Professional Documents
Culture Documents
In Support of OII.14-11-008
Prepared for
The Safety and Enforcement Division
California Public Utilities Commission
Prepared by
P Wood Associates (PWA)
David Berger, John Gawronski and Paul Wood
TABLE OF CONTENTS
0. EXECUTIVE SUMMARY ....................................................................................................... 1
0.1 Scope of Investigation ......................................................................................................... 1
0.2 Facts Related to PG&E Recordkeeping ............................................................................... 1
0.3 Major Findings..................................................................................................................... 2
0.4 Categories of Violations ...................................................................................................... 3
1. INTRODUCTION ..................................................................................................................... 5
1.1 Purpose and Scope ............................................................................................................... 5
1.2 Approach.............................................................................................................................. 5
1.3 Background .......................................................................................................................... 6
1.3.1 Incidents identified in the OII ............................................................................... 6
1.3.2 PG&E Response to the OII ................................................................................... 7
1.4 Impact of Records Gaps on Distribution System MAOP .................................................... 8
2. PREVIOUS PG&E AND CPUC INVESTIGATION OF RECORDS...................................... 9
2.1 Previous Consideration of Recordkeeping Issue ................................................................. 9
2.2 Findings of Duller and Norths Related to Recordkeeping at PG&E.................................. 9
2.3 Previous Studies of Records Adequacy at PG&E ............................................................. 11
3. PWA APPROACH TO THE INVESTIGATION ................................................................... 12
4. APPLICABLE REGULATIONS ............................................................................................ 25
4.1 Elements of a Safety Code Violation................................................................................. 25
4.2 Applicable Pipeline Safety Requirements ......................................................................... 25
4.3 Records Necessary to Demonstrate Compliance ............................................................... 25
4.4 General Recordkeeping Requirements .............................................................................. 31
5. FACTORS CONTRIBUTING TO RECORDKEEPING-RELATED INCIDENTS
AND VIOLATIONS ...................................................................................................... 34
6. EVIDENCE OF NON-COMPLIANCE .................................................................................. 36
6.1 Violations Associated with the Six OII Incidents.............................................................. 37
6.2 Additional PG&E Violations Identified during the Investigation ..................................... 40
6.2.1 Violations associated with additional incidents .................................................. 41
6.2.2 Violations associated with the relationship between incidents at
Mountain View and Carmel................................................................................ 47
6.2.3 Violations associated with establishment of maximum allowable
operating pressure (MAOP) ................................................................................ 49
ii
0.
EXECUTIVE SUMMARY
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0.1
Scope of Investigation
The Safety and Enforcement Division (SED) of the California Public Utilities Commission (CPUC)
contracted with P Wood Associates (PWA) to:
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Investigate whether PG&E violated any provision of the CPUC code, Commission
general orders or decisions, applicable rules or requirements, or other state or federal
laws pertaining to safety recordkeeping for its natural gas distribution system.
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Evaluate whether the actions the PG&E has planned and initiated to compensate for
known deficiencies in recordkeeping are reasonable, are taking hold in the field, and are
having the desired impact on safety.
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Provide a report and testimony in support of the PG&E Gas Distribution Records
proceeding I.14-11-008.
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This section summarizes the facts and findings assembled from a series of presentations by PG&E
managers, structured interviews of PG&E staff, PG&E responses to an extensive set of data requests,
and evaluation of select CPUC incident and inspection reports.
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0.2
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19
Regulations describing requirements for records retention have been in place for decades, with the
earliest identified being issued by the California Railroad Commission in 1932.1
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Over the years PG&E has developed policies and procedures intended to assure compliance with
these regulations.2
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Violations related to recordkeeping were not the result of defective procedures, rather resulted from
failure to follow the procedures, including failure to keep the records secure. Early versions of
PG&E standard practice for mapping standards such as SP 410.21 effective April 1977 through
May 1980 appear to have adequate detail3 to capture accurate and sufficient information for maps
to be used by operating personnel. Requirements addressed security4 of original maps to prevent
their loss, and included an instruction to keep authorizations concerning installed mains
permanently for reference.
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Inaccurate and missing records and maps have contributed to incidents, including those described
in the OII.
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PG&E has designed and implemented numerous measures intended to correct acknowledged
imperfections5 in its maps and records and to provide backstops to minimize risks associated with
Standards for Gas Service in the State of California, General Order No. 58-A, effective July 1, 1932. This was
the third edition of this standard; the initial version was effective September 1, 1919.
2
See for example PG&E Mapping Standards, Standard Practice No. 410.21-1, 04/01/77.
See SP 410.21-1 page 9 for main pressure requirements, position of valves, page 11 for gas mains character
and history such as type of joint, size, location, kind of pipe, authorization, year installed, page 15 for insert
mains, pages 16-19 for posting gas service information (house number, size, year installed, additional
measurements when service pipe is not at right angles to the main or property line, stub services, and insert
services.
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these errors and omissions. However, ongoing map correction activities are typically opportunistic
(i.e., carried out in the normal course of maintenance) rather than proactive.
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PG&E has avoided implying that completeness and accuracy issues will be fully resolved through
completion of the Pathfinder Project.
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The DIMP regulation requires utilities subject to its provisions to implement measures to improve
the accuracy of maps and records based on numerous sources of information associated with
normal activities in the field.
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PG&E has implemented a program to, among other functions, address certain aspects of this
requirement the Corrective Action Program (CAP).
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PG&E has not implemented programs beyond CAP that are designed to identify and characterize
recognized imperfections in its maps and records associated with pipe inserts and stubs.
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PG&E has not fully addressed the root cause of damages to its gas lines resulting from the
elimination of retired and abandoned gas lines from maps. Information on the locations of retired
in place gas lines is needed to support locate and mark activities as well as other operating and
maintenance activities to help avoid confusion over live versus retired in place gas lines when
excavations in their proximity take place.
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27
PG&E has established the Maximum Allowable Operating Pressure (MAOP) for 243 of its 1,376
hydraulically independent distribution systems using an approach different from that prescribed in
the 1970 pipeline safety regulation Title 49 of the Code of Federal Regulations (49 CFR)
192.619(c).
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0.3
Major Findings
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Evidence from recent incidents gathered in support of this OII indicates that PG&E has failed to
follow the regulations and its procedures regarding record keeping - including both maps and
records.
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Factors contributing to accidents, incidents and third party damage included: lack of records, maps
not being updated in accordance with mapping procedures, and PG&E not maintaining control and
updating historical records of gas distribution mains and service lines.
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PG&Es approach to establishing the MAOP for 243 hydraulically independent distribution
systems is in violation of the 1970 requirement of 49 CFR 192.619(c) describing the bases on
which MAOP is to be established for so called grandfathered segments of its system. It is
probable that this violation resulted because of the absence of the distribution system pressure
records/charts associated with the five years (1965 through 1970) needed to comply.
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1
2
We have seen no evidence that PG&E reviewed or requested approval of its approach to
establishing MAOP of its distribution systems with the CPUC7.
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PG&Es handling of the incident at Mountain View (07/30/13), a clear precursor of the incident at
Carmel (03/03/14), supports the conclusion that PG&E has failed to comply with these learning
from experience regulations; until an incident is sufficiently high profile that action must be taken.
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12
California Government Code (CGC) 4216.3(a)(1) requires utilities either to locate and mark
(L&M) underground structures near identified excavation sites, or to agree with the excavator on a
delay in excavation until the L&M activity can be completed.
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An interview with
, Sr. Gas Compliance Representative an individual responsible for
locating and marking gas lines prior to excavation, supports the conclusion that PG&E has
substituted a permissive notification policy/practice (i.e., contact of the excavator when the L&M
cannot be completed on time can be as late as the night before the excavation and does not need to
include direct contact with the excavator a voice mail message is acceptable) for the requirement
to mutually agree with the excavator on a delay in the completion of the L&M activity. This
substitution, evidenced in the San Jose incident (11/07/14) described in Table 4 of this report,
violates CGC 4216.3(a)(1).
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Evidence gathered in CPUC inspections during July and August of 2015 shows that some of the
new processes and procedures PG&E has put in place to prevent inaccurate and incomplete
changes to maps and records are not yet working as intended.
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26
PG&E has established an Internal Audit (IA) program, which management is using to investigate
the completeness and effectiveness of the numerous changes in information systems, procedures
and practices it has implemented.
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0.4
Categories of Violations
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34
The CPUC adopted the 1958 edition of ASA B 31.8 code for transmission and distribution piping as
well as additional requirements for design, construction, testing, maintenance and operation in General
Order (GO) 112, effective January 17, 1961. The CPUC stated its intention in GO 112 Section 104.1
that all work performed within the scope of these rules shall meet or exceed the safety standards
expressed or implied herein. GO 112 Section 301.1 states the utility is responsible for maintenance of
necessary records to establish compliance with these rules. CPUC General Order112-E Section 101.2
incorporates 49 CFR Part 192.
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PWA found that PG&E lacked the necessary records to comply with code requirements, primarily as a
result of not maintaining its maps and records up to date. The following identifies the primary areas
of violations PWA identified as a result of its investigation into PG&Es distribution record-keeping
practices. Further details and information concerning these violations are provided in in Section 6 of
this report.
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Failure to follow written procedures to ensure operating maps and data are updated and
accurate. Not maintaining control and updating historical records of gas distribution mains and
In 1999 the Pipeline and Hazardous Materials Safety Administration (PHMSA) issued guidance providing for
regulatory review of alternative approaches to the 1971 code requirement for establishing MAOPs of
distribution systems.
1
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3
service lines. Repeated failure to correct recordkeeping violations despite having adequate
knowledge for decades. 49 CFR 192.603(b), 192.605(a), 192.605(b)(3), 192.13(c) and
Public Utilities (PU) Code Section 451 and Section 961.
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5
6
Failure to mark out and inspect its gas lines in the area of excavation after receiving valid
Underground Service Alert notification in accordance with California Government Code
4216.3(a)(1), 49 CFR 192.614(c)(5) and 49 CFR 192.614(c)(6).
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Failure to carry out data gathering to evaluate the causes and implications of incidents, and to
incorporate the lessons from these investigations into utility policies, procedures and programs
in accordance with 49 CFR 192.605(b)(4), 192.605(b)(8), 192.613, 192.617, 192.1007
and PU Code Section 451 and Section 961.
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1.
INTRODUCTION
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1.1
In November 2014, the California Public Utilities Commission (CPUC) issued an Order Instituting
Investigation8 with the following purpose:
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Investigate whether PG&E has violated any provision of the CPUC code,
Commission general orders or decisions, or other state or federal laws or
applicable rules or requirements pertaining to safety recordkeeping for its natural
gas distribution system;
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Evaluate whether the actions the operator has planned and initiated to compensate
for known deficiencies in recordkeeping are reasonable, are taking hold in the
field, and are having the desired impact on safety;
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1.2
Approach
In preparing this report, PWA consultants carried out the following activities:
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Reviewed the OII, the six Safety and Enforcement Division (SED) incident
evaluation reports referenced in the OII, and PG&Es initial response to the OII;10
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Reviewed the twelve data requests (DRs) prepared by the SED and submitted on
March 4, 2015 to PG&E - prior to the beginning of the PWA engagement;
Order Instituting Investigation and Order to Show Cause on the Commissions Own Motion into the
Operations and Practices of Pacific Gas and Electric Company with Respect to Facilities Records for its Natural
Gas Distribution System Pipelines, OII.14-11-008, November 20, 2014, San Francisco Office.
9
Collectively, the three P Wood Associates (PWA) subject matter experts bring (46+15+23) 84 years of gas
transmission and distribution pipeline experience, including experience as regulators, operators and consultants.
See Attachment A for a description of the background and experience of the PWA subject matter experts:
Berger, Gawronski and Wood.
10
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Over the course of the investigation prepared an additional 102 DRs as well as 25
interrogatories under oath directed to four specific PG&E senior managers and
executives. These DRs and interrogatories are listed in Attachment B;
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6
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9
Visited the locations where the 6 incidents identified in OII 14-11-008 occurred,
and accompanied SED inspectors on a corrosion inspection in one of those
Divisions;
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Reviewed select incident reports, including those for the six OII incidents;
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Screened and reviewed the over nine thousand documents PG&E provided in
response to the 114 DRs;
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Made and reviewed the responses to eight (8) oral requests of PG&E for data
discussed during the presentations and interviews noted above;
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Conducted a search of past CPUC general orders and decisions that relate to
recordkeeping requirements, other state and federal recordkeeping requirements,
as well as reviewed recordkeeping issues identified during the San Bruno
investigation of PG&Es failed gas transmission line.
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27
The information gathering approach described above was designed to support investigation of the
consistency among management intentions and direction, procedures used in the field and for mapping,
and how working-level staff actually carries out the work.
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In an effort to supplement the information gathered as described above with actual results from PG&E
implementation of maintenance and related mapping activities, PWA consultants relied upon
inspections carried out by SED inspectors during July and August of 2015. These inspections included
a review of how consistently leak repairs involving insertion of plastic pipe resulted in correct changes
to the maps in the Gas Distribution Geographic Information System (GD-GIS) the field-accessible
system (using Pathfinder Viewer) in which distribution system maps along with supporting
information is stored.
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1.3
Background
1.3.1 Incidents identified in the OII
In the OII, the CPUC identified six incidents that have occurred during the past 5 years associated with
PG&Es record keeping practices. The six incidents include the following:
1. A release of gas from a 1 plastic gas service line in Castro Valley in September 2010
due to a mapping error that contributed to an erroneous locate and mark of the gas service
line. There were no injuries and minor property damage.
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2
3
2. A release of gas from a steel stub service line in Morgan Hill in June 2012 that was
not marked because it was not included on the current underground utility map. There
were no injuries and minor property damage.
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8
3. The loss of gas service to nearly 1,000 customers in Milpitas in October 2012 resulting in
part from a map showing a back-feed valve in the open position when it was closed. The
job work resulted in gas flow being curtailed during a planned main replacement project
for which an approved clearance existed. There were no injuries but many customers
were without gas service.
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4. The release of gas from a 2 plastic gas main in Milpitas in March 2013 resulting from
the locate and mark being more than 2 away from the pipe. There were no injuries and
only minor property damage.
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5. The release of gas resulting from welding on and tapping of a 1 steel service that had
an unknown 1 plastic insert in Mountain View in July 2013. There were no injuries but
property damage was estimated at $10,000.
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6. The release of gas and an explosion that destroyed a house resulting from tapping of a 2
steel main that had an unknown 1 plastic insert in Carmel in March 2014. There were
no injuries but significant property damage.
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In its 12/22/14 response, page 5 lines 3-4, PG&E states With the minor exceptions noted below,
PG&E does not disagree with the factual contentions and conclusions regarding its gas distribution
recordkeeping stated in the SED Reports. 11 PWA has evaluated these and other mapping-related
incidents, as well as additional information on the processes and procedures PG&E uses to assure the
accuracy of its maps and records, to determine whether violations have occurred and the nature of such
violations.
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PG&E essentially agrees with the factual events in each of the six OII
incidents, but disagrees there were any related violations, or at least stated that
the violations cited by the CPUC in the OII are not valid;
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PG&E has long recognized that it has imperfections in its maps and records,
and has initiated major improvement projects to improve the completeness,
accuracy and accessibility of its maps and records, as well as other changes to
prevent the recurrence of incidents similar to the six noted in OII.
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As evidence of its ongoing efforts, PG&Es initial response to the OII enumerates approximately 24
activities in four categories:
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Consistent with our charge by SED, PWA has evaluated each of these 24 improvement activities in
Section 8.
1.4
Subsequent to issuance of the OII, the SED decided to roll into the investigation consideration of the
fact that records gaps in the late 1960s led PG&E to establish the MAOP for 243 hydraulically
independent distribution systems using an approach different from that prescribed by 49 CFR
192.619(c). The PG&E response to Data Request #87 stated that in 2008, PG&E concluded that the
use of the method described in TD-4125S to establish MAOP does not pose a safety risk to the
distribution system. Therefore, PG&E has not implemented any additional compensatory measures
specifically applicable to the associated pipe. Since no compensatory measures have been used, only
the compliance aspects of the MAOP issue have been evaluated in this report.
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2.
2.1
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10
The subject of generally accepted recordkeeping principles is not a new one for PG&E or the CPUC.
It was addressed in testimony by Duller and North as well as by Margaret Felts in Docket I. 11-02-016.
The findings of Duller and Norths work were based on Generally Accepted Record-keeping Principles
(GARP) Information Maturity Scores.14 The testimony of Duller and North found gas transmission
records and safety related documents were scattered, disorganized, duplicated, and were difficult if not
impossible to access in a prompt and efficient manner.15 Issued in connection with the same
proceeding, the testimony of Margaret Felts16 addressed how PG&Es record keeping practices
affected PG&Es transmission pipeline engineering.
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PWA did not evaluate PG&Es recordkeeping practices in relation to GARP. PWA did however
review and learn from the Duller and Norths findings as they relate to companywide and distribution
recordkeeping practices. PWA has checked the applicability of findings from these reports to PG&Es
distribution record keeping practices. In our evaluation we found that factors contributing to accidents,
incidents and third party damage included: the lack of records, maps not updated in accordance with
mapping procedures, and not maintaining control of and updating historical records of gas distribution
mains and service lines. The PWA report concentrates on the gas distribution engineering and
operations aspects of PG&E. Its findings complement the two transmission-focused reports noted
above, and point out deficiencies in record keeping practice that constitute violations of requirements
in the safety code.
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2.2
While Duller and North focused on transmission pipeline record keeping, many of the policies and
procedures it cited in its review included both transmission and distribution systems. For example, the
following quote includes both transmission and distribution systems:
PG&Es Internal Report17 goes on to state that even today related paper and
electronic records can be difficult to locate from office to office because of the
unique process each office has created to ensure the Mappers have access to the
information they need; the location and organization of physical records varies by
location and is often only known to a few individuals performing the filing; and
additionally, that maps are inconsistent between Gas Transmission and Gas
Distribution, as well as between divisions. The lack of process and controls for field
personnel submitting map corrections is cited, as a further cause for concern as the
map correction process varies by location, while the lack of controls over
contractors, is cited for completeness, consistency, and quality of work issues.
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16
Revised Report and Testimony of Margaret Felts, Docket I.11-02-016, March 16, 2012.
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This report finds that PG&Es pipeline records were widely distributed and poorly
controlled across the Gas Transmission Division.
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This review has used the "Generally Accepted Record-keeping Principles" (GARP)18 and
the Information Maturity Model19 defined by ARMA International20 as the basis of an
assessment and evaluation of PG&Es records management activities.
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On the basis of the GARP criteria we find that records management within PG&Es
Gas Transmission Division prior to the San Bruno pipeline rupture and fire were SubStandard21 (Average Maturity Score = 1.2). PWA note, the highest possible score
was 5.
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As a result of these failures: PG&Es historical pipeline records would not have been
readily available, traceable, verifiable or complete; there was no single source of
trusted pipeline-related documents, records management was not optimized to support
operations, decision making, planning or safety; and inconsistent, incomplete and out
of date information would have been present in a significant number of its pipeline
related job folders, as well as those systems, such as GIS, which relied upon them.22
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Duller and North did note in their testimony that PG&E has begun to address the records issues. These
changes are well underway, and PWA has included a discussion of the changes in Section 8.
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18
www.arma.org/garp/metrics.cfm .
20
ARMA International was previously known as Association of Records Managers and Administrators, and is
the authority on managing records and information in the USA (www.arma.org); Records management themes
include: strategy, responsibilities, training, policies/standards/procedures, records retention, business continuity
& vital records, records management processes, records management storage, and technology.
21
Level 1 (Sub-standard): An environment where record-keeping concerns are either not addressed at all, or are
addressed in a very ad hoc manner. Organizations that identify with these descriptions should be concerned that
their programs will not meet legal or regulatory scrutiny.
22
Duller and North report dated March 5, 2012 page 6-25 lines 5-18.
23
Duller and North report dated March 5, 2012 page 5-24 lines 3-5.
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2.3
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PG&E commissioned Bechtel Corporation to carry out two studies, one in 198425 and a follow-on
study in 199526, designed to evaluate pipe replacement priorities. This work was initially focused on
transmission pipelines, but ultimately included distribution mains.
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P 13 During the data collection process, the area engineers were sometimes
confronted with the problem of missing records that prevented them from finding
variable values.
The follow-up 1995 report included the following observations:
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P ES-1 There has been an ongoing effort to build and improve upon the data base of
information that goes into the prioritization program.
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P 5-1 Transfer of the Distribution Feeder Mains (DFMs under 20% SMYS) from the
distribution subprogram to the transmission database necessitated research of company
records for the data required for evaluation under the transmission methodology.
Results of this research, conducted by PG&E personnel, were mixed at best due to the
absence of the underlying documents or due to recent organizational changes that have
made collection of data problematic. [The amount of pipe affected by incomplete or
missing data is not known at this time.]
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P 5-1 The subject of data verification is one that deserves greater emphasis by PG&E.
Though time consuming, verification of pipe data should be a prerequisite to the
replacement decision to ensure that erroneous or missing data is not defaulting a
pipeline segment into a high replacement priority.
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It seems clear these PG&E commissioned reports demonstrate that the utility has known of problems
related to its data and records for some time. The continuing presence of imperfect maps and records,
such as those discussed in Section 8.1, shows that the remediation efforts are incomplete.
30
24
Duller and North report dated March 5, 2012 page 5-24 lines 15-17.
25
Pipeline Replacement Program - Transmission Line Risk Analysis, Rev 0, Bechtel Corporation, January
1984.
26
Review of Transmission Priority Analysis (1995 Revision) for the Gas Pipeline Replacement and
Rehabilitation Program, Bechtel Corporation, May 1995.
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3.
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The PWA team used four means to carry out the evaluation. In addition to reviewing the
documentation prepared by the CPUC and PG&E in support of and in response to the OII, we learned
from (a) a series of presentations by PG&E managers, (b) a few structured interviews of PG&E staff,
(c) PG&E responses to an extensive set of data requests, and (d) review of numerous incident reports
and results from select SED inspections. This section briefly summarizes each of the first three
sources, then summarizes our review of recent map and records-related CPUC reportable incidents,
and finally discusses our investigation of the issue related to establishment of the maximum allowable
operating pressure (MAOP) for a large number of older distribution systems.
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In response to our initial request to interview a number of its distribution pipeline executives, PG&E
offered two information briefings to help acquaint us with activities they are pursuing to update maps
and records and to help assure future errors do not occur. The first of these briefings was by telephone,
the second was face-to-face in PG&Es San Ramon offices.
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16
To address our request for field interviews with key working-level employees at the four divisions in
which the OII incidents occurred, PG&E offered six employees they selected to be interviewed, in the
presence of PG&E monitors, in their offices in Salinas and San Jose.
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The primary source of documentation used in support of our investigation was the over nine thousand
documents PG&E provided in response to our 114 DRs. In addition, PG&E provided responses to
eight oral requests made during the presentations and interviews, and responded to twenty-five (25)
interrogatories under oath made to PG&E executives.
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Another primary information source in our evaluation of the impact of PG&Es mapping and
recordkeeping practices was reports on incidents prepared by the SED staff. Inspection findings are
discussed further in Section 8.1. The initial documents consisted of the incidents noted in the OII.27
From that start, the team then reviewed the incidents in the February 20, 2015 Notice of Probable
Violation (NOPV) letter28 and PG&Es response to that letter. Additional documentation, consisting of
the SED incident reports, was then reviewed, as were PG&E responses to SED inspections.29 Finally,
we visited several of the sites where incidents30 listed in OII occurred.
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For all of the six (6) incidents listed in the OII either recordkeeping or mapping issues were significant
contributing factors. These six incidents are summarized in Table 1. Two of the six incidents involved
steel mains or services inserted with plastic which was not identified on the maps given to the field
crews. The crews performing the work, such as tie in or service transfer, were not aware that plastic
was inside of the steel and thus did not know that their actions had created an unsafe condition. In one
of the other incidents where stubs31 were not marked, a third party excavator hit one, thus releasing
27
28
See Letter of Ken Bruno dated February 20, 2015 and response of Larry Deniston dated March 24, 2015 pages
A-1 to A-22.
29
PG&E's letter of April 4, 2014, Sumeet Singh (PG&E) to Michel Robertson Safety and Enforcement Division
California Public Utilities Commission states: In its letter, the SED found PG&E in violation of Title 49 of the
Code of Federal Regulations Part 192.605(b). PG&E agrees with this violation.
30
General Order 112-E Section 122 (now GO 112-F) requires operators to report within a specified timeframe
incidents that resulted in loss of life, an injury, an estimated property damage of more than $50,000, attracted
public attention or given significant media attention. Incidents that are considered significant, even if they do
not meet any of these criteria, may also be reported and/or investigated by SED.
31
A stub is defined as a short service that was abandoned on a property or at the property line but not removed
all the way to the supply main. These capped stubs do have gas under the same pressure as the main and are
considered active.
12
1
2
3
4
gas. This stub was not on the map provided to the locating32 personnel. Another incident was the result
of a supply valve being shown on the map as open when it was actually closed; hence when the feed
from the other side of a tee was isolated to perform the tie in safely, almost 1,000 customers lost gas
service.
5
6
7
8
9
The final two incidents of the six listed in the OII involved mapping errors with one being on a plastic
service that was damaged by a third party excavator. This service had been inaccurately mapped and,
therefore, two earlier leak surveys had been carried out incorrectly before the listed incident. Each of
these documented incidents involved PG&E either not keeping accurate records or incorrectly mapping
the actual location of the underground facility.
10
11
12
These are not the only map or records-related incidents that have occurred over the last several years
that have resulted in damage, loss of supply or a release of gas. As discussed below, we have
evaluated a sampling of other map and record-related incidents in this report.
13
14
15
16
17
18
19
20
21
A sort of incidents for the period of 2010 to 2014 to identify those for which a valid locate ticket was
issued (Underground Service Alert - USA) and for which the incident cause was listed as a mark or
map error yielded in excess of 100 incidents. This total excludes any damages that listed no tracer
wire, no USA request was called in, poor excavation practice (such as digging with power equipment
near a known facility), and other causes or unknown causes. For just the first quarter of 2015 - after
PG&E instituted new procedures, implemented part of its database and records improvement program
known as the Pathfinder Program in many divisions and other database and operational improvements
and enhancements - there were still in excess of 25 incidents due to incorrect facility records/maps or
the facility was not properly located.
22
23
24
25
26
27
Table 2 presents a listing of some of the incidents occurring between 2010 and 2014 that the SED
investigated. Poor or inaccurate record keeping and/or miss-locating the PG&E facilities contributed
to each of these events. Some the incidents were not caused by outside excavation contractors but
rather by PG&E crews doing work on their own systems. There were many more incidents reported by
PG&E that may not have resulted in an SED investigation because they did not meet the incident
reporting criteria.33
28
29
30
31
32
33
34
35
36
37
38
Another records-related issue we have investigated is the approximately 243 hydraulically independent
distribution systems for which the maximum allowable operating pressure (MAOP) was not
determined by a recorded pressure test or a pressure certification during the regulation-mandated five
(5) year look back or grandfathered period between 1965 and 1970.34 During this period PG&E
procedures required that pressure records be retained for only two years. This retention time was the
same as that required by General Order 58A (effective 07/01/32) Sections 20(c) and 20(d). For many
of these systems the MAOP was set during a period from 1977 through 1979. By missing the
regulatory prescribed grandfathered period, PG&E failed to determine the MAOP for these systems
using the prescribed method. After the grandfathered period expired, only a valid pressure test per 49
CFR Part 192 Subpart J was allowed as the basis for establishing MAOP except where the operator
had obtained permission from its regulator to deviate along with a concurrence from PHMSA.
39
32
All marking and locating for PG&E gas distribution are performed by company personnel.
33
Per footnote 31, certain incidents require immediate reporting to the CPUC. General Order 112-E Section
122.2(d) requires quarterly reporting of all CPUC reportable and non-reportable gas leak related incidents,
including underground dig-ins.
34
13
System Characteristics
Underlying Cause
Consequences
1 Castro Valley
09/17/10
(Mission
Division)
2 Morgan Hill
06/21/12
(San Jose
Division)
3 Milpitas
10/10/12
(San Jose
Division)
4 Milpitas
03/04/13
(San Jose
Division)
5 Mountain View
07/30/13
(De Anza
Division)
14
Location/Date
6 Carmel 03/03/14
(Central Coast
Division)
System Characteristics
Underlying Cause
Consequences
System Characteristics
Underlying Cause
Consequences
San Jose
(01/20/15)
15
Location/Date
System Characteristics
Underlying Cause
Lafayette
(8/27/13)
Consequences
16
Location/Date
System Characteristics
Underlying Cause
Consequences
San Jose
(11/07/14)
17
Location/Date
System Characteristics
Underlying Cause
Consequences
Kentfield
(4/1/11)
Goodhill Road &
Diablo Drive
18
Location/Date
System Characteristics
Underlying Cause
Consequences
Antioch
(3/15/10)
Colusa
(03/19/09)
19
Location/Date
System Characteristics
Underlying Cause
Consequences
Alameda
(09/28/10)
20
Location/Date
System Characteristics
Underlying Cause
Consequences
Roseville
(10/21/10)
21
Location/Date
System Characteristics
Underlying Cause
Consequences
Sacramento
(10/31/11)
22
Location/Date
System Characteristics
Underlying Cause
Consequences
San Francisco
(04/08/14)
35
35
and
23
Location/Date
System Characteristics
Underlying Cause
Consequences
San Ramon
(8/12/09)
24
4.
APPLICABLE REGULATIONS
2
3
4
5
6
7
8
9
4.1
A pipeline safety code violation may be one of commission or omission. That is PG&E may be found
in violation of pipeline safety requirements when its actions deviate from or fail to address
requirements including those in California State Laws, California Public Utilities Commission General
Orders, Minimum Requirements contained in California State Safety Codes or Federal Pipeline Safety
Codes such as 49 CFR Part 192 Requirements for Transmission and Distribution by Pipeline. A
violation exists either when PG&E fails to follow its procedures or when procedures are inadequate to
support compliance.
10
11
12
13
14
4.2
As a part of providing natural gas to end users, PG&E must also provide adequately for public safety.
To accomplish this PG&E is required, at a minimum, to comply with a number of pipeline safety
requirements. These include:
15
16
17
18
19
20
21
22
23
CPUC/CA Natural Gas Safety Code incorporates by reference all of the USDOT Federal
Minimum Natural Gas Safety Code 49 CFR Part 192
24
25
26
27
28
29
30
PG&E Standards, Specifications, Plans, Standard Operating Procedures and Emergency Plans
developed to comply with the above State Laws, General Orders, State and Federal Pipeline
Safety Codes, and Standards Incorporated by reference
31
32
Advisory bulletins and findings from outside evaluation reports (e.g., those of the NTSB)
which are specifically required by the California legislature.
33
34
35
36
37
38
39
40
PG&E is required to comply with all of these requirements, generally by having procedures in place,
following its procedures, and documenting its actions to demonstrate it has complied with these
requirements.
4.3
Table 3 below details historical requirements related to maps and records. These requirements and
their subsequent revisions (see Attachment C for current requirements) must be met to demonstrate
compliance. Inaccurate information contained in required records or the lack of such records
constitutes non-compliance. Such non-compliance is considered a violation of pipeline safety
25
1
2
3
requirements. While the wording associated with some of the earliest of these requirements has
evolved over the years, changes to the requirements have typically been to provide clarification, to
update requirements to reflect new information, and to strengthen requirements.
4
5
6
7
We should note that, as PG&E has pointed out in its response to the OII,36 and as has been recognized
by the Pipeline and Hazardous Materials Safety Administration in 49 CFR 192.1007,37 there may
be gaps in the knowledge an operator has when it develops its initial IM plan. Following is a quote
from that regulation.
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
36
37
49 CFR 192 Subpart PGas Distribution Pipeline Integrity Management (IM), page 63906 Federal Register /
Vol. 74, No. 232 / Friday, December 4, 2009 / Rules and Regulations.
26
Records-Related Event
1955
ASA B31.1.8-1955
1958
ASA B31.8-1958
Regulatory Requirement
3. System Maps and Records
a. Each gas utility shall keep on file with the Commission up-todate maps of the general territory, which it holds itself in readiness
to serve, outlining operating districts and showing major
transmission lines.
b. A suitable map or maps shall be kept on file in the principal
office of each division or district. Maps shall at all times show the
size, character and location of each street main, district regulator,
operating valve and drip, and when practicable, each service
connection in the corresponding territory served. In lieu of
showing service locations on maps, a card record or other suitable
means may be used.
c. In each division or district office there shall be available such
information relative to the distribution system which will enable
the local representatives at all times, to furnish necessary
information regarding the rendering of service to existing and
prospective customers.
20. Pressure Testing Equipment and Tests
(c) On low pressure distribution systems each gas utility shall
during the six months of the peak season of the year make at least
one 24-hour record of pressure each week at the outlet of
customer's meters for each one hundred (100) miles or less of
distribution main in each district or separate distribution system.
Such records shall be filed and retained as a continuous record
for a period of at least two calendar years in the principal office of
each district or division. there may be substituted an equal
number of twenty-four (24) hour records from recording pressure
devices permanently located at critical points on the distribution
system.
(d) On high pressure distribution systems gas utilities shall
maintain permanently located pressure gauges at critical points
and shall preserve in the district or division offices the charts from
these gauges as a continuous record for a period of at least two (2)
years.
850.3 Basic Requirements - Each operating company having gas
transmission or distribution facilities within the scope of this code
shall (a) Have a plan covering operating and maintenance
procedures in accordance with the purpose of this code. (b)
Operate and maintain its facilities in conformance with this plan.
(c) Keep records necessary to administer the plan properly.
850.3 Basic Requirements - Each operating company having gas
transmission or distribution facilities within the scope of this code
shall (a) Have a plan covering operating and maintenance
27
Date
Records-Related Event
Regulatory Requirement
procedures in accordance with the purpose of this code. (b)
Operate and maintain its facilities in conformance with this plan.
(c) Keep records necessary to administer the plan properly.
Sec. 107 Compliance with ASA Code; 107.1 Gas transmission and
distribution facilities shall be constructed and operated in
compliance with the provisions of Section 8 of the American
Standard Code for pressure piping, known as the American
Standard Code for Gas Transmission and Distribution Piping
Systems, ASA B 31.8-1958, and in compliance with the further
requirements of the additional rules herein prescribed.
Sec. 301 General: 301.1 The responsibility for the maintenance of
necessary records to establish that compliance with these rules has
been accomplished rests with the utility. Such records shall be
available for inspection at all times by the commission or the
commission staff.
Sec. 302 Specifications: 302.1 Specifications for material and
equipment, installation, testing and fabrication shall be maintained
by the utility.
Sec. 303 Operating and Maintenance Procedures:
303.1 Plans covering operating and maintenance procedures,
including maximum actual operating procedures to which the line
is intended to be subjected, shall be maintained by the utility.
303.2 No pipeline shall be operated in excess of the maximum
operating pressure recorded by the company in accordance with
this section.
850. O&M; 850.3 Basic Requirements - Each operating company
having gas transmission or distribution facilities within the scope
of this code shall (a) Have a plan covering operating and
maintenance procedures in accordance with the purpose of this
code. (c) Keep records necessary to administer the plan
properly.
Incorporated by CPUC GO 112-C (01/12/71)
192.13 (a) No person may operate a segment of pipeline that is
readied for service after March 12, 1971, unless that pipeline had
been designed, installed, constructed, initially inspected, and
initially tested in accordance with this part.
(b) No person may operate a segment of pipeline that is replaced,
relocated, or otherwise changes after November 12, 1970, unless
that replacement, relocation, or change has been made in
accordance with this part.
(c) Each operator shall maintain, modify as appropriate, and
follow the plans, procedures and programs that it is required to
establish under this part.
192.517 Records - Each Operator shall make and retain for the
useful life of the pipeline a record of each test performed under
192.505 and 192.507 (strength testing). The record must
28
Date
Records-Related Event
Regulatory Requirement
contain at least the following information:
(a) Operator information (described)
(b) Test medium used
(c) Test pressure
(d) Test duration
(e) pressure recording charts or other records of pressure readings
(f) Elevation variations
(g) Leaks and failures noted and their disposition
192.603(b) Each operator shall establish a written operating and
maintenance plan meeting the requirements of this part and keep
records necessary to administer the plan.
192.605 Each operator shall include the following in its O&M
plan: (a) Instructions for employees covering operating and
maintenance procedures during normal operations and repairs.
192.613(a) Each operator shall have a procedure for continuing
surveillance of its facilities to determine and take appropriate
action concerning changes in class location, failures, leakage
history, corrosion, substantial changes in cathodic protection
requirements, and other unusual operating and maintenance
conditions.
192.613(b) If a segment of pipeline is determined to be in
unsatisfactory condition but no immediate hazard exists, the
operator shall initiate a program to recondition or phase out the
segment involved, or, if the segment cannot be reconditioned or
phased out, reduce the maximum allowable operating pressure in
accordance with 192.619 (a) and (b).
192.617 Investigation of Failures Each operator shall establish
procedures for analyzing accidents and failures, including the
selection of samples of the failed facility or equipment for
laboratory examination, where appropriate, for purpose of
determining the causes of the failure and minimizing the
possibility of a recurrence.
192.619(c) Notwithstanding the other requirements of this
section, 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
July 1, 1970, subject to the requirements of 192.611 (changes in
class location).
192.621(a) No person may operate a segment of a high pressure
distribution system at a pressure that exceeds the lowest of the
following pressures, as applicable:
(5) The pressure determined by the operator to be the maximum
safe pressure after considering the history of the segment;
particularly known corrosion and the actual operating pressure.
192.1007 What are the required elements of an integrity
29
Date
2006
Records-Related Event
Regulatory Requirement
related requirements)
management plan?
A written integrity management plan must contain procedures for
developing and implementing the following elements:
(a) Knowledge. An operator must demonstrate an understanding of
its gas distribution system developed from reasonably available
information.
(1) Identify the characteristics of the pipeline's design and
operations and the environmental factors that are necessary to
assess the applicable threats and risks to its gas distribution
pipeline.
(2) Consider the information gained from past design, operations,
and maintenance.
(3) Identify additional information needed and provide a plan for
gaining that information over time through normal activities
conducted on the pipeline (for example, design, construction,
operations or maintenance activities).
(4) Develop and implement a process by which the IM program
will be reviewed periodically and refined and improved as needed.
(b) Identify threats. The operator must consider the following
categories of threats to each gas distribution pipeline: corrosion,
natural forces, excavation damage, other outside force damage,
material or welds, equipment failure, incorrect operations, and
other concerns that could threaten the integrity of its pipeline. An
operator must consider reasonably available information to
identify existing and potential threats. Sources of data may
include, but are not limited to, incident and leak history, corrosion
control records, continuing surveillance records, patrolling
records, maintenance history, and excavation damage experience.
4216.3 (a) (1) Any operator of a subsurface installation who
receives timely notification of any proposed excavation work in
accordance with Section 4216.2 shall, within two working days of
that notification, excluding weekends and holidays, or before the
start of the excavation work, whichever is later, or at a later time
mutually agreeable to the operator and the excavator, locate and
field mark the approximate location and, if known, the number of
subsurface installations that may be affected by the excavation to
the extent and degree of accuracy that the information is available
either in the records of the operator or as determined through the
use of standard locating techniques other than excavating,
otherwise advise the person who contacted the center of the
location of the operator's subsurface installations that may be
affected by the excavation, or advise the person that the operator
does not operate any subsurface installations that would be
affected by the proposed excavation.
30
1
2
3
Attachment C to this report provides a list of current requirements and provisions of the CPUC code,
Commission general orders, applicable rules or requirements or other state or federal laws pertaining to
pipeline safety recordkeeping that are applicable to PG&Es natural gas distribution system.
4.4
5
6
7
8
9
10
11
12
The six incidents identified in the OII and listed in Table 1 all stem from PG&E or excavator actions
undertaken in the light of imperfect maps and records caused by deficient recordkeeping practices.
PG&E practices have been deficient given the requirements that a prudent operator is expected to
meet. (For a discussion of the concept of appropriate standard of care see Section 6 and Attachment
D.) This is supported by the report by Duller and North discussed above. Although focusing on
PG&Es Gas Transmission Line records, Duller and North in its report (dated March 5, 2012) on
records management following the San Bruno fire and explosion, states that the reports findings are
also referenced against PG&Es corporate approach to records management.38
13
14
15
16
17
18
19
20
21
22
23
24
Historically, mapping and recordkeeping requirements for utilities have been mandated by the CPUC
in General Orders 58 and 112. Over the years the recordkeeping requirements in these orders have
been periodically updated, with the most recent requirements provided in General Orders 58A and
112-E and 112-F. The Research and Special Programs Administration (RSPA) the federal agency
that preceded the Pipeline and Hazardous Materials Safety Administration (PHMSA) in regulating
pipeline safety - in addressing the need that gas company system maps and records be maintained
accurately to identify the locations, size, and operation[al] pressure of all their pipelines39 also requires
that all gas and hazardous liquid pipeline operators must maintain an operating and maintenance plan
that includes procedures for making construction records, maps, and operating history available to
appropriate operating personnel to enable them to safely and effectively perform their duties (49 CFR
192.605). CPUC General Orders are routinely updated to incorporate and often to exceed the most
recent federal requirements.
25
26
27
28
29
30
31
32
33
34
35
PWAs investigation, which has focused on evaluating recent incidents in which records imperfections
were the underlying causes, found that PG&E has had a series of procedures in place to comply with
CPUC mapping and recordkeeping requirements. Those procedures required each Division to
establish and maintain maps and records for its gas distribution lines.40 PG&E procedures required
each Division to maintain maps and records that provided details of its gas distribution lines on plat
maps, gas service records and file folders on sections of distribution mains. However, PG&E and
Division records management procedures inadequately detailed which records needed to be retained
and maintained to demonstrate compliance with general order requirements, California Laws, and gas
pipeline safety requirements. As a result an evolving set of PG&E record retention procedures focused
more on which records could be destroyed rather than on required records and their retention
requirements.
36
37
38
39
40
PG&Es records retention procedures were inconsistently followed, resulting in map plats becoming
outdated; containing incorrect and incomplete information. Key pipeline history records and files were
lost, misplaced and/or inadvertently destroyed. Plats maps have been found to be incomplete or
misleading because they do not contain up to date information on the location, nature, diameter and
material of current lines. Examples of such incomplete or misleading information are described in the
38
39
Advisory Bulletin 02-03 - Federal Register Volume 67, Number 114 [Pages 40768-40770] (June 13, 2002) 2nd
paragraph Page 40769.
40
As discussed in the report by Duller and North, many of PG&Es current procedures and standards apply to
both gas transmission and gas distribution.
Page 31
1
2
3
4
discussion below concerning the six incidents in the OII as well as those in Tables 2 and 4. These
imperfections and missing or misleading information on maps and records include those associated
with inserted gas service lines and inserted gas mains, stub services, and records to substantiate the
MAOP of lines consistent with the initial 1970 requirements in 49 CFR Part 192.
5
6
7
8
9
Some plat maps have been found to contain lines that do not exist, and exclude gas lines that do exist.
Until recently, plat maps were the primary means by which field crews located gas lines in support of
marking to prevent excavation damage, leak detection and identification of needed repairs. PG&E is
currently pursuing a program to update maps and records as well as to make them more accessible to
crews in the field.
10
11
12
13
14
15
16
17
Current procedures used to locate and mark (L&M) gas lines use plat maps as secondary or tertiary
guidance rather than the primary source on line location by locate and mark (L&M) crews. The PG&E
procedures require L&M crew actions to rely on tracking frequencies techniques by electrically
directly connecting to gas lines and locating wire, or to indirectly induce a signal frequency to track,
locate and mark out gas lines within the scope of proposed excavations. Because of occasional
difficulty or inability to track such frequencies due to signal jumping, broken or missing locating wire,
or long distances from direct connections to the area to be marked, gas lines are occasionally
mismarked or not marked at all rather than basing markings solely on information in maps.
18
19
20
The following current General Orders and code sections were found to apply to the six incidents
identified in the OII. A more complete set of requirements to which PG&E records practices are
subject is shown in Attachment C.
21
22
23
24
25
26
27
1. General Order 58A (December 16, 1992) - Section 3. (b) A suitable map or maps shall be kept on
file in the principal office of each division or district. Maps shall at all times show the size,
character and location of each street main, district regulator, operating valve and drip, and when
practicable, each service connection in the corresponding territory served. In lieu of showing
service locations on maps, a card record, a computerized system, or other suitable means may be
used.
28
29
30
31
2. General Order 112-E (August 21, 2008) Section 101.4 The utilities shall maintain the necessary
records to ensure compliance with these rules and the Federal Pipeline Safety Regulations, 49 CFR
Part 192, that are applicable. Such records shall be available for inspection at all times by the
Commission or Commission staff.
32
33
34
3. 49 CFR 192.605(a) (November 11, 1970) - Each operator shall prepare and follow for each
pipeline, a manual of written procedures for conducting operations and maintenance activities and
for emergency response.
35
36
37
4. 49 CFR 192.605(b) (November 11, 1970) - Maintenance and normal operations. The manual
required by paragraph (a) of this section must include procedures for the following, if applicable, to
provide safety during maintenance and operations.
38
39
(3) Making construction records, maps, and operating history available to appropriate operating
personnel.
40
41
42
(8) Periodically reviewing the work done by operator personnel to determine the effectiveness, and
adequacy of the procedures used in normal operation and maintenance and modifying the
procedures when deficiencies are found.
43
44
5. 49 CFR 192.13(c) - Each operator shall maintain, modify as appropriate, and follow the plans,
procedures, and programs that it is required to establish under this part.
Page 32
1
2
3
4
5
6
7
8
6. Advisory Bulletin - ADB-02-03 Gas and Hazardous Liquid Pipeline Mapping - RSPA41
identified the need for accurate maps of pipeline systems in this Advisory Bulletin and stated that
pipeline operators should review their information and mapping systems to ensure that the operator
has clear, accurate, and useable information on the location and characteristics of all pipes, valves,
regulators, and other pipeline elements for use in emergency response, pipe location and marking,
and pre-construction planning. This includes ensuring that construction records, maps, and
operating history are readily available to appropriate operating, maintenance, and emergency
response personnel.
9
10
11
7. NTSB42 - Safety Recommendation P-87-34 urged RSPA to revise the pipeline safety regulations
to require that gas company system maps and records be maintained accurately to identify the
locations, size, and operating pressure of all their pipelines.
12
13
14
15
8. NTSB - Safety Recommendation P-97-19 emphasized the need for RSPA/OPS to ``develop
mapping standards for a common [pipeline] mapping system, with a goal to actively promote its
widespread use.'' NTSB recommends that pipeline mapping should consider the amount of detail
and the accuracy of information necessary for effective use.
16
17
18
The ADB and NTSB recommendations, though not included in actual gas safety code requirements,
are advice and indicative of what RSPA/OPS (now PHMSA) as well as NTSB expect operators to
achieve.
19
41
OPS, the Office of Pipeline Safety and RSPA, the Research and Special Programs Administration are both
predecessor agencies to PHMSA, the Pipeline Hazardous Materials Safety Administration of the US Department
of Transportation.
42
These NTSB recommendations resulted from a series of accidents in which a lack of accurate maps played a
role.
Page 33
1
2
5.
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
The underlying cause of the six incidents in the OII are failures in record keeping, most commonly
related to PG&Es failure to include records of maintenance and other changes to its facilities
subsequent to the original installation. As discussed in Section 6.1 in this report, of the six incidents in
the OII, two were caused by not having accurate records of mains or services that that had plastic
inserted into existing steel or other pipe materials. One of the remaining four incidents was caused by
stubs not being mapped on existing maps and current records used by L&M43 technicians/personnel.
Since the stub was not on the maps the L&M crew was not seeking to mark out the unknown line and
the stub was not marked as part of the L&M process. Unmarked stubs represent a records issue due to
inaccurate or faulty mapping following a maintenance activity (e.g., partial removal or retirement of a
portion of a service which was then listed as totally retired to the main and removed from the map and
possibly from the records themselves). One of the remaining three incidents was caused by a field crew
doing a routine tie in not checking the position of an isolation valve. The valve was noted on the map
as open when in reality it was closed thus causing loss of gas supply to nearly 1,000.44 Of the
remaining two incidents, one was caused by a mismark and one incident was due to a faulty map that
did not show an electronic test station45 (ETS) close to a service that needed to be located. The L&M
technician used an ETS located a considerable distance away, and the signal used to locate the pipe
was either too weak or associated with the wrong facility. Thus, the locate was not accurate causing an
excavator to damage the service and leading to a gas release.
21
22
23
24
25
For the plastic inserted steel mains and service incidents, for which the plastic inserts were made in
the 1980s and 1990s based on the manufacturing date of the inserted plastic, the maps were never
updated to reflect the inserts. More recently46 a SED inspection discovered plastic mains and/or
services - inserted, in 2013 and 2014 that were not shown on maps as of August 2015. These
inspections are discussed in Section 8.1.
26
27
28
29
30
31
32
33
34
35
The incidents in the OII - consisting of mis-mapped or unmapped stubs off a main - highlights a major
source of marking errors that have caused damage by third parties (as well as PG&E crews) when
doing work adjacent to or on the existing mains. These unmarked stubs were initially thought by
PG&E to be rare but are located throughout the service territory.47 PG&E has recently completed
collecting available data in each of its 18 division regarding service stubs.48 Initially PG&E thought
that there were on the order of 17,000 stubs but checking records in additional divisions has increased
the known total of identified stubs to more than 71,000. These are just the known stubs and, as
indicated in recent incidents, there are certainly additional unknown stubs. The stub for the incident in
the OII was not shown on the map and it was thought that it had been cut off at the main and not at or
near the property line.
43
L&M stands for locate and mark, the people who complete USA tickets to identify gas line locations at
excavation sites and thereby help prevent outside force damage on underground facilities.
44
PG&E only started requiring clearances for distribution work in either late 2014 or early 2015, see the
responses to SED DR 004-Q79 through DR 004-Q82.
45
This particular test station is a location to attach a locating device onto a tracer wire or connect to the main.
46
In July and August of 2015 the SED performed a records/mapping audit in the San Jose and San Francisco
Divisions of PG&E and found over 9% of the services that had plastic inserts were not mapped in a reasonable
period of time that is several months.
47
See response to DR SED 003-Q52. 71,131 is the most recent count of stubs in the 18 PG&E districts as of
9/3/15.
48
Page 34
1
2
3
4
5
6
7
8
Until recently, PG&E had a policy that when a stub could not be located it would be eliminated from
the map and from the related records. An internal audit investigation49 in one division found that a
foreman/supervisor had reported doing excavations to locate a stub and not finding anything. These
excavations were never conducted, but since the policy was to remove the record of the stub from the
map based on locating it via excavation, the stub was apparently removed from the map. PG&E did not
check other foreman/supervisors and we are not sure whether it checked other records on the
individual who may have claimed to be unable to find other stubs. Since this may not be an isolated
occurrence,50 there could be more stubs that were erroneously removed from maps.
9
10
11
12
13
14
Another contributing factor in having unmapped stubs is that PG&Es policy on stubs contributes to
their existence in the first place. PG&E can essentially have a stub forever since known stubs are only
reviewed periodically and then if there is any chance of it being needed in the future, removal is not
scheduled. There does not appear to be a formal program to remove stubs (cut them back to the main)
after certain timeframe, thus stubs appear to be rarely removed although, as noted above, in at least one
instance, a stub has inappropriately been deleted from the maps.51
15
16
17
18
19
20
21
22
23
24
25
26
When federal regulations for pipeline safety were first proposed and issued for comment in the late
1960s, there were explicit requirements for how to determine the safe operating pressure on pipelines
and mains. These requirements included having valid pressure tests. Industry requested, and was
granted a so called grandfather provision, a five year window looking backward from the
implementation date of the regulations (1970 back to 1965) for those operators that did not have
records of a pressure test on which to base the MAOP. This grandfather provision was allowed based
on pressure records only for a onetime window. PG&E did not have all of the requisite pressure
records. Lacking records required by the new 49 CFR Part 192 regulations, PG&E developed its own
approach to establish the MAOPs of grandfathered systems. This approach included using either
certification by individuals or pressure records from the mid and late1970s as the basis. Using its
alternative approach, PG&E established the MAOP for approximately 243 of its 1,376 hydraulically
independently distribution systems by 1979.
27
28
29
30
31
32
33
34
35
Neither certification by individuals or use of pressure records from the 1970s was consistent with the
regulations. To date, PG&E has not identified any interaction with its regulator to discuss and request
approval to validate its alternative approach to establishing MAOP. A Data Request52 to obtain copies
of all correspondence relating to these systems shows that the SED only became aware of the issue
during an audit in 2014. PG&E has stated that they will continue to search their records to see whether
there is evidence of earlier correspondence with the CPUC on the issue and their approach to
addressing it. Additional discussion of the map and records issues contributing to incidents is
presented in Attachment E. The examples in Attachment E were derived from a review of PG&E CAP
reports provided in response to SED-001-Q12.
49
See responses to DR SED 001-Q12 Supplemental 01, Bates Nos. GDR 00007486 and 00007572 aka File 05047 and 05-052 (5B5-2650 and 1B5-1394) in San Rafael.
50
As reported in the SFGate, December 25, 2011 in an article titled PG&E incentive system blamed for leak
oversights, Jaxon Van Derbeken, several foreman/supervisors and others in the late 2000s were found to be
falsifying leak test and repair records.
51
Page 35
6.
2
3
4
5
The focus of the OII was on a specific set of six incidents. These incidents are summarized in Table 1.
PG&E has admitted that it violated title 49 CFR 192.605(b) regarding the Mountain View incident.53
In PG&Es letter dated April 4, 2014, Sumeet Singh of PG&E wrote the following to Michael
Robertson of the Safety and Enforcement Division:
6
7
EVIDENCE OF NON-COMPLIANCE
In its letter, the SED found PG&E in violation of Title 49 of the Code of Federal
Regulations Part 192.605(b). PG&E agrees with this violation.
8
9
10
11
12
13
In our investigation PWA considered violations associated with those six incidents, and looked further
at other records-related violations including: those associated with other incidents, those arising from
consideration of the relationship between two of the OII incidents, and those associated with the
acknowledged fact that PG&E lacking the necessary records - has established the MAOP for 243 of
its 1,376 hydraulically independent distribution systems using a procedure that is different from that
required by 49 CFR 192.619(c).
14
15
16
17
18
19
20
21
22
23
24
In its initial response to the OII,54 PG&E has acknowledged that its maps and records include errors
and omissions that they have referred to as imperfections.55 It also asserts that the problem of
imperfect maps and records exists throughout the pipeline industry, but is especially intractable at a
utility as large as PG&E. Furthermore, as also described in its initial response to the OII,56 PG&E has
undertaken major efforts both to correct these imperfections and to put in place backstop measures to
minimize the risk associated with these acknowledged imperfections. However, since PG&E has
avoided implying that these efforts will eliminate all imperfections,57 it is possible that incidents
caused by map and record imperfections will continue to occur. Given acknowledged imperfections in
PG&E distribution maps and records, which wording in the Distribution Integrity Management
Program regulation (DIMP)58 also acknowledges as existing throughout the industry, we will identify
the basis for citing non-compliances related to these imperfections.
25
26
27
28
29
30
31
32
33
34
As applied to pipelines, utilities are required to demonstrate compliance with applicable regulatory
requirements, and should adhere to industry best practices employed in assuring compliance. It could
be argued that violation of the standard of care for pipeline operators should include an incident or
accident directly linked to non-compliance with applicable regulatory requirements, or non-adherence
to industry best practices employed in assuring compliance. Because pipeline safety regulations
include a threshold for reporting of incidents and accidents to the safety regulatory authority, events
satisfying these thresholds provide one reasonable basis for evaluating operator conformance with the
standard of care. In addition, repeated non-compliance with regulatory requirements also may
demonstrate that the standard of care is not being met, even though there is not a reportable incident or
accident.
35
36
37
The reality that current maps and records may be inadequate to support effective integrity management
does not relieve the utility of its responsibility to operate its facilities safely. While many violations
are framed in terms of failure to comply with state and federal regulations, the actions underlying this
53
See letter Sumeet Singh (PG&E) to Michael Robertson (SED), April 4, 2014, Attachment G to this report.
54
55
PG&E managers responses to Interrogatories under Oath #3 (Response of John Higgins), #9 (Response of
Sumeet Singh), and #15 (Response of Raymond Thierry), August 24, 2015.
56
57
58
Page 36
1
2
failure also constitute violations of PG&Es obligation to furnish such services necessary to promote
the safety, health, comfort, and convenience of its patrons, employees, and the public.59
3
4
5
6
7
8
To understand how this might translate to pipeline operation we should consider the regulations, which
as noted in California Public Utilities Code Section 451, represent the minimum requirements for safe
operation. As it relates to maps and records, there are two elements to consider, both driven by
regulations: (1) what information should be retained in an accessible form to support operations and
maintenance, and (2) what process should be employed to address the acknowledged imperfections in
maps and records.
9
10
An operator is required to ensure the safety, health, comfort, and convenience of its patrons,
employees, and the public.60 This is demonstrated by three observables:
11
12
13
14
15
3. Ongoing operation in which zero defects are evidenced in the utilitys maintenance of
maps and records.
16
17
This report has included all three of these observables in its evaluation of information to identify
violations.
18
6.1
19
20
21
22
23
24
This section discusses violations associated with the initial six incidents. The following section
considers the other three sources of records-related violations: those associated with other incidents,
those arising from consideration of the relationship between two of the OII incidents, and those
associated with the acknowledged fact that PG&E lacking the necessary records - has established the
MAOP for 243 of its 1,376 hydraulically independent distribution systems using a procedure that is
different from that required by 49 CFR 192.619(c).
25
26
The initial focus of our evaluation of the six OII incidents is on investigating whether accurate
information necessary to prevent impactful events has been retained and is accessible.
27
28
29
30
31
32
33
34
35
1.
36
37
38
39
40
41
2. Main Street, Morgan Hill, 06/21/12 Third party contractor (directional bore installing a water
line) damaged a diameter 60 psig service stub not marked by locate and mark personnel. The
stub was on record map, not on 5 year stub review program, once identified as stub, to be removed
within a year per TD9500P-16. PG&E received a valid USA notification. The 1951 service line
was cut at property line in 1966, and in 46 years PG&E had not cut the stub off at the main. The
L&M crew noted service on plat map, did not find service riser, presumed service was previously
59
60
Page 37
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2
3
4
5
6
7
8
9
10
cut off, did not mark stub in field; This is a violation of California Government Code 4216.3.(a)(1).
The L&M crew did not follow its mark-out procedure - Damage Prevention Handbook TD-5811M
did not communicate with excavator. L&M personnel stated he mentioned to supervisor that it was
difficult to manage current mark out workload, possible violation of California Public Utilities
Code Section 961 d(10). PG&E did not follow its standard to keep their maps and records updated
and accurate. Our review of the information provided as well as SEDs investigation found PG&E
in violation of: not providing up to date operating history of its facilities to appropriate personnel
(L&M personnel), 49 CFR 192.605(b)(3), and not following its procedures 49 CFR 192.605(a).
PG&E has reported a number of incidents and events involving stubs under its corrective action
program (CAP).61
11
12
13
14
15
16
17
18
19
20
21
22
23
3. Montague Expressway and Great Mall Parkway, Milpitas, 10/10/12 The operating position of a
2 diameter 60 psig valve on PG&Es map did not indicate it was closed. Field crews presumed
the valve was open and during the main shutdown process, crew did not verify the valve was in the
open position, relied on the map, resulting in pressure in the line dropping below that required for
safe operation of the system and a gas outage to 987 customers, a violation of 49 CFR 192.605(a).
PG&E was in violation of 49 CFR 192.605(b)(3) - for having a map with the incorrect valve
position (map indicated open and it had been previously closed). The Gas operating personnel did
not verify the position of the valve to ensure a gas supply from that direction. PG&Es pressure
and capacity SynerGEE model for that area shows back feed, which can only occur when the valve
is in the open position, would be sufficient to supply customer demand during the maintenance
activity. Who had closed the valve, when this occurred, and why it was left in the closed position
without notifying mapping to correct its map was not determined. At the time PG&E did not have
any type of clearance procedure for gas distribution.
24
25
26
27
28
29
PG&E standards A-93.1, D-S0454 - PG&E did not assign personnel to monitor the pressure to
verify minimum safe operating pressure was being maintained during the work activity (main
shutdown - isolation and tie-in associated with replacing 6steel with 4 plastic main). PG&E did
not follow the guidance concerning the nature of its valves on its maps as indicated in RSPA
Advisory Bulletin ADB-02-03 issued June 13, 2002. A summary of the advisory bulletin is
provided as follows.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
PG&E has developed a distribution clearance procedure as part of D-S0454 and A93.1 to ensure
such non-emergency valve positions are checked for their position and validated during shutdowns
or tie-ins. As part of its new gas distribution control center, the GDCC now monitors the process
for such tie-in activities and ensures valve positions are verified and actions taken to monitor
61
See PG&E response to SED Q-12 Supplement 3 Bates 30404, 30453, 30530, 30891.
Page 38
1
2
pressures during work activities. The use of gas clearance form WCD 8000 started in 2013-2014,
(no date is on the form) for taking out of service (shutting down) and hotting up a main.
3
4
5
Currently, a clearance decision is made by Gas Distribution Control Center in cooperation with
Field Engineer on what steps are required, approximately 10 days before application for gas
clearance. This was previously made at the Division level.
6
7
8
9
10
11
12
13
14
15
16
17
4. Great Mall Parkway, Milpitas, 03/04/13 Third party contractor installing a storm drain damaged
a 2 diameter 60 psig plastic main. The damage was caused by a PG&E mapping error; the map
had not been updated to show the nearest electronic test station (ETS) installed in 1994. Had the
ETS been known to the L&M personnel, they would have been able to connect their locate tool to
the nearby tracer wire thereby improving the accuracy of their locate signal to better locate the gas
main. As a result, the L&M crew mismarked the 2 diameter plastic main by 6 feet. L&M crew
did not use the map for locating and instead elected to use an ETS some distance away resulting in
the mismark and excavation damage. PWA determined that PG&E was in violation of 49 CFR
192.605(b)(3) - for not providing its construction records, maps and operating history to its L&M
crew (the map had not been updated with the location of the nearest ETS installed 1994).
Following the incident, PG&E processed a map change request to update the plat map to include
the missing ETS.
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
5. Charleston Road, Mountain View, 07/30/13 PG&E field crew welded a tapping fitting on a
vintage 1947 1 diameter service line casing. Unknown to the welding crew, the 1 service
line had previously been inserted with 1 diameter 60 psig plastic.62 The welding on the 1 steel
service casing line damaged and/or melted the plastic insert resulting in a gas leak and hazardous
condition. Neither the plat map nor construction documents indicated the 1947 1 service had
been previously inserted with plastic sometime during 1970-1972 (PG&E response indicated the
line was inserted sometime between 1972-1980). PWA determined that PG&E was in violation of
49 CFR 192.605(b)(3) - for not providing its construction records, maps and operating history to
its welding crew (the map had not been updated with the plastic insert information). USDOT
advisory bulletin June 13, 2002 ADB-02-03 states that operator maps should provide: diameter,
pipe grade, material wall thickness. Welding on a previously inserted line is a hazardous situation
that could easily have resulted in a fire, injuries or worse. Yet, according to the information
provided PWA, PG&E issued no stand down to its employees or even an advisory to its workers
companywide of the dangers that this lack of accurate map and or records could happen again, and
to check and verify whether the lines were inserted prior to working on them. PWA determined
that PG&E was in violation of 49 CFR 192.605(a) and 192.617 for not following its procedures
and failing to determine the cause of the failure and minimize the possibility of a recurrence. It is
unclear how many similar events had occurred prior to this incident in which service line or main
inserts were not accurately reflected on PG&Es maps and records, and yet PG&E took no
proactive actions to update its maps and or warn its workers.63 PG&E did indicate in response to
SED-004-Q70 that it fixed the specific problem and looked for other similar situations. Certainly
as part of PG&Es investigation of failures following the Mountain View incident, these issues
should have been identified and communicated as a caution to other gas operations personnel.
62
PG&E response to the OII, page 5 footnote indicates this was a plastic inserted in 1970. The plastic insert
was vintage 1972 plastic NIPAK TR 418, which leads one to believe it was installed sometime in 1972 or
thereafter.
63
Since the Mountain View and Carmel unknown plastic insert incidents, PG&E reported that other unmapped
service inserts have been reported under the corrective action program, see PG&E response to SED DR Q-12
Supplement 3 Bates 30499 for
, Selma.
Page 39
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2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
6. Guadalupe Street and 3rd Avenue, Carmel 03/03/14 In preparing to tie-in new plastic mains
installed in the area, a PG&E general construction field crew welded and tapped into a Mueller
tapping tee onto what they believed was a 2 diameter steel main. Unknown to the construction
crew, the 2 service line had previously been inserted with 1 diameter 52 psig plastic
(manufactured 07-17-1997). The general construction crew was not aware they had tapped into an
inserted plastic gas main causing a hazardous situation until the M-2 line stopper tapping tool
removed both metal and plastic coupons cut from the steel casing and live plastic gas main. PG&E
maps did not show that the line had been previously inserted, resulting in hazardous gas leaking
and migrating, including a house explosion. PG&E personnel reacted poorly to the abnormal
operating condition and emergency, and were ill-prepared to rapidly shut down or isolate the
damaged inserted main, especially since PG&E had outdated maps and did not know the extent of
the inserted gas mains in the area. PWA determined that PG&E was in violation of a number of
code requirements, but will cite here the ones associated with recordkeeping and its failure to
prevent a recurrence of creating an unsafe condition by welding on an inserted line. PWA
determined that PG&E was in violation of 49 CFR 192.605(a) for failure to follow its procedures
and update its maps and records following the 199764 1 plastic main insertion, and 49 CFR
192.617 for not following its procedures and failing to determine the cause of the Mountain View
accident and minimize the possibility of a recurrence. PWA determined that PG&E was also in
violation of 49 CFR 192.605(b)(3) for failure to provide its crews with accurate records and maps
in performing their duties.
21
22
23
24
25
Following the house explosion in Carmel associated with this event, PG&E implemented a several
week stand down of its workforce. Subsequently, the Gas Carrier Pipeline Checklist was
introduced at field crews tailboard meetings across the company. The field crews follow the Gas
Carrier Checklist to verify that field condition matches records. If not, the job is stopped. The
checklist was developed to check for presence of an inserted line not indicated on map.
26
27
28
29
30
31
Additionally, as part of the tie-in process and prior to welding on a gas line suspected of being
inserted, PG&E now requires installation and tapping of a bolt-on mechanical tapping tee. The tee
has a built in hard stop so it does not travel into the gas line far enough to pierce the plastic if the
line has previously been inserted and not mapped or not on record. The cutter, while not a drill bit,
can still damage the inserted plastic but does not result in a leak while allowing the crew to identify
the presence of inserted plastic.
32
6.2
33
34
35
36
37
Other potential records-related violations including: those associated with other incidents, those arising
from consideration of the relationship between two of the OII incidents, and those associated with the
acknowledged fact that PG&E lacking the necessary records - has established the MAOP for 243 of
its 1,376 hydraulically independent distribution systems using a procedure that is different from that
required by 49 CFR 192.619(c).
38
39
40
41
42
43
Additionally, inspections by SED personnel conducted in July and August of 2015 have identified
continuing mapping update violations and deficiencies. These are discussed further in Section 8.1.
Briefly summarized, SED audited maps and records for 42 service line insertion projects in San Jose
and San Francisco divisions, and found four (4) instances where the inserts were not mapped; a
violation of mapping requirements.
64
We conclude the 2 diameter steel main was inserted sometime in 1997 as that was the earliest it could have
been installed. The plastic pipe was manufactured on July 17, 1997.
Page 40
1
2
3
4
5
Page 41
1
2
System
Characteristic
s
Comments/ Violation
1.25 steel
service stub
extending
from a 4 steel
main, 60 psig
MAOP
Lafayette
(8/27/13)
steel
service line
and service
line valve 60
psig MAOP
Page 42
Location/Date
System
Characteristic
s
Comments/ Violation
2 plastic
distribution
main, near 3way tee,
which
branches off a
4 plastic
distribution
main
Kentfield (4/1/11)
Goodhill Road &
Diablo Drive
2 plastic
main 60
psig MAOP
Page 43
Location/Date
System
Characteristic
s
Comments/ Violation
Antioch
(3/15/10)
Lonetree Way & James
Donlon Blvd.
2 plastic
main
60 psig
MAOP
Colusa (03/19/09)
Grimes/Arbuckle Road
and First St.
2 steel main
150 psig
MAOP
Alameda (09/28/10)
4 plastic
main 60
psig MAOP
Page 44
Location/Date
System
Characteristic
s
Comments/ Violation
Roseville (10/21/10)
2 plastic
main 60 psig
MAOP
Page 45
Location/Date
System
Characteristic
s
Comments/ Violation
Sacramento (10/31/11)
1 plastic
service
San Francisco
(04/08/14)
1 plastic
service line,
60 psig MAOP
1 plastic
service line,
60 psigMAOP
65
Fresno (09/24/14)
65
Both addresses are indicated for the damaged service line on PG&Es records.
Page 46
Location/Date
System
Characteristic
s
Comments/ Violation
2 plastic
service line
60 psig
MAOP
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Page 47
1
2
Requirement Violated
Evidence
Missed
Opportunities for
Corrective Actions
Failure to
implement
compensatory or
backstop measures
promptly in the face
of evidence of an
unanticipated high
risk situation.
49 CFR 192.617
Investigation of Failures - It is
not clear whether or not the
Charleston Road - Mountain
View incident was the first
time an unmapped plastic
insert was identified as being
present and not previously
mapped as well as records
inaccurately reflecting gas line
conditions and materials as per
PG&E mapping update
procedures.
49 CFR 192.605(b)(3)
Neither is it clear whether this
issue of maps not accurately
reflecting actual working
conditions (such as mains or
services having been inserted
and maps not being updated)
was shared as a concern or
warning to other gas
operations personnel to be
looking for such conditions
prior to performing work on a
gas line, especially welding or
tapping. Certainly as part of
PG&Es investigation of
failures following the
Mountain View incident, these
issues should have been
identified and communicated
to other gas operations
personnel following the
Mountain view incident.
Response to PHMSA
Advisory Bulleting
ADB-02-03
Failure to
address/ensure
maps and records
provide diameter,
grade, pipe type and
wall thickness per
PHMSA Advisory
Bulletin ADB-0203
3
4
5
6
Investigation of PG&E Distribution System Recordkeeping
Page 48
1
2
3
4
5
6
7
8
9
10
11
The issue associated with distribution system MAOP is that PG&E acknowledges it has not complied
with the 1970 version of 49 CFR 192.619 (see Federal Register on August 19, 1970) in which the
approaches to establishing MAOP for pipelines installed prior to promulgation of that regulation were
specified. In particular, PG&E has indicated that, for 243 hydraulically independent distribution
systems, pressure records did not exist in 1970 to support the required five year pressure history
review. Hence it developed a procedure66 that relied on either certification of the maximum operating
pressure during the five years from 1965 through 1970, or use of pressure records during the mid to
late 1970s during leak surveys as the basis for the MAOP. Both approaches are an unapproved
alternatives to those described in the regulation.
12
13
In its evaluation of the MAOP issue, PWA developed a timeline of relevant events, which is shown
below as Table 6.
14
15
16
17
18
19
o MAOP is the highest actual pressure to which the segment was subjected during the
five years preceding the applicable data (July 1, 1965 - July 1, 1970 for distribution
piping).
20
21
22
July 26, 1971 The CPUC granted PG&Es waiver request to allow an extension of time for
compliance with Section 192.619 (a)(3), Maximum allowable operating pressure; steel or
plastic pipelines, through July, 1971.
23
24
November 22, 1972 - PG&E internal letter to Division Gas Superintendents communicating
the ASME Committee interpretation of 192.619.
25
26
27
28
29
30
31
o Letter communicates the opinion of the ASME Committee on Gas Safety, PG&E, and
other unspecified utilities all of which concur that 192.619 covers all pipeline systems
and must be adhered to when determining the MAOP of distribution piping systems.
April 5, 1977 - PG&E internal letter to Division Managers disclosing that a recent systemwide audit disclosed that many of our distribution systems lack tangible documentation of
operating pressures for that five years period in 192.619 (July 1, 1965 - July 1, 1970 for
distribution piping).
32
33
34
35
36
37
38
o The letter described three alternative approaches to establishing the MAOP none of
which is consistent with those described in the regulations.
February 13, 1978 - PG&E issued Standard Practice 463-6 to Division Managers and the
Manager of Pipeline Operations prescribing a uniform procedure to establish, document,
review and revise MAOP for all distribution systems which contain plastic, cast iron,
wrought iron, or copper pipe and steel pipe which is operated below a hoop stress of 20%
SMYS.
39
40
41
o Allows certification of the highest operating pressure in the five year period
(July 1, 1965 - July 1, 1970 for distribution piping) as the basis for determination of
MAOP.
66
Page 49
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2
3
4
5
6
7
8
9
10
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12
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14
15
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17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
October 20, 2014 - SED audit identified non-compliant establishment of the MAOP, later
determined to be for at least 240 of PG&Es 1,376 hydraulically independent distribution
systems.
40
41
42
43
Page 50
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2
3
4
5
6
prior to July 1, 1970 for some distribution systems could not be found. PG&Es
standard practice provided an option to require a pressure record after July 1, 1970
with a subsequent leak survey in order to demonstrate safe operation and
establishment of a systems MAOP. PHMSAs instructions on the determination of
MAOP in natural gas pipelines (attached and currently available on PHMSAs
website:
7
8
9
10
11
12
13
http://www.phmsa.dot.gov/staticfiles/PHMSA/DownloadableFiles/Files/maop_deter
mination.pdf ), dated April 22, 1998, describes considerations of missing records in
Section C. It is not known whether PG&E consulted the CPUC in the late 1970s in
specifying this option to establish distribution MAOPs. PG&E has reviewed
distribution system MAOP records and determined that of the 1376 hydraulically
independent systems, approximately 240 systems have had their MAOP established
using this basis.
14
15
August 14, 2015 - PG&E corrects the number of systems and states the number of systems
are actually 243. PG&E response to DR_SED-004_Q-86.
16
17
18
19
20
September 14, 2015 In its response to SED-004-Q87, PG&E stated In 2008, PG&E
concluded that the use of the method described in TD-4125S to establish MAOP for the
subject 243 hydraulically independent distribution systems does not pose a safety risk.
Therefore, PG&E has not implemented any additional measures specifically applicable to the
associated pipe.
21
22
23
24
25
26
27
28
29
30
Review of this timeline shows that the earliest available correspondences discussing the issue were: an
internal PG&E letter dated November 22, 1972 to Division Gas Superintendents communicating the
ASME Committee interpretation of 49 CFR 192.619, and an internal PG&E letter dated April 5, 1977
that described three alternative approaches to establishing the MAOP none of which was consistent
with those described in 192.619. The primary inconsistencies were related to (a) PG&Es apparent
willingness to use certification of a knowledgeable manager concerning the pressure history as a
substitute for pressure records, and (b) PG&Es willingness to use pressure records for a five year
period much later than that stipulated in the regulation as the basis for establishing the MAOP.67
PG&E Procedure TD-4125S, p. 4 states:
31
32
33
34
35
36
37
38
39
40
41
42
43
PWAs review of the MAOP issue included issuing a data request (DR SED-004-086) for related
correspondence. In response to the DR, PG&E provided Table 7. The DR and PG&Es response are
67
Letter Kenneth Bruno to Sumeet Singh, General Order 112-E audit of PG&Es Operations and Maintenance
Plans, Item 23, October 20, 2014.
Page 51
1
2
3
4
5
6
7
8
9
10
11
12
13
shown below. Note that the discussion of the MAOP in 2006 referenced in the first entry in Table 7
was unrelated to the basis on which MAOPs were established by PG&E for the 243 hydraulically
independent distribution systems; rather it was referencing how the MAOP was established for two
systems with different historic MAOPs that were being integrated into a single hydraulically
independent distribution system. Available information shows that PG&Es activities to develop and
implement an alternative approach to assigning MAOP for the 243 Hydraulically Independent
Distribution Systems occurred in the 70s (1972-1979) which indicates they had not maintained
distribution system pressure charts to monitor the pressures on at least the 243 systems in question as
required by General Order 58A (effective 07/01/32) Sections 20(c) and 20(d). GO 58A Section 20(c)
required that (for low pressure distribution systems) such 24 hour pressure charts of the system
pressures be maintained for a minimum of 2 years, and Section 20(d) required that (for high pressure
distribution systems) such 24 hour pressure charts of the system pressures be maintained for a
minimum of 2 years.
14
15
16
17
18
19
20
21
22
23
Following the promulgation of 49 CFR 192.619 Maximum allowable operating pressure for Steel
or plastic pipelines, published in the Federal Register on August 19, 1970, PG&E was required to
establish the maximum allowable operating pressures of their gas distribution lines in accordance with
its provisions. For pipeline segments not pressure tested in accordance with code requirements, this
code section 192.619(c) required that PG&E was to identify records that demonstrate the basis for a
pipeline segments MAOP. The code limited distribution operating pressures on segments of steel or
plastic pipeline to the highest actual operating pressure to which the segment was subjected during the
5 years preceding 1970 if installed prior to (Nov. 12, 1970). If installed after that date, pressure
restrictions apply unless the segment was tested according to the requirements in paragraph (a)(2) of
this section.
24
25
26
27
28
In summary, PG&E developed its approach to establishing the MAOP for the 243 hydraulically
independent distribution systems and implemented that approach without seeking either review or
approval by the SED. This is a violation of 49 CFR 192.619. Even in light of the 1998 PHMSA
guidance that the regulator needs to review and approve any alternative approach to establish MAOP
the earliest correspondence (2014) was sixteen years after PHMSA published its guidance.
29
30
31
32
33
34
35
36
37
38
39
Page 52
1
2
3
4
5
6
7
8
9
10
11
12
13
Bates No.
Begin
GDR_000030028
GDR_000030039
GDR_000030040
GDR_000030045
GDR_000022880
GDR_000022880
GDR_000022864
GDR_000022873
GDR_000030046
GDR_000030236
GDR_000030237
GDR_000030239
GDR_000022881
GDR_000022886
GDR_000022874
GDR_000022879
GDR_000030240
GDR_000030269
PG&E is continuing to search its records for additional responsive correspondence and may
supplement this response.
In additional DR #87, PWA has asked about the risk represented by these 243 systems relative to other
grandfathered systems for which the MAOP was established in conformance with the regulations,
and about the measures PG&E proposes to address these risks. An indirect response was provided by
Raymond Thierry in response to Interrogatory under Oath #17 My understanding is that, in 2008,
PG&E concluded that the use of the method described in TD-4125S to establish MAOP does not pose
a safety risk to the distribution system. This position was reiterated in response to DR #87 that in
2008, PG&E concluded that the use of the method described in TD-4125S to establish MAOP does not
Page 53
1
2
3
4
pose a safety risk to the distribution system. Therefore, PG&E has not implemented any additional
measures specifically applicable to the associated pipe. PWA concludes that this PG&E workaround
necessitated by the associated recordkeeping deficiencies is a clear violation of 49 CFR 192.619(c).
Page 54
1
2
7.
3
4
5
6
7
8
9
10
11
12
13
14
15
Since state and federal regulations were enacted, there have been requirements on natural gas
operators, both transmission and distribution, to keep some of their records for the life of the pipe.
PG&E has had procedures and standards to meet these requirements since before the enactment of the
federal standards in 1970.68 California has had public safety regulations for utilities since the early
1900s (the first edition of GO 58-A was effective on September 1, 1919). Industry has also had
standards such as ASA B31.1.8 which had recordkeeping requirements and provisions since at least
1955. The early safety regulations in California (i.e., CPUC GO 112 effective January 17, 1961)
required natural gas operators to comply with requirements in these industry standards. Thus PG&E
had procedures and standards in place to mandate that its underground facilities be properly mapped
and records of their testing, composition, and location be kept.69 These records are required to safely
operate a natural gas system. Therefore PG&E has violated federal safety regulations under 49 CFR
Part 192 and California regulations under GO 112 (A to E) and GO 58A [Section 3, effective
December 16, 1992] by failing to maintain such records and maps.
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Many of the early PG&E records retention procedures/standards were more geared to when records
needed to be purged70 than the identification and safe guarding of existing records. Additionally
records were being maintained and retained at various offices throughout the service territory and an
official copy was not centrally stored. Lose controls on records borrowing, some of which have yet to
be strengthened,71 and wide geographic diffusion of storage have caused many of the critical
retained for life records to be lost over time. Maps incorporating these critical records in as builts
including plastic inserts and the locations and characteristics of stubs were apparently not developed.
Hence field personnel, including those carrying out maintenance, leakage surveys, and those who
locate and mark underground facilities do not have accurate and complete maps of all company
underground facilities. Additional factors have exacerbated development of accurate maps, such as a
long lag time between when field personnel submitted updates to when they were mapped leading to
mapping backlog of months and not days, mapping updates were paper based and thus prone to being
lost, there was no formal quality control on map updates, and there was no verification that what was
mapped was actually installed.
30
31
32
33
34
35
36
37
38
Since 2010 PG&E has started several recordkeeping and mapping improvement initiatives. These
include the Pathfinder Program which involves moving plat maps to the GD GIS. The program
integrates maps and records of all of the currently known information on the gas distribution system.
As part of this project, records and information in prior databases are being analyzed and integrated
with all of the other information on the system. Where miss matches are identified, a report of the
discrepancy is generated to be evaluated by an engineer and corrected. Thus, assuming continued
attention, we anticipate that many of the inaccurate records will be corrected. PG&E has also instituted
a tracking and correcting mechanism whereby field reported discrepancies are reported to mapping and
resolved. Maps are now available on an electronic format, called the Pathfinder viewer, to all field
68
See responses to SED DR 001-Q02Supp 01 (Bates Nos. 00006818 to and including 00006864, from 1959 to
1969)
69
70
Paul Duller and Alison North, Records Management within the Gas Transmission Division of PG&E, March
5, 2012, page 6-33.
71
Page 55
1
2
crews with access to GD-GIS. Mapping is attempting to update changes from the field and to address
discrepancies in 30 days or less.72
3
4
5
6
7
8
Another positive technology addition is using the SAP framework to track all work on the gas system,
all discrepant information, investigating all allegations of false record keeping, and having all new data
systems linked and the data verified and integrated with older data known to be reliable. Because of the
size of the undertaking, PG&E has also increased its commitment to quality assurance, including
performing quality control checks on existing and new data being entered into the database and records
of the actual field conditions.
9
10
11
12
13
The Milpitas incident that cut off service to almost 1,000 customers was a direct result of ineffective
procedures and non-centralized controls. Subsequently PG&E has implemented a new gas distribution
control center, and implementing a new clearance control process where clearance decisions are made
and coordinated between field engineers and the control center in the light of more complete
information.
14
15
72
Prior to the addition of more resources in the mapping area and splitting the common electric and gas the
mapping department, the backlog was 130 days or more.
Page 56
8.
2
3
8.1
4
5
6
7
8
9
10
11
During July and August of 2015, SED conducted inspections in the San Jose and San Francisco
Divisions of PG&E. These inspections included determining whether pipe repairs completed in 2013
and 2014, such as using plastic inserts, are adequately represented on current maps. The table below
shows four recent instances of the forty-two inspected (over 9%) in which map corrections were either
not completed or were inaccurate. Of these the San Jose inspection examined 27 leak repaired by
insertion of a plastic pipes of which two (2) had documentation problems. The San Francisco
inspection examined 15 leak repaired by insertion of a plastic pipes of which two (2) had some
documentation problems.
12
13
City
Work Description
Date Work
Completed
Date GDGIS
Checked
Time
Delay
San
Francisco
12/19/13
~08/07/15
~588
days
05/29/13
~08/07/15
~788
days
10/04/13
~07/17/15
~643
days
07/15/14
~07/17/15
~362
days
San
Francisco
San Jose
San Jose
14
15
16
17
18
8.2
In its response to the OII, PG&E described at least twenty four system improvements, corrective
actions and backstop measures designed to accomplish four objectives:
19
To improve accuracy
20
21
To improve controls
22
Page 57
1
2
3
4
5
6
7
8
9
10
Among these activities, PG&E discusses the specific steps it has taken to improve its records and
actions it has implemented to compensate for inaccurate or incomplete records.73 To this end PG&E
states that it has taken steps to improve its records using management practices which include
maintaining accurate, traceable, verifiable, and complete asset information.74 Some of these
improvements are updating systems to provide more accessibility to existing records, another - the
Pathfinder Project - will consolidate multiple sources of gas distribution asset records, including
paper records, into one integrated GIS data model called GD GIS. To increase map consistency and
accuracy, PG&E performs a comparison of existing records within the new GIS system, thereby
seeking out discrepancies and through a tool called the problem/action report (PAR), resolving these
discrepancies. Since 2012, 25,000 discrepancies have been resolved.75
11
12
13
14
15
PG&E is also working to speed up the incorporation of capital work orders which change field assets
on gas distribution maps. They checked 61,000 open gas work orders and found that 18,000 had not
been updated on gas distribution maps.76 PG&E had reduced this back log to only several hundred by
the end of 2014. Currently PG&E has a target of mapping all capital jobs within 32 days of
completion, which it claims to have met in 2014 with a completion time of 29 days.77
16
17
18
PG&E asserts it is performing other processes to improve its gas distribution records such as
electronically importing leak repair information and comparing the data base with the customer bill
data with distribution maps.
19
20
21
22
23
24
25
26
PG&E recognizes that even if data is imported into a single data base quickly, if that data is incorrect,
the resulting data base will not be better. In their response, PG&E assert that a newly implemented
Quality Management group is charged with conducting quality reviews of many of the facets of the gas
distribution organization to ensure that new procedures and/or processes are being followed and do not
have any gaps. Since 2011, at the formation of this group, they have been reviewing as-built and gas
service record quality.78 In addition, PG&E executives are making use of the corporate Internal Audit
function (IA) to evaluate aspects of operation and changes to operation that have the potential for
difficulties.
27
28
29
30
31
32
33
34
35
36
37
Since the Carmel incident, PG&E has instituted a gas carrier pipe checklist to backstop the lack of
records for inserted plastic. To address several of the other incidents, PG&E has instituted a new
Damage Prevention Handbook incorporating the updated procedures and processes for locating gas
facilities. In the 2014 rate case PG&E requested, and received, funding for its centralized gas control
center comprising both gas distribution and gas transmission which also includes the gas dispatch
operations.79 PG&E has also implemented clearance procedure changes to reduce the likelihood that
maintenance or construction activities will affect gas flow to customers in its distribution system.
There are a number of other improvements that PG&E presents in its response to the order. In Table 9,
we have listed the PG&E improvements described in its response to the OII and, based on what we
have learned, made an initial appraisal of the likely effectiveness of each of these improvements. Our
evaluation of the likely effectiveness uses the following set of ratings:
73
74
75
76
77
78
79
Page 58
Evidence of Effectiveness
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
IP
MV
EI due to large backlog of
PAR reports to be
addressed
EI
II
Page 59
Evidence of Effectiveness
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
MV
EI
IP
PM
MV
Page 60
Evidence of Effectiveness
on those jobs where the sketch or asbuilt may be missing information. This
clock is currently reset when a job is
returned for better information.
(However, the time from job completion
to acceptance by mapping is also
tracked.) The current target of 30 days
to update maps is considered a best
practice. Another IA report (see Bates
No. GDR 000008364) states there
continue to be problems with map
update timeliness.
Updating pipeline records with leak
There still appears to be an issue with
repair records (A-Forms).
whether the nature of a leak repair
requires some type of map updating, or
just that the repair record needs to be
scanned into SAP and be available as a
job package. The A-form is initiated
when PG&E identifies a gas leak and
serves to document information about
the leak from identification through
recheck and or repair. Evidence from
recent SED inspections (see Section 6.1)
reveals repairs by insertion that were not
captured on maps.
Validated gas distribution asset data by We have not evaluated this programs
comparing distribution asset maps with effectiveness. This practice has been
meter locations in customer billing data. performed by other gas distribution
operators not just for checking maps but
for customer relations issues such as
billing, meter requirements, etc. PG&E
needs to check on the effectiveness of
this service/billing mis-match process.
A simple check might be to identify the
services being reported under the CAP
as not being mapped and found by leak
surveys, leak repairs, and other field
activities and inspections.
Efforts to improve map and record accessibility include:
Employees performing leak repair have Have not had the opportunity to evaluate
the effectiveness of this PG&E program.
been enabled to initiate A-Forms, take
pictures of completed work, document
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
IP
EI
MV
BP
II
IP
II
Page 61
Evidence of Effectiveness
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
BP
II
BP
EI
MV
See the incident in San Jose on 11/07/14 Described in Table 4 of this report.
Page 62
Evidence of Effectiveness
81
complaints are an additional source of
information on the sufficiency of L&M
staff.
We have not evaluated this aspect of
PG&Es program, or to determine how
often PG&E personnel actually stand by.
PG&E needs to develop a metric to
determine the effectiveness of this
activity, including whether sufficient
resources are being provided.
We have not evaluated this aspect of
PG&Es program. It is unclear how the
backlog of as built packages that had not
been previously updated due to potential
errors or lack of data and information is
being addressed, and how the associated
accuracy and data quality have been
addressed. Providing electronic
accessibility to field personnel is always
useful.
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
BP
MV
BP
II
IP in pipelines, although
standard practice in
nuclear plant operation
II The program appears
promising with the
number of CAP suggested
corrections increasing
yearly. It is too early to
tell how well the
corrective action process
will work.
MV
Email, PG&E Gas Line Locate, William Heinselman (excavator) to PG&E, August 4, 2015.
Page 63
Evidence of Effectiveness
82
83
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
IP
II
MV
BP
MV
Page 64
Evidence of Effectiveness
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
MV
II
IP
MV
Page 65
Evidence of Effectiveness
exception.
We have not evaluated this aspect of
PG&Es program.
We have not evaluated this aspect of
PG&Es program. PG&Es workforce
should not be experiencing an undue
number of damages to its gas lines. A
number of damages appear to be caused
by PG&E failure to hand dig to expose
its gas lines as required by its procedures
and damage prevention code.
Integration and control via the GDCC
represents a shift away from a monitorand-respond philosophy to a monitorand-prevent philosophy, with an
emphasis on predictive assessment and
proactive control. While this is laudable,
we have not evaluated whether and how
GDCC enables PG&E to respond to
emergency conditions in a timely
manner.
Additional centralized oversight should
add rigor and consistency to the
clearance process thereby helping to
prevent unsafe situations from
developing. PG&E has stated that this
new GDCC has allowed it to start
issuing clearances for work on the
distribution system, a practice that
should have been instituted well before a
central control became a reality.
Gas mapper manual and the mapper
apprenticeship program should help
improve map quality. However,
unmapped plastic inserts are still being
identified more than a year after
initiation of new programs.
We have not evaluated this aspect of
PG&Es program, nor have we
determined how often or consistently
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
BP
MV
MV
II
BP
MV
BP
MV
II
EI
IP
MV
II
Page 66
Evidence of Effectiveness
Judgment on Likely
Effectiveness (see
guidance preceding
the Table)
Page 67
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
While, as shown in Table 9, PG&E has undertaken a number of improvement initiatives, other
opportunities, as yet untapped, may offer opportunities to address factors contributing to recent
incidents that are as yet unexplored. It appears from a response to a DR84 that PG&E is
opportunistically seeking out unmapped plastic inserts and stubs. That is, when a discrepancy appears
between what is shown on maps and records and actual or apparent conditions in the field, the
corrective action program is used to record and initiate resolution of the discrepancy. Additionally,
when a maintenance crew comes across an area with suspected inserts, a newly designed and revised
checklist is being used to determine if the main has been inserted.85 The number of known inserted
services is currently over 300,00086 and at least 3.9 million feet of main have been inserted.87 While
the work around procedure for addressing suspected inserts not shown on maps, by using a special
device to tap steel mains without damaging the suspected plastic inserts is a very useful backstop
measure, PG&E should consider implementation of systematic programs to identify and correct
mapping imperfections. Such programs could focus on identifying plastic inserts and stubs in addition
to incorrect location and gas line attribute data at third party excavation sites, which have contributed
to recent incidents, and will likely continue to contribute until they have been identified, characterized
and mapped.
17
18
19
20
21
22
23
Other than promoting greater awareness and improved locate practices, PG&E does not appear to have
developed a work around for stubs that are not on the maps.88 This will likely mean that damage will
continue to occur during excavation near existing mains, such as water and sewer main work. Of the
corrective actions that PG&E has proposed to address this concern, the Damage Prevention
Handbook89 which provides guidance on hard to locate or find facilities is noteworthy. However, it
seems to assume that the locator knows that a stub is present and decides to apply the difficult to locate
procedure.
24
25
26
For hard to locate conditions or locates that identify apparent discrepancies with the map, PG&E has
provided its locating staff with job aid TP 5811P-103-JA0190 in addition to the normal procedure TP
5811P-103 both of which appear to have been issued in 2013 based on their copy write date.
27
28
29
30
31
32
Until very recently91 there was no corporate procedure for obtaining a gas clearance to work on gas
distribution main, this contributed to the OII incident that interrupted service to almost 1000 customers
due to a valve being in the closed instead of open position. It appears that no one was tasked to verify
the valve position, or to monitor pressure in the line to ensure flow to customers. We believe that this
sort of event should not happen again since clearances, involving the gas distribution control center,
are now required for main work.
33
34
Overall Observations on the Effectiveness of PG&E Corrective Actions and Backstop Measures Based on continuing problems and the short time many of these backstops and corrective actions have
84
85
See response to DR SED 004-Q76 and is included in Form 61-0604 Job Site Safety Analysis form, Bates No.
000018820.
86
87
88
89
90
91
Page 68
1
2
3
4
5
6
7
8
9
10
11
12
been in place, it is extremely difficult to determine the effectiveness or the possible unintended
consequences of these actions.
PG&E Management use of Internal Audits - PG&Es reliance on internal and external audits of its
programs, processes, and procedures is commendable. We were not, however, able to ascertain
whether the corrective actions that resulted from these audits were appropriate, timely and effective.
The corrective action forms were prepared and apparently closed out for many IA audits, but we did
not see evidence that internal audit performed a follow up to determine these qualities. Responsibility
for understanding the IA findings and following up on their implementation and effectiveness lies with
management. Ultimately, PG&Es Vice President of Gas Operations and/or CEO must assume
responsibility for follow through and assure that the high level vision translates into effective operation
on the ground.
8.3
Adequacy of Training
13
14
15
16
17
PWA has based its evaluation of the adequacy of training received by the PG&E staff that have an
impact on the completeness and accuracy of maps and records on interviews with six people in two
Divisions Central Coast and San Jose. These people were selected by PG&E as representative of
several key positions having records-related responsibilities. Table 10 below summarizes the
positions, responsibilities and training regimen which they must navigate to be qualified for their jobs.
18
19
Typical Responsibilities
Working
Foreman B,
General
Construction
Gas Crew
Foreman,
Division
Construction
Page 69
Position
Typical Responsibilities
Sr Distribution
Engineer
Gas Associate
Distribution
Engineer
Mapping
Principal
Trained in job functions, e.g., preclearance endorsements using webbased training (WBT)
On-job training (OJT)
Page 70
Position
Typical Responsibilities
Gas Compliance
Representative
Locate & Mark
1
2
3
4
Based on interview information it appears that training for the people we interviewed - which included
apprenticeships, OJT and qualification testing - was adequate. Additionally, if individuals have any
difficulty with their assignments, an expert is available to offer advice or assistance.
5
6
However, in response to DR SED 001 Q12 (see Attachment B), PG&E provided a recent internal audit
report92 in which it was noted:
7
8
9
10
11
12
We noted that the Utility hasn't designed its training program to ensure that all users
are identified and trained before they use the new systems and processes. Based on
our analysis of training records and leak repairs, approximately 700 users haven't
completed one or more of the training courses offered, and approximately 600 leak
repairs recorded after deployment showed that 212 of them (35 percent) were
recorded by users who haven't completed the related training.
13
8.4
14
In our experience a root cause analysis can be performed for many reasons, including:
15
16
a. Identifying a cause or contributing factor that, if corrected, will prevent future similar
accidents;
17
18
19
20
c. Identifying a set of contributing factors that inform both corrective actions and identification of
similar vulnerabilities (physical, operational, and cultural characteristics) for elimination or
change;
21
22
d. Evaluation of whether negligence contributed to the occurrence of or to adverse consequences such as economic loss, death or injury - from an event.
23
24
25
26
27
28
29
PG&E has a long-established root cause analysis program, including seeking outside expertise when
needed. Our concern here is twofold: (1) that PG&E failed to adequately identify and respond to the
causes of the incident at Mountain View, and (2) that a root cause analysis, such as that performed by
Exponent following the incident at Carmel (see Attachment F), whose scope focuses on the first of the
four reasons, potentially misses opportunities to identify important corrective actions. Additionally, a
root cause analysis focused on addressing the first three reasons cited above might also contribute
information of use in addressing the fourth reason (negligence related to liability). Thus, liability
92
PGE_GDR_000008321, Review of Leak Repairs and Rechecks Under Mariner Bundled Deployment,
Internal Auditing, January 30, 2015.
Page 71
1
2
concerns have the potential to seriously limit the value of a root cause investigation. Avoiding this
limitation seems critical to learning as much as possible from consequential events.
Page 72
9.
9.1
Conclusions
3
4
Based on the information we have been provided, we have concluded the following regarding PG&E
violations:
5
6
1. Using the current and historic regulations and the standard of care we have proposed in Attachment
D, we have identified numerous violations.
2. Our investigation has assembled evidence of safety code violations of four types:
8
9
10
11
12
13
a. Evidence from recent incidents gathered in support of this OII indicates that PG&E has
failed to follow written procedures to ensure operating maps and data are updated and
accurate. Not maintaining control and updating historical records of gas distribution mains
and service lines. Repeated failure to correct recordkeeping violations despite having
adequate knowledge for decades. 49 CFR 192.603(b), 192.605(a), 192.605(b)(3),
192.13(c), and PU Code Sections 451 and 961.
14
15
16
b. PG&E has failed to mark out and inspect its gas lines in the area of excavation after
receiving valid Underground Service Alert notification in accordance with California
Government Code 4216.3(a)(1), as well as 49 CFR 192.614(c)(5) and 192.614(c)(6).
17
18
19
20
21
22
23
c. PG&Es approach to establishing the MAOP for 243 hydraulically independent distribution
systems is in violation of the 1970 requirement 49 CFR 192.619(c) describing the bases on
which MAOP is to be established for so called grandfathered segments of its system.
This approach disregarded the regulatory process. It is probable that this violation resulted
because of the absence pressure records during the years 1965 through 1970, needed to
comply. Note that General Order 58A (effective 07/01/32) Sections 20(c) and 20(d)
required retention of pressure records for a period of two years.
24
25
26
27
As yet we have seen no evidence that PG&E reviewed its alternative approach to
establishing MAOP with the CPUC until 2014, well after the 1970 regulation and the 1998
instructions provided by the Pipeline and Hazardous Materials Safety Administration
(PHMSA)93 identifying the need for regulatory review of alternative approaches.
28
29
30
31
32
33
34
35
36
37
PG&Es handling of the incident at Mountain View (07/30/13), a clear precursor of the
incident at Carmel (03/03/14), supports the conclusion that PG&E has failed to comply with
these learning from experience regulations; until an incident is sufficiently high profile
that action must be taken.
38
39
Failure to carry out data gathering, to evaluate the causes and implications of incidents, and
to incorporate the lessons from these investigations into utility policies, procedures and
93
Page 73
1
2
3
4
5
Regarding the efforts by PG&E to correct and provide backstops for recognized imperfections in maps
and records and deficiencies in their maintenance, we have concluded, based on the information we
have been provided, the following:
6
7
8
1. PG&E maps and records have suffered from years of neglect, leading to a situation in which maps
are inaccurate and records are incomplete; the inaccuracy and incompleteness has contributed to
numerous incidents, some serious.
9
10
11
2. PG&E has recognized the need to improve its maps and records, has sought funding in the 2014
general rate case, and is proceeding (through the Pathfinder Project) to complete many needed
improvements to its maps and records.
12
13
14
15
16
17
18
3. Through the Pathfinder Project, PG&E is undertaking a major consolidation and quality
improvement effort of its maps and records in GD-GIS and SAP. While this effort will
significantly improve their quality and accessibility, PG&E has given no assurance that the
resulting maps and records will be completely accurate. Therefore measures will continue to be
needed both to backstop work procedures and to continuously improve and maintain the accuracy
of maps and records. PG&E has put many such measures in place, but vigilance will be required to
ensure their effectiveness.
19
20
21
22
23
4. Other than a corrective action program (CAP) to allow inconsistencies between maps and field
observations to be resolved and maps corrected, PG&E has not yet undertaken a systematic
program to identify and correct two of the major sources of incidents resulting from mapping errors
and gaps: unmarked or incorrectly marked stubs, and unmapped plastic inserts in steel mains and
services.
24
25
26
27
5. To address the fact that its maps and records will not be completely accurate, PG&E has instituted
numerous backstop measures to minimize the impact of map and records inaccuracies on public
and worker safety. Management vigilance will be required to assure the effectiveness of these
measures.
28
29
30
31
6. While PG&E has root cause analysis procedures and processes to identify and address root causes,
evidence from the Mountain View and Carmel incidents (which occurred seven months apart)
indicates that these procedures and practices have not addressed underlying issues on a time frame
consistent with their risk significance.
32
33
34
35
36
37
7. While the advertised time for incorporating changes from new construction and certain
maintenance activities (those classified as capital) in the maps and records is less than thirty days,
evidence exists from SED inspections carried out in July and August of 2015 that some updates
require much longer, potentially leading to a false sense of confidence in the accuracy of maps and
records residing in the GD-GIS - that have been processed in the Pathfinder Project. Recent
evidence also suggests a disconnect between quality expectations and results.
38
39
40
41
42
43
44
45
8. The improvements being undertaken by PG&E include basic changes to the way operations,
maintenance and construction activities are carried out. These changes, together with more
focused improvements on activities affecting incident frequency such as locate and mark practices,
all require changes in implementing procedures and related training. To develop these procedures,
PG&E has involved the performers of related activities, thereby increasing the likelihood that basic
content and implementation issues will be effectively addressed. However, the rate of introduction
of and change to these procedures imposed unprecedented training demands and has the potential
to cause confusion, indifference and to increase error rates.
Page 74
1
2
3
4
5
6
9. PG&E has implemented a system of internal audits based on identified management concerns and
the level of risk among other factors. In addition, it has implemented a quality management
program, including quality assurance and quality control involving periodic routine audits. Based
on our review of IA reports and follow-up action plans, we believe PG&E management is making
good use of these processes to monitor the impact, as well as potential unintended consequences of,
its improvement programs.
7
8
9
10
10. In our experience, successful navigation of the transition PG&E is undertaking will require
constancy of executive attention and visible behavior supporting the desired changes over a period
of at least a decade. This magnitude of sustained commitment has historically been difficult for
PG&E to achieve.
11
12
13
14
15
16
11. PG&E does not have a program to reduce and eventually eliminate unused service stubs. With all
18 divisions moved to the Pathfinder Program, a small known problem has escalated to a much
larger one with over 71,000 known stubs on the gas distribution system. Recent incidents have
highlighted that PG&E has problems not only with the accurate mapping of known service stubs
but also with unmapped stubs. This problem has grown over decades, and an aggressive removal
program may be necessary to stem the tide.
17
18
19
20
21
22
23
12. Weak safety culture has been an historic problem at PG&E. Inconsistent and destructive
management behaviors, underpinned by inappropriate safety values, have apparently contributed to
this state of affairs. Current management seems to recognize and to be equipped to address this
serious concern however PG&Es Vice President of Gas Operations and/or CEO must assume
responsibility for recordkeeping quality expectations and meeting pipeline safety compliance.
Strengthening the safety culture is a long-term job, requiring visible management-level attention
and demonstration of the behaviors characteristic of the values the organization wished to promote.
24
9.2
Recommendations
25
26
27
28
29
30
31
32
1. There are two map and records-related issues that PG&E has decided to address through
opportunistic approaches, that is, make map corrections as the need is identified through
normally scheduled work in the field. These issues are unmapped or incorrectly mapped stubs, and
plastic inserts that are not shown on GD-GIS maps. While PG&E has initiated practices to
minimize the risk associated with unmapped plastic inserts, identifying unmapped and incorrectly
mapped stubs is left to the skills of the L&M staff. PG&E should examine the costs and benefits
associated with undertaking a systematic identification and correction effort for these features,
relying on the experiences of other utilities in dealing with these issues.
33
34
35
36
2. Even stubs currently shown on maps have been a source of locate errors and resultant excavation
damage. While PG&E has a policy for addressing these mapped, but often inappropriately
characterized stubs, it should, again considering risk tradeoffs, reexamine the wisdom of more
aggressively eliminating existing stubs.
37
38
39
40
41
42
43
44
45
3. Documentation provided by PG&E has revealed that the utility has established the MAOP for 243
hydraulically independent distribution systems using an approach that deviates from that required
by the 1970 version of 49 CFR 192.619, and for which formal CPUC approval was neither sought
nor granted. These systems are part of a group of grandfathered systems for which the MAOP
was established using approaches other than pressure testing. Often older systems are part of a
long-term systematic replacement program. PG&E should reexamine the risk characteristics on
which priorities for replacement of these older systems are based to assure that the adequacy of
MAOP establishment is appropriately considered. PG&E should also evaluate whether the
alternative approach to establishing MAOP for these systems, for example by certification of the
Page 75
1
2
highest pressure attained during the required five year window, contributes to the risk represented
by these systems, and if so, propose measures to deal with this higher risk.
3
4
5
6
7
8
9
4. In our review we have observed that PG&E management uses the Internal Audit (IA) function as
an ingredient in its vigilance to evaluate aspects of new systems and programs about which it has
concern. In each case following an IA report, the responsible PG&E operating division develops
an action plan to address the IA findings. The CPUC should take advantage of these insights into
potential soft spots in the massive change effort being undertaken by PG&E to help focus its
inspections, perhaps on the adequacy of the action plan given the IA findings on the effectiveness
of implementation, and on the impact of corrective actions.
10
11
12
13
5. Several recent SED inspections included reviewed to determine whether plastic pipe inserted in
existing steel lines have been adequately mapped. This is a useful approach, and should be
extended to focus on the results of major maintenance activities undertaken subsequent to full
implementation of the new GD-GIS and its associated practices and procedures.
14
15
16
17
18
19
20
21
22
23
6. In our view, an effective root cause analysis program focused on incidents, on close calls, and on
repetitive violations of regulatory requirements is a critical part of strengthening PG&Es safety
culture. Clearly, the nature, scope and effectiveness of corrective actions resulting from identified
root cause analyses will communicate management commitment to strengthening safety culture to
the organization. Our belief is that the Exponent Report95 on the underlying causes of the incident
at Carmel missed the mark in demonstrating this commitment, principally by imposing an
excessively narrow definition of root cause If the removal of a contributing cause prevented
the occurrence of the problem, this cause was considered a root cause. PG&E should consider
reexamining both how it defines root cause and how it integrates corrective actions related to those
root causes into existing management practices. Objectives of a root cause analysis might include:
24
25
a. Identifying a cause or contributing factor that, if corrected, will prevent future similar
accidents;
26
27
28
29
c. Identifying a set of contributing factors that inform both corrective actions and
identification of similar vulnerabilities (physical, operational, and cultural
characteristics) for elimination or change.
30
95
Carmel Gas Incident, Exponent, Failure Analysis Associates, April 2014, Doc. no. 1401752.000 6877.
Page 76
ATTACHMENT A
QUALIFICATIONS OF PWA STAFF
Overview
Paul Wood, currently a principle in P Wood Associates, was a founder and partner in Cycla
Corporation which over the last 15 years has assisted the US Department of Transportation in writing
and evaluating pipeline safety regulations for gathering lines, gas distribution systems and gas
transmission systems. He has also previously done work for the CPUC in evaluating the PG&E 2014
GRC proposals.
John Gawronski a professional engineer with over 46 years of experience is expert in all matters
affecting public safety due to the operation of natural gas, petroleum, and steam pipeline systems. He
specializes in pipeline safety inspection processes, code compliance and enforcement policies for
inspections, and evaluating risks associated with gas distribution systems. For over 25 years, he was
the Chief of Gas & Petroleum Safety, for the New York Public Service Commission, addressing all
matters affecting public safety due to operation of the States natural gas, petroleum, and steam
pipeline systems. Prior to joining the Commission, John served at a forerunner of National Grid
(Brooklyn Union Gas Company) as a Field Engineer, Senior Engineer, and Section Manager. John
Gawronski has provided consulting service on gas and steam system issues for the last 12+ years for
various State and Federal clients.
David Berger has also been doing gas system and pipeline system consulting for 10+ years for various
federal and state clients including incident investigations and expert testimony. Prior to becoming a
consultant, he worked in gas operations for 15+ years in a forerunner of National Grid (KeySpan
Energy which was the combination of the gas operations of Brooklyn Union, Boston Gas and Long
Island Lighting).
Resumes for these three individuals follow.
Page 77
Paul J Wood
Summary
Employment
Mr. Wood has over 35 years experience in developing risk management and process safety programs
for industrial facilities ranging from nuclear power and fuel processing plants to pipeline facilities. He
has worked with regulators and operators to identify common goals as the basis for implementing
mutually agreeable approached to managing health and safety risk.
2015 Present
P Wood Associates
Executive Consultant
Naples, FL
1990 2014
Cycla Corporation
Alexandria, VA
Senior Partner
CoFounder of Cycla Corporation
A key manager for multiyear prime contracts with Department of Energy and Department of
Transportation
Education
19721973
Massachusetts Institute of Technology
ScD Nuclear Engineering
Cambridge, MA
19661968
Massachusetts Institute of Technology
S.M. Nuclear Engineering
S.M. Chemical Engineering
Cambridge, MA
19621966
Purdue University
B.S. Chemical Engineering
West Lafayette, IN
Page 78
DavidB.Berger,Principal
DavidBergerAssociates
AreasofSpecialization
Mr.Bergerspecializesinpipelineandsystemintegritymanagement,corrosioncontrol,gasinfrastructureasset
management,andgassystemoperationandsecurity.
RelevantExperience
Mr.Bergerhasbeeninvolvedinratemakingcasesforgasdistributioncompaniesformanyyearsfromboth
theoperatorandregulatoryperspective.MostrecentlyheadvisedtheMainePUConaratecaseforthe
largestgasdistributioncompanyinthestateandinparticularontheirproposedinfrastructurereplacement
program.Previouslyhehadperformedasafetyandmanagementauditonthiscompanyforthecommission
staffaspartofsettlementagreement.WhenMr.BergerwaswithKeySpanEnergy(nowpartofNationalGrid)
hewasinvolvedinseveralratecaseswithregardtogasmeteringandcorrosioncontrolissuesalongwith
infrastructureimprovements(systemintegrityakaDIMP).
Mr.BergerperformedtwomanagementauditsfortheNewYorkPSConthreegasdistributioncompanieson
theirrecentlyapprovedratecaseswithregardtosafetyprogramsandmainandservicecapitalreplacement
programs.Theseauditsincludedthestateslargestutilityandalsoamoreruralutility.
Mr.Bergerwasthetaskarealeaderfortheareasofcorrosioncontrolandemergencyplansinaninvestigation
ofoperationalsafetyfortheIllinoisCommerceCommission.TheauditreviewedandevaluatedanLDCsoverall
operationsandmaintenanceactivitiesanditsgassafetyprogramstodeterminethedegreetowhichtheyare
incompliancewithfederalandstateregulationsandconformanceofthoseactivitiesandprogramwith
industrybestpracticesandthebestpracticesdeterminedbytheICCStaffinconsultationwiththeLDC.
HeisconsultingfortheVermontPublicServiceDepartmentonevaluatingthesafety,constructionand
operatingissuesonproposedexpansionwhichrequiresacertificateofpublicgood.Thisexpansionwillinvolve
bothtransmissionanddistributionpipelinesandmains.
Hewasthetaskarealeaderforgasoperationsinaninvestigationofoperationalsafetyandmanagement
practicesofasmallgasoperatorfortheNewJerseyBoardofPublicUtilities.
Heprovidedexpertreviewandpossibletestimonyregardingasafetyissueonmechanicalcouplingsforthe
DistrictofColumbiaPublicServiceCommission.
Mr.BergerisundercontracttoUnitedStatesDepartmentofTransportation(DOT)PipelineandHazardous
MaterialsSafetyAdministration(PHMSA)toassistindevelopingandimplementingagasandliquidpipeline
integritymanagementprogramandtoassistininspectingoperatorsofpipelinesthroughCyclaCorporation.He
istheauthorandinstructoratPHMSAsTrainingandQualificationsSection(T&Q)ondirectassessment
trainingmodulesforExternalCorrosionDirectAssessment(ECDA)(includingacourseonECDAindirect
Page 79
inspectiontechniques)InternalCorrosionDirectAssessment(ICDA),StressCorrosionCrackingDirect
Assessment(SCCDA),andConfirmatoryDirectAssessment(CDA).Inaddition,heisaconsultanttoPHMSAon
integritymanagementnotifications,specialpermits(suchasalternateMAOPandclasslocationchanges)and
corrosioncontrolissuesforbothgasandliquidpipelines.
HeconsultswiththeWashingtonUtilitiesandTransportationCommissionforcorrosioncontrolandintegrity
issuesandprovidesexpertadviceregardingcommissioninvestigationsandconsentorderspertainingtogas
infrastructureissues.Heisatechnicalconsultantforariskmodelregardingdistributionintegrityissues.
Currentlyheisperformingavalidationauditontheimplementationofauditrecommendationsastheoutcome
ofconsentorder.
MostrecentlyMr.BergerhasbeenretainedbytheCaliforniaPUCtoassistinaninvestigationofanincidenton
atransmissionpipelineinNorthernCalifornia.Hehasassistedcommissionstaffwithpreparingrelevant
documentsandreviewedandcommentedondocumentsprovidebytheutility.
Mr.BergerisalsoundercontractasatechnicalexpertandpossibleexpertwitnessfortheUSDepartmentof
Justice.Heiscurrentlyworkingonacasethathasbeenproposedforlitigationinvolvingfatalitiesand
significantpropertylosses.
HeisworkingfortheFloridaDepartmentofTransportationasanexpertwitnessinalitigationconcerninga
rightofwayissuewithgaspipelinealongtheFloridaTurnpike.
UntilJuly2004,Mr.BergerwastheDivisionManager,AssetManagement,forKeySpanEnergy(nowpartof
NationalGrid).Inthiscapacity,hemanagedagroupofengineers,clerks,technicianassistants,supervisors,and
fieldlabortoassess,maintainandimprovetheassetsofthegasinfrastructure(bothdistributionand
transmissionfacilities)andthecathodicprotectionsystemsonallKeySpanEnergygasandelectricfacilities
(LongIsland,NewYorkCity,NewEngland).HewastheprocessownerofKeySpanEnergysgastransmission
systemanddirectedtheoverallcorrosioncontrolprogramsforallKeySpanEnergysassets(gas,electric,
electricgeneration).Manyoftheissuesheprovidedguidanceonrelatedtoimplementationofimprovements
inthegasdistributionassetsoneofwhichincludedworkonamechanicalcouplingissuerelatingtochangein
gasquality.Heprovidedguidancetocorporatesecurityongasoperationalsecurityissuesandimplemented
securityplansforthegasinfrastructureinallserviceareas.Hewasadeveloperofthedirectassessment
methodofdetermininggaspipelineintegrity.
InthepositionofsectionheadoftheEnvironmentalEngineeringDepartmentforKeySpan,Mr.Berger
managedagroupofengineersthatwasresponsibleforallofthehazardouswaste,industrialwasteand
petroleumstoragefacilitiesforthecompany.Henegotiatedpermitsandcompliancescheduleswithalllevels
ofregulatoryofficials(local,county,stateandfederal).Hepreparedandsubmittedallsuperfundandother
legalnotifications.Heprovidedsupporttooperatingorganizations,legaldepartment,andfuelmanagement
personnelforenvironmentalmatters.
PriortohisemploymentatKeySpan,Mr.BergerwastheDirectorofOperationsforRussellPlasticsTechnology
Inc.andaPlantManagerforICIAmericas,Inc.AerospaceandChemicalDivisions
Education
UniversityofDelaware,coursework(32+credits)forM.S.inEnvironmentalEngineering
NewYorkUniversity,B.Ch.E.(ChemicalEngineering)
OtherHonors,Societies,andPapers
Page 80
MemberA.I.Ch.E.
MemberNACE
AuthorandcoauthorofpapersinWPCF,AGA,NACE
AGACorrosionControlCommitteeChairperson2000to2004
AGADistributionEngineeroftheYear,2002
CIS,PCMandACVGCorrosionTools
AGAAchievementAwards,2003,2004
BassTrigonCorrosionControlDataBase
NumerouspapersinvariouspipelinetechnicaljournalsandNACEpublications
NewYorkStateRegentsScholarship(College)andIncentiveAward
Page 81
John E Gawronski
AreasofSpecialization
Mr.Gawronskispecializesinpipelinesystemintegritymanagement,leakmanagement,naturalgas
infrastructureassetmanagement,gassystemoperationandsecurity.
RelevantExperience
Mr.Gawronskihasbeeninvolvedinratemakingcasesinvolvinggasdistributioncompaniesformanyyears
fromtheregulatoryperspective.Priorto2004whenMr.GawronskiwaswiththeNewYorkStateDepartment
ofPublicService,hewasresponsibleforgassafetyoversightofthepublicandmunicipalgasdistribution
companiesoperatinggaspipelinesthroughouttheState.Inthatcapacityhehasreviewedtheengineering,
assetplanningandoperationsofallmajorNewYorkcombinationcompaniesandgasutilities,includingsenior
supervisoryresponsibilityforstaffinvestigationsofsignificantincidentsandaccidents,andotherunusual
events.HewasthesenioradvisortothePublicServiceCommissiononallmattersinvolvingpipelinesafety,
includingevaluatingratecaseproposals,operationsandmaintenanceactivitiesandvulnerableinfrastructure
replacementprogram,aswellaswellasthedevelopmentofkeypipelinesafetymetricsforutilityoperators.
HehasadvisedtheMainePUCaspartofasettlementagreementinperformingasafetyandmanagement
auditonthelargestgasdistributioncompanyinthestateprimarilyevaluatingrecords,leakmanagement
activitiesandinfrastructurereplacement.
HehasparticipatedinTransmissionIntegrityManagementPlanreviewsandinspectionswiththeUSDOTof
transmissionpipelineoperators,andhasassistedtheUSDOTindevelopingsecurityinspectionprotocols
regardinggasoperatorsinfrastructure.
Mr.Gawronskiwasthetaskarealeaderfortheareasofleakmanagement,managementandmaintenanceof
systemassetsincludingevaluationofvulnerableinfrastructurereplacementprograms,systemsupport,and
recordsinaninvestigationofoperationalsafetyfortheIllinoisCommerceCommission.Theauditreviewedand
evaluatedanLDCsoveralloperationsandmaintenanceactivitiesanditsgassafetyprogramstodeterminethe
degreetowhichtheyareincompliancewithfederalandstateregulationsandconformanceofthoseactivities
andprogramwithindustrybestpracticesandthebestpracticesdeterminedbytheICCStaffinconsultation
withtheLDC.
FortheDistrictofColumbiaOfficeofPeoplesCounsel,Mr.Gawronskiiscurrentlyparticipatinginagas
distributionoperatorsratecaseevaluatingproposedreplacementprogramsofbaresteel,unprotectedcoated
steel,castironmainsandvulnerableservicelinesandmechanicalcouplings.AlsofortheOfficeofPeoples
Counsel,hepreviouslyevaluatedthesafetyandmaintenancepracticesofthissamegasdistributionoperator
regardingvulnerablevintagesofmechanicalcouplingsresultinginthedevelopmentofamechanicalcoupling
replacementprogram.
InaratecaseproposalbyamajorConnecticutgasdistributionoperator,Mr.Gawronskiadvisedthe
ConnecticutOfficeofConsumerCounselinevaluatingtheutilitysleakratesandproposedcastironand
unprotectedsteelinfrastructurereplacementprograms.
Page 82
MostrecentlyinCaliforniaonbehalfoftheCityandCountyofSanFrancisco,Mr.Gawronskiwasthetask
leaderinevaluatinganddevelopingtestimonyonPacificGasandElectricsGasTransmissionPipeline
ModernizationandTestingProgram,hesubmittedtestimonyinproceedingsinvolvingPG&Estransmission
facilitiesrecords,andviolationsinconnectionwiththeSanBrunoexplosionandfireonSeptember9,2010.
PriortocomingtoworkfortheNewYorkStatePublicCommissionin1977,Mr.Gawronskiheldpositionswith
amajorgasutilityintheNewYorkCityarea.ThosepositionsincludedFieldEngineer,SeniorEngineer,and
SectionManager.AsSectionManagerhemanagedafieldsectionconsistingof170+employeesand
contractors.AsSeniorEngineerfordistributionoperations,providedoversightofthedesignofmajorpipeline
systems,ensuredupdatedmappingsystems,andinterfacedandcoordinatedactivitieswithpermitting
agencies.AsFieldEngineer,heprovidedoversightoftheconstructionofnewpipelines,aswellasthe
maintenanceandemergencyresponseandleakrepairactivitiesofcompanyandcontractorcrews.
Education
M.S. MechanicalEngineering,TheCityCollegeofNewYork(CUNY),1974
B.S.
MechanicalEngineering,TheCityCollegeofNewYork(CUNY),1969
OtherHonors
Mr.GawronskiservedasChairoftheUSDOTTechnicalPipelineSafetyStandardsCommittee.
Page 83
ATTACHMENT B
SUMMARY OF DRS AND STATUS OF RESPONSES
STATUS AS OF SEPTEMBER 28, 2015
The table below shows that PG&E has submitted one or more responses to all SED questions except
the three that were deleted by mutual agreement.
DR #
Date
Request
Submitted
PG&E Responses
to Date
Comment on
Response
March 4,
2015
March 4,
2015
March 4,
2015
March 4,
2015
March 4,
2015
SED-001-Q01;
SED-001-Q01 (Att
001 thru Att 086);
SED-001-Q01
Supp01;
SED-001-Q01
Supp02
SED-001-Q02; SED001-Q02 Att01 thru
Att10;
SED-001Q02Supp01;
SED-001-Q03;
SED-001-Q01Q03Atch001;
SED-001-Q01Q06Atch002;
SED-001-Q01Q05Atch003;
SED-001Q03Supp01;
SED-001-Q03Supp02
SED-001-Q04;
SED-001Q04Atch001 (PGEGDR-5922);
SED-001Q04Supp01;
SED-001-Q04Supp02
Resubmit (PGEGDR-6115)
SED-001-Q05;
SED-001Q05Atch001 (PGEGDR-5923);
SED-001-
Page 84
DR #
Date
Request
Submitted
March 4,
2015
March 4,
2015
March 4,
2015
March 4,
2015
10
March 4,
PG&E Responses
to Date
Comment on
Response
Q05Supp01; SED001-Q05Supp02
is PGE-GDR-6116
SED-001-Q06;
SED-001Q06Atch001 (PGEGDR-5924)
SED-001Q06Supp01; SED001-Q06Supp02;
SED-001Q06Atch002
SED-001-Q07; SED001-Q07Supp01
SED-001-Q06Supp01
is PGE-GDR-6117
See also PGE-GDR5924 and PGE-GDR15353
SED-001-Q08Supp02
includes PGE-GDR12399 thru PGE-GDR12466;
18 reportable in 2010
thru 2014;
7 reportable in 2004
thru 2009
See PGE-GDR-0061
thru 0091
SED-001-Q10; SED-
SED-001-
List is in PGE-GDR0060;
Page 85
DR #
Date
Request
Submitted
PG&E Responses
to Date
Comment on
Response
2015
001Q10Atch01CONF;
SED-001Q10Atch02CONF;
SED-001Q10Atch03CONF
thru Atch608
Q10Atch03CONF thru
Atch609 is an index of
the 608 Attachments
See PGE-GDR-0098
thru 4651
SED-001-Q11
352,479 inserted of
2,155,290 PE services
SED-001-Q12;
SED-001-Q12Supp01
SED-001-Q12Supp02
SED-001-Q12Supp03
SED-001-Q12Supp04
11
March 4,
2015
12
March 4,
2015
13
May 29,
2015
inspects applicant-installed
distribution facilities. Please
provide copies of all such policies
and procedures, including forms
used by PG&E to do final
inspection(s) prior to serving gas
to applicant- installed distribution
facilities.
In PG&Es Gas Distribution
System Annual Report for
Calendar Year 2013, PG&E
reports 2,155,290 Plastic PE
services. Please identify the
number of these PE services that
are inserted into an existing
conduit such as a deactivated steel
service line.
Provide each and every document
in your possession that references
PG&Es gas distribution recordkeeping problems. Include all
audit records regarding PG&Es
gas distribution recordkeeping,
and indicate the dates of such
audits, the personnel involved, and
any corrective actions taken.
SED-002-Q13
Page 86
DR #
Date
Request
Submitted
PG&E Responses
to Date
14
May 29,
2015
SED-002-Q14
15
May 29,
2015
SED-002-Q15
SED-002-Q15Supp01
SED-002-Q15Supp02
SED-002-Q15Supp03
SED-002-Q15Supp04
SED-002-Q15Supp05
SED-002-Q15Supp06
Comment on
Response
Page 87
DR #
Date
Request
Submitted
16
May 29,
2015
17
May 29,
2015
18
May 29,
2015
19
May 29,
2015
PG&E Responses
to Date
SED-002-Q16
SED-002-Q16Supp01
SED-002-Q16Supp02
Comment on
Response
38340;
PGE-GDR-38349 to
38938
Includes PGE-GDR8583 and a table
describing PGE-GDR
documents (by Bates
number) containing
various Departments;
Tables of documents
highlighting
organizations based on
the type of utility
supported;
On 07/13/15 Mr. Nick
Stavropoulos became
President Gas
Operations;
PGE-GDR-38348 &
38939
SED-002-Q17
SED-002-Q18
SED-002-Q18Supp01
SED-002-Q18Supp02
References document
in response to SED002-Q19 and Q20, as
well as SED-001-Q08
and Q12; also refer to
SED-002-Q19Supp01;
also refers to response
to SED-002Q19Supp02
SED-002-Q19
SED-002-Q19Supp01
SED-002-Q19Supp02
Referenced documents
in response to SED001-Q08 and Q12;
Additional CAP data
Page 88
DR #
Date
Request
Submitted
PG&E Responses
to Date
20
May 29,
2015
21
May 29,
2015
22
May 29,
2015
23
May 29,
2015
SED-002-Q20
SED-002-Q20Supp01
SED-002-Q20Supp02
Comment on
Response
base PGE-GDR-18302
thru 18466
Additional selfidentified noncompliances as PGEGDR-22739 to 22825
Excel of events & nearmisses (2004 thru
07/08/15) PGE-GDR23098 thru 23103 and
30022 thru 30027;
PGE-GDR-26163 thru
30021
Refers to response to
SED-002-Q19;
also refer to SED-002Q19Supp01; refers to
response to SED-002Q19Supp02
SED-002-Q21
SED-002-Q22
Response references
earlier submittals in
response to SED-001Q02 and Q02Supp01;
Lists Bates numbers of
specific procedures
Refers to response to
SED-002-Q22;
Also refers to response
to SED-001-Q09 or
SED-002-Q32 listing
Bates Stamp (GDR)
Numbers
SED-002-Q23
Page 89
DR #
Date
Request
Submitted
PG&E Responses
to Date
Comment on
Response
24
May 29,
2015
SED-002-Q24
25
May 29,
2015
26
May 29,
2015
27
May 29,
2015
SED-002-Q27
28
May 29,
2015
29
May 29,
2015
SED-002-Q29
SED-002-Q25
SED-002-Q25Supp01
SED-002-Q28; SED002-Q28Supp01
Page 90
DR #
Date
Request
Submitted
30
May 29,
2015
31
May 29,
2015
32
May 29,
2015
33
May 29,
2015
34
May 29,
2015
PG&E Responses
to Date
SED-002-Q30
Comment on
Response
I.14-11-008 and lists
ongoing initiatives;
Discussed how
effectiveness of
corrective measures is
evaluated : QA/QC;
Internal Audit; CAP
PGE references its
earlier response to
SED-001-Q01, Q03
thru Q06
SED-002-Q31
Response references
PGR response to OII
I.14-11-008 and to
SED-002-Q29
SED-002-Q32
Table summarizes
L&M and map
correction procedures,
including Bates
numbers
SED-002-Q33
PGE tabulates
procedures (PGEGDR) and references
its earlier response to
SED-001-Q01, Q03
thru Q06;
New documents to be
provided include: PGEGDR-8430 thru GDR8443 as well as PGEGDR-8467 thru GDR8582
Refers to pages in PGR
response to OII I.14-
SED-002-Q34
Page 91
DR #
Date
Request
Submitted
35
May 29,
2015
36
May 29,
2015
37
May 29,
2015
38
June 17,
2015
39
June 17,
2015
PG&E Responses
to Date
Comment on
Response
11-008 for description
of quality protocols
SED-002-Q35
Response references
PGR response to SED002-Q33
SED-002-Q36
SED-002-Q36Supp01
Good summary
narrative;
Expensed jobs (vs.
capital) require an
average of 30 days to
map.
SED-002-Q37; SED002-Q37Supp01
PG&E respectfully
objects; PGE described
recent acquisition in
response to SED-002Q28
Response references
PGR response to SED002-Q26; Rev 1
includes map correction
tracking process
description & forms
SED-003-Q39
SED-003-Q39Supp01
SED-003-Q39Supp02
SED-003-Q39Supp03
Page 92
DR #
Date
Request
Submitted
40
June 17,
2015
41
June 17,
2015
42
June 17,
2015
PG&E Responses
to Date
Comment on
Response
Response references
and reiterates PGR
response to SED-002Q10 and SED-003Q42; gas design
standards enumerated
and Bates numbers
provided; table
provided describing
forms to be used
Response references
earlier PGR responses
to SED-002-Q01, Q09
and Q10
Page 93
DR #
Date
Request
Submitted
43
June 17,
2015
44
June 17,
2015
45
June 17,
2015
46
June 17,
2015
PG&E Responses
to Date
completed. Who is
responsible for verifying that
all of these policies and
procedures are followed?
SED-003-Q43
Which organization is
charged with performing the
quality control function on
the dGIS system? Please
provide any and all reports
on the actual quality of the
data in the system.
SED-003-Q44
Since 2005 how many
SED-003-Q44Supp01
distribution leak surveys
were performed at an interval
greater than those listed in
TD-4110P-01 (and its
predecessor procedures)
Table 1? Please describe
each by location, number of
services, and length of main.
Comment on
Response
Response references
PGR response to SED003-Q53;
Two people involved in
map changes
implementer and
verifier
Initial submittal PGEGDR-18467 thru 18479
references earlier
submittal in response to
SED-001-Q12, SED002-Q19, and SED003-Q45;
Final pre-audit leak
surveys PGE-GDR24444 thru 2497;
Responsive internal
reviews PGE-GDR23592 thru 23607;
Responsive SED GO
112E Audits PGEGDR-23608 thru
24443;
Also see response to
SED-002-Q15Supp02
and to SED-003Q48Supp01
Self-reporting program
has been in place since
December 2011;
reports provided
See Bates Documents
PGE-GDR-17296 thru
17297 and PGE-GDR5925 thru 5930
Page 94
DR #
Date
Request
Submitted
47
June 17,
2015
48
June 17,
2015
49
June 17,
2015
50
June 17,
2015
51
June 17,
2015
PG&E Responses
to Date
SED-003-Q47
Please provide an
explanation on how PG&E
implemented TD-01 for its
gas distribution workforce.
Please provide the results of SED-003-Q48
SED-003-Q48Supp01
PG&E's quality control
activities to correct any
deficiencies in its gas
distribution records on: plat
maps, as built drawings,
repair records, leak repair
forms and gas service records
from 2005 to the present in
Divisions where 6 incidents
in OII are located.
SED-003-Q49
SED-003-Q51
SED-003-Q50
Comment on
Response
Distinguished between
QA and QC;
Lists records requested
by QC;
References as-Built
Drawing Handbook and
Training;
Internal quality
improvement reports
PGE-GDR-25265 thru
25309;
Refer to response in
SED-003-Q44Supp01
and SED-00Q15Supp02
References discussion
in testimony supporting
the 2014 GRC (PG&E3);
Testimony does not
state pathfinder is
focused on correcting
potential data and
records inaccuracies
References Internal
Audit Department 2015
audit of Pathfinder
implementation,
provided in response to
SED-001-Q12Supp01;
Problem Action
Resolution (PAR) is
not designed to find
and correct all data
anomalies
Page 95
DR #
Date
Request
Submitted
are missing.
Are there any additional
service stubs other than the
28,000 that PG&E has
recently migrated into GD
GIS?
PG&E Responses
to Date
Comment on
Response
SED-003-Q52
SED-003-Q52Supp01
Response references
PGR response to OII
I.14-11-008 and
provides additional
information; Following
deployment of GD-GIS
to all 18 Divisions, the
total stub service
inventory is 71,131
Measures provided as
PGE-GDR-17298 thru
17319; also see
response to SED-003Q43; results of 2013
internal audit provided
as PGE-GDR-17484
thru 17486; results of
PGE 2015 internal
audit were provided in
response to SED-001Q12Supp01 (see PGEGDR-8370 thru 8372)
PGE references
response to SED-001Q12 and SED-002-Q15
52
June 17,
2015
53
June 17,
2015
SED-003-Q53
Please describe how PG&E
is ensuring the data quality of Resubmit
the data sets being imported
into the new Pathfinder/ GD
GIS data bases.
54
June 17,
2015
55
June 17,
2015
56
June 17,
2015
SED-003-Q54
Please provide any and all
reports, audits (from both
internal and external sources)
on data quality in both legacy
and current gas distribution
databases and records since
2000.
Please provide a narrative on SED-003-Q55
how PG&E will correct its
database for work orders,
maintenance orders, and leak
repairs that were never
inputted and for which there
currently may not be a paper
trail.
Please provide the number of SED-003-Q56
records that have been
Refers to PG&E
response to SED-003Q48 and PG&E
Page 96
DR #
Date
Request
Submitted
57
June 17,
2015
58
June 17,
2015
59
June 17,
2015
60
June 17,
2015
61
June 17,
corrected by comparing A
Form data to data base
records. Also provide the
time frame from when this
process has been in effect.
Please provide a list of the
number of CAP submissions
by year since the program
started, the number
outstanding at each year end,
the average time it takes to
implement the requested
correction, what were the
monthly and yearly numbers
of CAP submissions PG&E
anticipated, and if PG&E
considers it a success.
PG&E Responses
to Date
Comment on
Response
response to OII
SED-003-Q57
SED-003-Q58
SED-003-Q61
Of 2,110 CAPs
submitted from Oct
2013 thru 06/18/15,
609 were outstanding
on 06/18/15;
Number of CAPs
submitted is
significantly
increasing;
Time to implement
corrective actions is
being reduced;
Inventory (as a
percentage of CAPs
submitted) is shrinking
PGE references
response to SED-002Q15Supp01
SED-003-Q59
SED-003-Q60
SED-003-Q60Supp01
Page 97
DR #
Date
Request
Submitted
2015
62
June 17,
2015
63
June 17,
2015
64
June 17,
2015
65
July 22,
2015
66
July 22,
2015
67
July 22,
2015
PG&E Responses
to Date
Comment on
Response
SED-003-Q63
PG&E offered no
opinion, no analysis to
evaluate
SED-003-Q64
Certification results
were provided as part
of PGE response to
SED-002-Q15Supp01
SED-004-Q65
Provided
SED-004-Q66
Provided, primarily in
response to SED-001Q10 and SED-003Q40; additional
procedures provided
SED-004-Q67
No longer utilized,
provided anyway;
CAP implemented in
March of 2013, prior to
the at OII referenced
Mountain View
Page 98
DR #
Date
Request
Submitted
68
July 22,
2015
69
July 22,
2015
70
July 22,
2015
71
July 22,
2015
72
July 22,
2015
73
July 22,
2015
74
July 22,
2015
PG&E Responses
to Date
SED-004-Q68
Comment on
Response
incident
The six OII incidents
preceded
implementation of the
GD-GIS
SED-004-Q69
SED-004-Q70
SED-004-Q71
SED-004-Q72
Good summary of
procedures provided in
response to earlier data
requests
General discussion, no
reference to valve
position verification in
procedures
SED-004-Q73
SED-004-Q74
Page 99
DR #
Date
Request
Submitted
75
July 22,
2015
76
July 22,
2015
77
PG&E Responses
to Date
SED-004-Q75
July 22,
2015
SED-004-Q77
78
July 22,
2015
SED-004-Q78
79
July 22,
2015
80
July 22,
2015
81
July 22,
2015
82
July 22,
2015
SED-004-Q76
Comment on
Response
has retained completed
work packages in SAP
for 8 years.
Lists previously
provided responses of
relevance
Summarizes careful
opportunistic approach;
no focused program
cited; Use of Gas
Carrier Pipe Checklist
Looking for new
technologies;
otherwise, uses
opportunistic approach
dependent on the nature
of activities
Provided procedure:
PGE-GDR-18480
SED-004-Q79
SED-004-Q80
References earlier
response to SED-004Q79
SED-004-Q81
References earlier
response to SED-004Q79
SED-004-Q82
References earlier
response to SED-004Q80
Page 100
DR #
Date
Request
Submitted
PG&E Responses
to Date
Comment on
Response
83
July 22,
2015
Deleted by agreement
with SED
84
July 22,
2015
85
July 22,
2015
86
July 22,
2015
SED-004-Q86
87
July 22,
2015
SED-004-Q87
Indirect response
Deleted by agreement
with SED
Deleted by agreement
with SED
Page 101
DR #
Date
Request
Submitted
PG&E Responses
to Date
Comment on
Response
was provided by
Raymond Thierry
in response to
Interrogatory under
Oath #17 My
understanding is
that, in 2008,
PG&E concluded
that the use of the
method described in
TD-4125S to
establish MAOP
does not pose a
safety risk to the
distribution
system.;
Formal response
reiterated that in
2008, PG&E
concluded that the
use of the method
described in TD4125S to establish
MAOP does not
pose a safety risk to
the distribution
system. Therefore,
PG&E has not
implemented any
additional measures
specifically
applicable to the
associated pipe.
88.
August 5
SED-004-Q88
Page 102
DR #
Date
Request
Submitted
89.
August 5
90.
August 5
91.
August 5
92.
August 5
93.
August 5
implemented as backstop
measures, as described in PG&Es
response to the OII.14-11-008, and
provide the results of the
performance measures since
implementation.
Based on the results of the
performance measures, please
describe how PG&E determines
whether each backstop measure is
effective or not. Are the new
processes and procedures
implemented to improve records
and the backstop measures
described in PG&Es response to
the OII.14-11-008 effective? Is the
rate of safety events decreasing?
Provide supporting documentation.
At the time of the Carmel incident
(03/03/14), had the Pathfinder
Project completed its update of the
GD-GIS in the area where the
incident occurred?
Please summarize PG&Es
measures to ensure maps and
records updates are accurate.
Based on PG&Es root cause
analysis of incidents as required by
49 CFR 192.617 and internal
audits, are there other potentially
high risk mapping and records
issues of which PG&E is aware in
addition to unmapped plastic
inserts, unmapped stubs and
incorrectly mapped services and
mains (e.g., absence on maps of
other utilities in the vicinity of gas
pipes)?
Please describe PG&Es efforts,
and provide a copy of reference
procedure(s), to address and/or
correct the map and or
recordkeeping deficiencies and
issues resulting from PG&Es
PG&E Responses
to Date
Comment on
Response
Q48, Q56, and Q57
SED-004-Q89
Response refers to
previously submitted
responses to SED-005Q88, SED-003-Q61,
SED-005-Q100; dig-ins
per 1, through June
2015000 tickets has
decreased from 2.8 to
2.2
SED-005-Q90
No
SED-005-Q91
Refers to previous
responses, including to
SED-002-Q29
Refers to previously
submitted responses
from Raymond Thierry
including the 20
highest risks; these
risks were described at
too high a level in
explicitly include
unmapped inserts and
stubs.
SED-005-Q92
SED-005-Q93
Refers to previously
provided material
including PG&Es
initial response to the
OII and subsequent
responses to SED-002-
Page 103
DR #
Date
Request
Submitted
94.
August 5
95.
August 5
96.
August 5
97.
August 5
98.
August 5
PG&E Responses
to Date
Comment on
Response
Q19 and Q20
SED-005-Q94
SED-005-Q95
Refers to previously
submitted response to
SED-004-Q70;
enumerates specific
actions and Bates
numbers in which these
actions have previously
been described. Other
than immediate followup actions, all of the
actions described were
undertaken following
the 03/03/14 incident at
Carmel.
Describes the process
and refers to previously
submitted responses to
SED-002-Q33 and
SED-003-Q48
SED-005-Q96
No additional safety
risks have been
identified. PG&E
seems satisfied with the
results of its evaluation
in 2008.
SED-005-Q97
Describes process,
references CAP risk
assessment tool
described in previous
response to Q33 (PGEGDR-8564 thru 8580)
SED-005-Q98
Refers to response to
SED-002-Q33, and
presents a table of CAP
Page 104
DR #
Date
Request
Submitted
99.
August 5
100.
August 5
101.
August 5
102.
August 5
103.
August 5
104.
August 5
105.
August 5
PG&E Responses
to Date
Comment on
Response
notifications
SED-005-Q99
SED-005-Q100
SED-005-Q101
SED-005-Q102
SED-005-Q103
Response may be in
PGE-GDR-31884 thru
31905
SED-005-Q104
SED-005-Q105
Page 105
DR #
Date
Request
Submitted
106.
August 5
107.
August 5
108.
August 5
109.
August 5
110.
August 5
PG&E Responses
to Date
Comment on
Response
SED-005-Q106
SED-005-Q107
SED-005-Q108
Refers to previous
response to SED-GDRQ87
SED-005-Q109
Refers to previous
response to SED-GDRQ87
SED-005-Q110
60 to 90 days, Provided
GOV-6102S as PGEGDR-31838 thru
Page 106
DR #
Date
Request
Submitted
completing its investigations of
incidents to determine contributing
factors and/or root cause?
What is PG&Es required
timeframe, and provide copy of
reference procedure(s), to
implement corrective or backstop
measures as a result of its review
and analysis of the contributing
and/or root cause(s) as described
in DR# 110?
Please list the type of maps and
records PG&E is including in its
backlog of maps to be updated and
the time required to complete
updates?
PG&E Responses
to Date
111.
August 5
112.
August 5
113.
August 5
SED-005-Q113
114.
August 5
SED-005-Q114
SED
Oral00201
July 20
OII DR SED
Oral002-Q01
SED
Oral00301
August 3
SED-005-Q111
SED-005-Q112
Comment on
Response
31845; Also provided
TD-4020P-02 as PGEGDR-31846 thru 31857
Refers to response to
SED-005-Q110 and
governing procedures
previously provided in
response to SED-002Q33
OII DR SED
Oral003-Q01
Page 107
DR #
Date
Request
Submitted
SED
Oral00302
August 3
SED
Oral00401
SED
Oral00402
August 5
SED
Oral00403
August 5
August 5
PG&E Responses
to Date
Comment on
Response
OII DR SED
Oral003-Q02
OII DR SED
Oral004-Q01
OII DR SED
Oral004-Q02
OII DR SED
Oral004-Q03
Page 108
Interrogatory No. 8. Please list the responsibilities of the Asset and Risk Management function as they relate to
managing and using maps and records.
Interrogatory No. 9. Please list the reasons for PG&Es mapping and records deficiencies that you have personal
knowledge regarding.
Interrogatory No. 10. Please list the measures taken by PG&E to ensure that the reasons for PG&Es mapping
and records deficiencies are being addressed to prevent recurrence.
Interrogatory No. 11. Please list PG&Es performance measures used to monitor the timeliness and effectiveness
of its mapping and records updating practices.
Interrogatory No. 12. When did you learn about the concerns expressed by PG&E field personnel and
contractors regarding unknown and/or unmapped inserted plastic mains and services prior to the 7/30/2013
Mountain View incident?
Interrogatory No. 13. Do you have personal knowledge of other incident(s) or near miss(es)/near-hit(s)
involving unknown and/or unmapped plastic inserts reported by PG&E personnel or its contractors after the
7/30/2013 Mountain View incidents, and before the 3/3/2014 Carmel incident?
Interrogatories Directed to Raymond Thierry, Director DIMP
Interrogatory No. 14. Please list the twenty most significant risks associated with operating the PG&E gas
distribution system.
Interrogatory No. 15. Please list the measures taken by PG&E to address the impact on risk resulting from the
acknowledged deficiencies in maps and records in complying with DIMP requirements, including those
requiring risk characterization and identification of measures to
address major contributors to risk.
Interrogatory No. 16. Provide evidence, if any, that PG&Es measures are working.
Interrogatory No. 17. What are the different risks associated with the distribution pipelines in which the
alternative approach to establishing MAOP (TD-4125S) was applied compared with parts of the system for
which the MAOP of grandfathered segments was established consistent with regulations?
Interrogatory No. 18. Please list the additional measures that PG&E has implemented to address the associated
pipe for which the MAOP has been established using the alternative method described in TD-4125S.
Interrogatory No. 19. When did you learn about the concerns expressed by PG&E field personnel and
contractors regarding unknown and/or unmapped inserted plastic mains and services prior to the 7/30/2013
Mountain View incident?
Interrogatory No. 20. Do you have personal knowledge of other incident(s) or near miss(es)/near-hit(s)
involving unknown and/or unmapped plastic inserts reported by PG&E personnel or its contractors after the
7/30/2013 Mountain View incidents, and before the 3/3/2014 Carmel incident?
Interrogatories Directed to Javid Khan, Senior Director Strategy & Process Excellence
Interrogatory No. 21. Please list the corrective actions that were implemented, along with implementation dates,
to address the underlying causes of the incident at Mountain View (07/30/13).
Interrogatory No. 22. Please list the provisions in the root cause analysis process, along with their
implementation dates, to expedite action to address newly identified significant risks?
Interrogatory No. 23. Please list the metrics that Financial and Resource Management uses to monitor and
evaluate improvements to gas recordkeeping and mapping at PG&E.
Interrogatory No. 24. When did you learn about the concerns expressed by PG&E field personnel and
contractors regarding unknown and/or unmapped inserted plastic mains and services prior to the 7/30/2013
Mountain View incident?
Page 109
Interrogatory No. 25. Do you have personal knowledge of other incident(s) or near miss(es)/near-hit(s)
involving unknown and/or unmapped plastic inserts reported by PG&E personnel or its contractors after the
7/30/2013 Mountain View incidents, and before the 3/3/2014 Carmel incident?
Page 110
ATTACHMENT C
Compilation Of Current Regulations Affecting Records And Maps
Provisions of California Law, the CPUC code, Commission general orders, applicable rules and
requirements in state or federal gas pipeline safety codes pertaining to pipeline safety
recordkeeping for PG&Es natural gas distribution system
The following General Orders, and gas pipeline safety code requirements are applicable to the
incidents addressed in the OII and those discovered by CPUC staff during their audits of PG&E actions
and activities as well as those identified by PG&E in their reports submitted to the CPUC.
California Law - California Public Utility Code (emphasis added by underlining)
Section 451 - Every public utility shall furnish and maintain such adequate, efficient, just, and
reasonable service, instrumentalities, equipment, and facilities, including telephone facilities, as
defined in Section 54.1 of the Civil Code, as are necessary to promote the safety, health,
comfort, and convenience of its patrons, employees, and the public.
Section 961 - (b) (1) Each gas corporation shall develop a plan for the safe and reliable
operation of its commission-regulated gas pipeline facility that implements the policy of
paragraph (3) of subdivision (b) of Section 963, subject to approval, modification, and adequate
funding by the commission.
(c) The plan developed, approved, and implemented pursuant to subdivision (b) shall be
consistent with federal pipeline safety statutes as set forth in Chapter 601 (commencing with
Section 60101) of Subtitle VIII of Title 49 of the United States Code and the regulations
adopted by the United States Department of Transportation pursuant to those statutes.
(d) The plan developed, approved, and implemented pursuant to subdivision (b) shall set forth
how the gas corporation will implement the policy established in paragraph (3) of subdivision
(b) of Section 963 and achieve each of the following:
(1) Identify and minimize hazards and systemic risks in order to minimize accidents,
explosions, fires, and dangerous conditions, and protect the public and the gas
corporation workforce.
(2) Identify the safety-related systems that will be deployed to minimize hazards,
including adequate documentation of the commission-regulated gas pipeline facility
history and capability. (emphasis added)
(9) Meet or exceed the minimum standards for safe design, construction, installation,
operation, and maintenance of gas transmission and distribution facilities prescribed by
regulations issued by the United States Department of Transportation in Part 192
(commencing with Section 192.1) of Title 49 of the Code of Federal Regulations.
(10) Ensure an adequately sized, qualified, and properly trained gas corporation
workforce to carry out the plan.
(e) The commission and gas corporation shall provide opportunities for meaningful, substantial,
and ongoing participation by the gas corporation workforce in the development and
implementation of the plan, with the objective of developing an industrywide culture of safety
Page 111
that will minimize accidents, explosions, fires, and dangerous conditions for the protection of
the public and the gas corporation workforce.
Section 963 - (b) The Legislature finds and declares all of the following:
(3) It is the policy of the state that the commission and each gas corporation place safety
of the public and gas corporation employees as the top priority. The commission shall
take all reasonable and appropriate actions necessary to carry out the safety priority
policy of this paragraph consistent with the principle of just and reasonable cost-based
rates.
Page 112
excavating or boring equipment may be used for the removal of any existing pavement if there
are no subsurface installations contained in the pavement
4216.6. (a) (1) Any operator or excavator who negligently violates this article is subject to a
civil penalty in an amount not to exceed ten thousand dollars ($10,000).
4216.6. (a) (2) Any operator or excavator who knowingly and willfully violates any of the
provisions of this article is subject to a civil penalty in an amount not to exceed fifty thousand
dollars ($50,000).
(c) If an operator of a subsurface installation has failed to comply with the provisions of
Section 4216.3, has failed to comply with paragraph (2) of subdivision (a) of Section
4216.2, or has failed to comply with subdivision (b) of Section 4216.4, the operator
shall be liable to the excavator who has complied with Sections 4216.2 and 4216.4 for
damages, costs, and expenses resulting from the operator's failure to comply with these
specified requirements to the extent the damages, costs, and expenses were proximately
caused by the operator's failure to comply.
Page 113
pressure is taken and the dates, together with such other information as the Commission may
from time to time direct and shall be filed and retained for a period of at least two calendar
years in the principal office of each district or division. In lieu of fifty percent (50%) of the
above required number of records from portable pressure recording devices at customer's
premises there may be substituted an equal number of twenty-four (24) hour records from
recording pressure devices permanently located at critical points on the distribution system.
d. On high pressure distribution systems, gas utilities shall maintain permanently located
pressure recording devices at critical points and shall preserve in the district or division offices
the data from these devices for a period of at least one (1) year.
General Order 112 effective Jan 17, 1961, Appendix A Rules Governing Design, Construction,
Testing, Maintenance and Operation of Utility Gas Transmission and Distribution Piping Systems
Sec. 102 Purpose: 102.1 The purpose of these rules is to establish minimum requirements for
the design, construction, quality of materials, location, testing, operation and maintenance of
facilities used in the transmission and distribution of gas, to safeguard life or limb, health,
property and public welfare and to provide that adequate service will be maintained by gas
utilities operating under the jurisdiction of the commission.
Sec. 104 Intent; 104.3 It is not intended that these rules be applied retroactively to existing
installations in so far as design, fabrication, installation, established operating pressure and
testing are concerned. It is intended, however, that the provisions of these rules shall be
applicable to the operation, maintenance, and up-rating of existing installations.
Sec. 107 Compliance with ASA Code; 107.1 Gas transmission and distribution facilities shall
be constructed and operated in compliance with the provisions of Section 8 of the American
Standard Code for pressure piping, known as the American Standard Code for Gas
Transmission and Distribution Piping Systems, ASA B 31.8-1958, and in compliance with the
further requirements of the additional rules herein prescribed.
Several Sections: Section 845.43, Section 847.13 and Section 852.3 of ASA B 31.8-1958 are
herewith amended in their entirety to conform with General Order 58-A of the Commission.
Section 212 for Maximum Allowable Operating Pressures for Low Pressure Distribution
systems, stated that section 845.43 of ASA B 31.8-1958 is amended entirely to conform to
General Order 58A.
Page 114
Sec. 301 General: 301.1 The responsibility for the maintenance of necessary records to
establish that compliance with these rules has been accomplished rests with the utility. Such
records shall be available for inspection at all times by the commission or the commission staff.
Sec. 302 Specifications: 302.1 Specifications for material and equipment, installation, testing
and fabrication shall be maintained by the utility.
Sec. 303 Operating and Maintenance Procedures: 303.1 Plans covering operating and
maintenance procedures, including maximum actual operating procedures to which the line is
intended to be subjected, shall be maintained by the utility.
303.2 No pipeline shall be operated in excess of the maximum operating pressure recorded by
the company in accordance with this section.
These requirements were imposed initially in California by CPUC General Order 112 imposed by Decision
S1269, effective January 17, 1961.
97
49 CFR Part 192 minimum requirements for the transportation of natural gas by pipeline were published in
the Federal Register (35 FR 13257) August 19, 1970; effective date November 12, 1970.
Page 115
192.605(b)(8) Periodically reviewing the work done by operator personnel to determine the
effectiveness, and adequacy of the procedures used in normal operation and maintenance and
modifying the procedures when deficiencies are found.
192.613(a) Each operator shall have a procedure for continuing surveillance of its facilities to
determine and take appropriate action concerning changes in class location, failures, leakage history,
corrosion, substantial changes in cathodic protection requirements, and other unusual operating and
maintenance conditions.
192.613(b) If a segment of pipeline is determined to be in unsatisfactory condition but no immediate
hazard exists, the operator shall initiate a program to recondition or phase out the segment involved, or,
if the segment cannot be reconditioned or phased out, reduce the maximum allowable operating
pressure in accordance with 192.619 (a) and (b).
192.614(c)(4) - If the operator has buried pipelines in the area of excavation activity, provide for
actual notification of persons who give notice of their intent to excavate of the type of temporary
marking to be provided and how to identify the markings.
192.614 Damage prevention program
(c) The damage prevention program required by paragraph (a) of this section must, at a minimum:
(5) Provide for temporary marking of buried pipelines in the area of excavation activity before, as far
as practical, the activity begins.
(6) Provide as follows for inspection of pipelines that an operator has reason to believe could be
damaged by excavation activities:
(i) The inspection must be done as frequently as necessary during and after the activities to verify the
integrity of the pipeline; and
(ii) In the case of blasting, any inspection must include leakage surveys.
192.615 (a)(3) Prompt and effective response to a notice of each type of emergency, including the
following:
(i) Gas detected inside or near a building.
(7) Making safe any actual or potential hazard to life or property.
192.617 - Each operator shall establish procedures for analyzing accidents and failures, including the
selection of samples of the failed facility or equipment for laboratory examination, where appropriate,
for the purpose of determining the causes of the failure and minimizing the possibility of a recurrence.
192.619 - (a) No person may operate a segment of steel or plastic pipeline at a pressure that exceeds a
maximum allowable operating pressure determined under paragraph (c) or (d) of this section, or the
lowest of the following:
(1) The design pressure of the weakest element in the segment, determined in accordance with
subparts C and D of this part. However, for steel pipe in pipelines being converted under
Page 116
192.14 or uprated under subpart K of this part, if any variable necessary to determine the
design pressure under the design formula (192.105) is unknown, one of the following
pressures is to be used as design pressure:
(i) Eighty percent of the first test pressure that produces yield under section N5 of
Appendix N of ASME B31.8 (incorporated by reference, see 192.7), reduced by the
appropriate factor in paragraph (a)(2)(ii) of this section; or
(ii) If the pipe is 1234 inches (324 mm) or less in outside diameter and is not tested to
yield under this paragraph, 200 psia. (1379 kPa)
(2) The pressure obtained by dividing the pressure to which the segment was tested after
construction as follows:
(i) For plastic pipe in all locations, the test pressure is divided by a factor of 1.5.
(ii) For steel pipe operated at 100 psia. (689 kPa) gage or more, the test pressure is
divided by a factor determined in accordance with the following table:
Class
location
Factors, segment
Installed before (Nov. 12,
1970)
Converted under
192.14
1.1
1.1
1.25
1.25
1.25
1.25
1.4
1.5
1.5
1.4
1.5
1.5
(3) The highest actual operating pressure to which the segment was subjected during the 5
years preceding the applicable date in the second column. This pressure restriction applies
unless the segment was tested according to the requirements in paragraph (a)(2) of this section
after the applicable date in the third column or the segment was uprated according to the
requirements in subpart K of this part:
192.619 - (c) 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
192.621 - (a) No person may operate a segment of a high pressure distribution system at a pressure
that exceeds the lowest of the following pressures, as applicable:
(1) The design pressure of the weakest element in the segment, determined in accordance with
subparts C and D of this part.
(3) 25 psia. (172 kPa) gage in segments of cast iron pipe in which there are unreinforced bell
and spigot joints.
Page 117
(4) The pressure limits to which a joint could be subjected without the possibility of its parting.
(5) The pressure determined by the operator to be the maximum safe pressure after considering
the history of the segment, particularly known corrosion and the actual operating pressures.
192.1007 What are the required elements of an integrity management plan? (DIMP)
A written integrity management plan must contain procedures for developing and implementing the
following elements:
(a) Knowledge. An operator must demonstrate an understanding of its gas distribution system
developed from reasonably available information.
(1) Identify the characteristics of the pipeline's design and operations and the
environmental factors that are necessary to assess the applicable threats and risks to its
gas distribution pipeline.
(2) Consider the information gained from past design, operations, and maintenance.
(3) Identify additional information needed and provide a plan for gaining that
information over time through normal activities conducted on the pipeline (for example,
design, construction, operations or maintenance activities).
(4) Develop and implement a process by which the IM program will be reviewed
periodically and refined and improved as needed.
(b) Identify threats. The operator must consider the following categories of threats to each gas
distribution pipeline: corrosion, natural forces, excavation damage, other outside force damage,
material or welds, equipment failure, incorrect operations, and other concerns that could
threaten the integrity of its pipeline. An operator must consider reasonably available
information to identify existing and potential threats. Sources of data may include, but are not
limited to, incident and leak history, corrosion control records, continuing surveillance records,
patrolling records, maintenance history, and excavation damage experience.
Page 118
ATTACHMENT D
Standard of Care for Pipeline Maps and Records
Page 119
Demonstrate compliance with generally accepted consensus standards such as ASA B31.1.8,
ASME B31.8, and eventually Part 192 requirements as well as guidance provided by the AGA
for transmission and distribution of gas by pipeline.
Understand the basis for design and selection of materials, fittings (valves, drips, couplings and
joining techniques), repair methods, methods to connect service lines, pressure control district
regulators, construction techniques, corrosion controls, functional and strength testing, and
leakage history.
Readily locate buried gas lines during normal operations, maintenance and emergencies,
including information needed to locate lines that may exist in non-paved areas; and the location
of equipment for shutting down and isolating sections of a main.
Documentation would have to include designs, constraints on operating conditions such as pressures,
documentation of testing of new or modified lines, charts to ensure operating pressures were not higher
98
Page 120
than MAOPs, material specifications, construction standards, joining techniques, operating history
data, (locations and numbers and the nature of repairs, leaks, corrosion records), inspections, operating
practices and procedures and emergency response plans.
Process to Compensate for the Acknowledged Imperfections in Maps and Records
Regulations, predating DIMP, that relate to the appropriate standard of care include:
Page 121
As implied by these pipeline safety regulations, a prudent operator would focus on:
a. Developing a base of information (maps and records) that incorporates the best and most
complete information available to the operator, and that is accessible to those whose work
responsibilities require that information be they employees, contractors, or others working in
and around the pipelines;
b. Identifying on an ongoing basis the imperfections (gaps, errors and inconsistencies) in available
information, and assuring that these imperfections, as well as their implications to safe
operation and maintenance practice, are recognized, and their significance understood by those
relying on the maps and records to safely conduct their work responsibilities; correct
imperfections as necessary;
c. Taking advantage of every possible opportunity to confirm the accuracy of and as necessary to
correct the information base;
d. Scrutinizing all available sources of information (e.g., reportable incidents, internally identified
close calls, internal and external audit findings) for evidence of errors and gaps in the
information base, and acting to correct the information and, as appropriate, to institute backstop
measures (to ensure the safety of those relying on the maps and records to safely conduct their
work responsibilities) when correction of the information base may be too long considering the
risk of the data errors or gaps;
e. Assuring that backstop measures are implemented on a time frame consistent with the risk
associated with or safety significance of the information imperfections being addressed;
f. Verifying implementation and effectiveness of backstop measures employed as stopgaps while
an accurate and complete information base is being developed;
g. Verifying both the timeliness and the accuracy of changes to the maps and records resulting
from new construction, maintenance and information from point (c) above.
Figure D-1 illustrated these process principles as they apply to distribution system maps and records.
Observables
The attainment of perfect maps and records is a worthy goal. An operator is required to ensure the
safety, health, comfort, and convenience of its patrons, employees, and the public.99 This is
demonstrated by three observables:
1. The absence of impactful events evidenced by its operation;
2. Rigorous application of root cause analysis to understand and support correction of contributors to
impactful events; and
3. Ongoing operation in which zero defects are evidenced in its maintenance of maps and records.
99
Page 122
Figure D-1
D Pruden
nt Management of Pip
peline Map
ps and Reccords
Correct Deficiencies in
Records & Procedures by
b
Addressing
g the
Underlying
g Causes of
Identified Deficiencies
D
for all Reco
ords, Maps &
Procedures Affected by
these Deficciencies
If Records Deficiencies
D
are too Exten
nsive for
Quick Correection:
o - Develo
op &
Implemeent Correctivee
Action Program
P
(Prioritizzed),
o - Identify
fy
Compen
nsatory
Measurees
(Backsto
ops),
o - Train Personnel
P
andd
Implemeent
m Recordkeeeping
Investigatiion of PG&E Distributtion System
Evaluate Opeerational
Experience ((e.g., leak
causes, inciddent causes,
inspection reesults,
necessary coorrosion
control practtices, pipe
exposure repports, audit
reports) for E
Evidence of
Inadequate R
Records &
Recordkeeping
Procedures
Monitor Corrrective
Action Progrram
Implementattion
Monitor Effeectiveness of
Compensatorry Measures
(Backstops); Modify as
Needed
Make effectiive use of
Performancee Measures in
Monitoring
Paage 123
ATTACHMENT E
Examples of Factors Contributing to Records and Mapping Issues
The six incidents cited in the OII are not the only sources that have revealed records or mapping issues
but rather are a representative set of examples. Table E-1 in this Attachment contains additional
examples of records or mapping issues, including: unmapped plastic inserts, unmapped stubs,
unmapped test stations, valve positions mapped incorrectly, maps that have removed abandoned mains.
The SED investigated each of the six incidents in the OII, but in many of these additional examples
there was no investigation because the incident did not meet the incident reporting criteria.100 We have
gathered the limited information on the additional example incidents from PG&Es CAP program.
These additional examples show that the incidents cited in the OII are not just isolated occurrences.
Plastic Inserts - PG&E has been routinely inserting plastic into steel and cast iron mains and service
lines for several decades. It appears that the records for these insertions have neither been consistently
created nor maps consistently updated and maintained. This appears to be the case not only for the
early insertions but also for ones that occurred at later dates.101 Thus the number and the extent of
inaccurate maps and records related to plastic inserts cannot be determined. PG&E uses its CAP
program to communicate and correct errors associated with plastic inserts as they are discovered.
Stubs - A second major issue identified in the six OII examples involves service line stubs created
from services that have been taken out service or never placed in service. Although there is a program
to reevaluate the necessity of keeping the record of the stub active, it appears that the program has not
been consistently followed and there are many stubs102 throughout the distribution system whose
records need to be evaluated for accuracy to prevent further incidents. The additional examples in
Table E-1 show that there are issues not only with inaccurate records of where the stub was cut-off, but
that some stubs shown on the maps are not in the location where they are shown, or they have
potentially been cut-off at the main and thus no longer exist. Inaccurately mapped stubs are an issue
when other infrastructure work requiring excavation is performed since service line stubs may cross
the street from the gas main to the property line for those properties that previously had gas service.
Valve Location - A third issue addressed by the six OII examples is valve locations and position. In the
OII example in Milpitas, a valve listed as normally open was actually closed and when the feed from
the opposite direction was closed to perform a tie in, approximately 1000 customers lost gas service.
Similarly, in the additional examples provided, while PG&E was working on a regulator station on
October 10, 2014 a valve listed as part of the Napa area Transmission system was closed but it actually
was a distribution valve and approximately 250 customers lost gas service.
100
The SED staff investigates incidents where there is a loss of life, an injury, a financial loss of more than
$50,000, or that media is on the scene. Other incidents that are considered important even if they do not meet
any of these criteria can also be investigated.
101
102
See PG&E response to SED 003-052 where PG&E has identified the number of stubs to be over 71,000 in
GD GIS based on records from 18 divisions. This record may not be accurate as PG&E field crews are finding
that some of the stubs may not exist.
Page 124
Test Station Location - Test stations where tracer wires can be accessed are an important tool to
accurately locate and mark underground gas facilities. Accordingly, it is important to have the location
of all ETS stations accurately reflected on maps and records. When L&M crews are forced to rely on
signals from stations located a long distance from the area being marked, the strength of the signal
from gas lines is drastically reduced. This loss of signal strength may also result from the signal
jumping onto other facilities. Thus it is important to utilize the closest ETS to the line being located.
Additionally, when ETS stations are a long distances from excavation locations, and the risk of
obtaining inaccurate signals is great, L&M crews are still not taking advantage of existing gas line
locations shown on readily accessible maps. Using such map information can at a minimum, be a red
flag to the L&M crew that signals obtained from remote ETS stations may not be accurate,
necessitating further coordination with the excavator to avoid excavation damage to gas lines.
Abandoned Mains - Another area of concern is that abandoned mains are removed from system maps
and in some situations they are located close to live mains. This situation has resulted from a PG&E
policy103 to delete these mains, with some discretion at the Division level as to whether or not to follow
through. Thus, when third party excavators, and sometime PG&E crews, uncover an unmarked
abandoned line, they may mistakenly believe that it is the live line, and may not exercise the needed
care in continuing excavation.
In summary, there are numerous records and mapping issues with the PG&E distribution system. Until
they have been corrected, damage from excavation will continue to occur.
Table E-1 Additional Incidents Derived from PG&E Responses to Data Requests
Date (Issue)
Reference
Description
Location
04/18/13
San Jose
01/20/15
(stub issue)
06/19/06
(valve issue)
SED 2013041802
SED 2015012001
SED 2006061901
Pittsburg
10/17/14
SED 003-Q38
(stub issue)
SED 003-Q52
(stub issue)
SED 001-Q12
Supp01, Bates
7710
103
San Jose
System wide
System wide
System wide
PG&E Standard Practice 410.21-1, Mapping Standards, effective 04/01/77, Section II.3.
Page 125
Date (Issue)
Reference
Description
Location
05/01/80
(stub issue)
(plastic
inserts)
(abandoned
main)
2014
(stub issue)
Filed with
CPUC staff
System wide
SED 002-Q19
Attach, CAP
7003107 Bates
18316
SED 001-Q12
Sup03, Bates
30353
SED 001-Q12
Sup03, Bates
30358
SED 001-Q12
Sup03, Bates
30404
SED 001-Q12
Sup03, Bates
30410
SED 001-Q12
Sup03, Bates
30453
SED 001-Q12
Sup03, Bates
30466
Santa Rosa
Antioch
Danville
Churchills-Green
Hills?
SED 001-Q12
Sup03, Bates
30495
SED 001-Q12
Sup03, Bates
30499
2014
2014
2015
(stub issue)
2014
2014
(stub issue)
(valve issue)
2014
10/08/14
(plastic
inserts)
10/10/14
(valve issue)
SED 001-Q12
Sup03, Bates
30503
No location given
Hollister
Napa
Page 126
Date (Issue)
Reference
Description
Location
11/14
SED 001-Q12
Sup03, Bates
30522 et.al
Menlo Park
(stub issue)
SED 001-Q12
Sup03, Bates
30530
SED 001-Q12
Sup03, Bates
30566
Mission Division,
no town given
2014 (plastic
inserts)
2014
(stub issue)
SED 001-Q12
Sup03, Bates
30600 to 30607
2015
SED 001-Q12
Sup03, Bates
30672
2015 (ETS
Box)
2015
05/28/15 (stub
issue)
SED 001-Q12
Sup03, Bates
30703 to 30714
SED 001-Q12
Sup03, Bates
30782
SED 001-Q12
Sup03, Bates
30833
SED 001-Q12
Sup03, Bates
30891
Chico
Multiple
Divisions
San Francisco
System wide
Sacramento
Division no town
given
San Jose
Santa Rosa
Page 127
ATTACHMENT F
Observations on Root Cause Analysis
Observations on the Exponent Root Cause Analysis
In our experience a root cause analysis can be performed for many reasons, including:
e. Identifying a cause or contributing factor that, if corrected, will prevent future similar
accidents;
f. Identifying lessons that may promote the achievement of better consequences;
g. Identifying a set of contributing factors that inform both corrective actions and identification of
similar vulnerabilities (physical, operational, and cultural characteristics) for elimination or
change;
h. Evaluation of whether negligence contributed to the occurrence of or to adverse consequences such as economic loss, death or injury - from an event.
The approach taken by Exponent in its analysis of the root cause of the incident at Camel104 (03/03/14 see discussion below) determined root cause by:
Root cause analysis: The root cause analysis was performed based on eliminating a
contributing cause and re-assessing the event timeline. If the removal of a contributing cause
prevented the occurrence of the problem, this cause was considered a root cause.
While this is certainly a valid approach for defining root cause, and in the analysis of the Carmel
incident helped define measures of great value in preventing future similar events, it inherently limits
the ability of the organization for which the analysis is performed to achieve the objectives noted in
point (c) above. For example, tracing the root cause back to a point in time, or to a particular
maintenance crew, or to a group of mappers that might have been dealing with an unmanageable
backlog at the time of the error, would add information of use in an organizations efforts to focus on
identifying other possible insertion mapping errors.
Our concern here is that a root cause analysis whose scope includes addressing the first three reasons
cited above might also contribute information of use in addressing the fourth reason (negligence
related to liability). Thus, liability concerns have the potential to seriously limit the value of a root
cause investigation. Avoiding this limitation seems critical to learning as much as possible from
consequential events.
104
Carmel Gas Incident, Exponent, Failure Analysis Associates, April 2014, Doc. no. 1401752.000 6877.
Page 128
Page 129
management causes that failed to prevent the incident. The root cause analysis was performed in the
following steps:
o Identification of initiating events from the timeline, as described above.
o Causal analysis: This step included the causal analysis for each of the identified initiating
events. The causal analysis results in identifying the cause of each initiating event. These are
identified as
o Root cause analysis: The root cause analysis was performed based on eliminating a
contributing cause and re-assessing the event timeline. If the removal of a contributing cause
prevented the occurrence of the problem, this cause was considered a root cause.
o Validation of the root cause: After completion of the root cause analysis, validation was
provided by review with key participants.
The outcome of this effort was the identification of a single root cause. This information formed the
basis for developing recommended corrective actions.
The problem statement developed for performing this root cause analysis is:
On March 3, 2014, while tapping into an existing 2" steel line, gas was released, entered a
residence and ignited causing an explosion.
A Causal Analysis Diagram, located in Appendix F, considers the two aforementioned initiating
events in the problem statement with the resulting root cause being:
Inadequate verification of system status and configuration when performing work on a live line.
Page 130
ATTACHMENT G
Page 131
Sumeet Singh
Vice President
Asset and Risk Management
Gas Operations
April 4, 2014
Replaced the damaged pipe, conducted a leak survey of the area (no additional leaks were detected), and
restored gas service.
Updated the distribution plat map to reflect the completed replacement work.
Conducted an extensive search into existing records and construction drawings in an effort to determine
why the inserted plastic gas service was not shown on the distribution plat map or the job installation
drawing. PG&E was not able to locate the records for the plastic insert job, which PG&E believes
occurred prior to 1980.
Reduced the average amount of time that it takes to update our mapping systems with the details of post
construction as-built jobs from 75 days to 34 days in 2013.
Implemented a Corrective Action Program across Gas Operations so that every employee has the ability
and is continuously encouraged to submit any issues from a personal safety related observation to any
differences they identify between the information on our maps and records to what is in the ground. Each
item is assigned an owner, prioritized, and tracked through completion.
As you are aware, on March 3, 2014 we had an explosion related to distribution work in Carmel. While the
specific circumstances of the Mountain View and Carmel incidents do not precisely match, we believe the
following additional steps instituted following the Carmel incident will also address the Mountain View
incident:
Distribution and training of a 5 Minute Meeting on March 24, 2014 to field personnel throughout
PG&Es system that enhances tapping procedures incorporating process safety principles. This introduces
new measures to be taken to identify whether or not steel pipe has been inserted. This guidance, which
includes a checklist to be followed for each job, walks employees through three successive steps, each
adding another level of confidence regarding possible insertions before work begins. These steps are: 1)
review associated documentation, looking specifically for indications that documents match; 2) look at the
job site to read the street, checking that facilities match documentation; and 3) perform a physical
verification for plastic or to utilize existing fittings to determine if a previous insertion exists.
Developing and implementing a field QA/QC plan to verify that the steps outlined in the March 24 5
Minute Meeting are being uniformly applied by field personnel. These quality verification activities are
also expected to identify further safety enhancements.
Approval of the use of a bolt-on steel tap fitting. Work Procedure TD-4150P-110 -Continental Steel to PE
Mechanical Bolt-On Saddle Punch Tee, published on March 24, 2014, provides field personnel detailed
procedures about how to use a bolt-on saddle punch tee as a further validation step that steel pipe has not
been previously inserted, as required. This is a technique that can be used to fulfill the physical verification
noted in the 5 Minute Meeting if other fittings are not available.
Continuing implementation of the Pathfinder Project to convert critical distribution asset data from an
existing Computer Aided Design (CAD)-based system and paper to an integrated SAP and Global
Information System (GIS). Deployment of the Pathfinder Project is continuing throughout PG&Es
operating divisions, with complete system-wide deployment planned in 2015.
Instituting an R&D project with other industry operators to develop non-destructive testing methods that
can be used to confirm inserted pipe prior to commencing work.
We would welcome the opportunity to meet with you and your team to further discuss our preventive action
plans. In the interim, should you have any questions please do not hesitate to contact ChristiAne Mason at
(925) 328-5795or C6MW@pge.com.
Sincerely,
/S/
Sumeet Singh
Vice President, Asset and Risk Management
cc: