The site spacing was tight but well organized. According to the site supervisor, the HDD site has sufficient drilling fluids products, including gel, polymer and lost circulation material.  
• TMEP said that buoyancy control is done by inserting a 3” pipe into the HDD pipe
• TEMP said, as per its contingency plan, that the water crossing is visually inspected by two workers every 2 hours 50 m upstream and downstream of the location of the HDD crossing,
• IOs verified the HDD equipment site inspection sheets (mobile cranes, pallet lifter, excavator lifting hook) and found no issues.
• IOs also requested TMEP to provide the operating permits of the thermal fluid and steam boilers (see “Operating Permit BPV-798090-2019_Unit BPV-044954.pdf” and “Operating Permit BPV-1479221-2022_Unit BPV-080408.pdf”).

Compliance tool used: No compliance tool used

Observations (company follow-up required)

Identified non-compliances to company plans or procedures are non-compliances either to: