CHAPTER 3

PROJECT DESCRIPTION

3.4 CONSTRUCTION PROCEDURES

The construction of the Praxair hydrogen and natural gas pipelines involves the use of three
different construction methods: conventional pipeline trenching, jack and bore, and HDD. Each
construction method is described below.

3.4.1 Conventional Pipeline Trenching

Conventional pipeline trenching (open cut trenching) would be used within roads, along railroad
rights-of-way, and on public and private property. Construction activities associated with
trenching include staking, fencing and gates, clearing, grading, trenching, stringing, bending,
lineup, welding, radiographic inspection, coating, pipeline lowering, trench backfilling,
hydrostatic testing, and cleanup. Each of these activities is discussed in more detail below.

STAKING
The pipeline alignment would be staked with reference to the trench centerline. Station numbers
would be marked on one set of stakes, and existing pipelines or buried cables would be located
and staked to avoid damage during the trenching.

All survey markers (monuments, witness corners, reference monuments, and bearing trees)
within the right-of-way would be protected against disturbance during construction, operation,
maintenance, and rehabilitation. If any survey markers are destroyed or damaged during
construction, operation, or maintenance, registered land survey services would be secured to
restore the disturbed monuments, corners, or accessories, at the same location, using surveying
procedures found in the Manual of Surveying Instruction (Bureau of Land Management 1973).

FENCING AND GATES

Temporary gaps would be installed in all fences that cross the right-of-way. These gaps would
not exceed 100 feet in length. Pressure-treated fenceposts would be used for braceposts when
installing the temporary gaps and for lineposts when installing permanent fence. If metal T-posts
are in the original fence, then metal T-posts would be used to rebuild the fence. To prevent slack
in the fence, ordinary fence wires would not be cut before being secured to sturdy H-type braces
placed on each side of the gap.

Gates and gaps would be kept securely closed at all times except during passage of construction
workers and equipment. Necessary precautions would be taken to prevent the escape of livestock
from pastures, corrals, or pens while fences are lowered or gates and gaps are opened. After
construction is completed, permanent gates may be installed in fences where gaps have been cut
and gates have been approved by the landowners. Materials used for repairs would match the
original fence as nearly as practicable in gauge, mesh, style, and appearance and would equal or
exceed the original size and strength.

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CONTRA COSTA PIPELINE PROJECT DRAFT EIR • MAY 2009

CLEARING
The pipeline construction corridor would typically be 75 feet wide. A narrower corridor would
be used in streets, areas with topographic constraints, and also to avoid environmental resources
such as trees and wetlands. The upper approximately 6 inches of topsoil and vegetation would be
stripped as required along the right-of-way. The topsoil would be separated from the subsoil
removed from the trench, so the topsoil could be used for restoration of the pipeline right-of-way
after construction is completed. Figure 3-3, Construction Easement Detail, shows a typical 75-
foot-wide construction corridor configuration with the topsoil and vegetation or brush set to the
side. The vegetation removed from the pipeline right-of-way would be stockpiled along the edge
of the working side of the right-of-way and disposed of off site as determined by the applicable
regulatory agencies, landowners, and in accordance with applicable regulations.

GRADING
Grading of the pipeline right-of-way is necessary to provide a level area on which the equipment
can operate. In areas where the pipeline must traverse steep side slopes (generally greater than
10 percent), benching or “two-toning” may be required. Benching would grade a level path for
the pipeline and for equipment to operate. A bank would be leveled on the higher side and
material deposited on the lower side in a terrace type manner. After installation of the pipe, the
graded areas would be returned as nearly as possible to their original contours. No areas would
be routinely graded where only vehicular construction traffic would occur and could occur
without grade.

TRENCHING
The pipeline trench would be excavated according to the approved plans. The trench would
typically be approximately 5 feet deep and approximately 4 feet wide. The depth of cover for the
pipeline would be a minimum of 4 feet. In the UPRR and BNSF rights-of-way, the trench would
be approximately 6 feet deep because both railroads require a minimum 5-foot cover. Where a
pipeline trench crosses drainage, the pipeline would be buried at a minimum depth of
approximately 5 feet at the low spot, resulting in approximately 4 feet of cover.

In Segment 2, where both a natural gas pipeline and hydrogen pipeline would be constructed, the
trench would be approximately 5 feet wide to accommodate both pipelines. The pipelines would
be located approximately 1 foot apart from one another.

3-28 3.0 Project Description_May2009 Draft.doc

 Source: Praxair 2007

E N T R I X E N V I R O N M E N T A L I M P A C T R E P O R T
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E n v i r on m e n t a l a n d N a t u r a l R e s ou r c e M a n a g e m e n t C on s u l t a n t s
Contra Costa Pipeline Project
CONSTRUCTION
EASEMENT DETAIL
FIGURE 3-3
 CHAPTER 3
PROJECT DESCRIPTION

Known pipelines, telephone cables, and other underground structures would be located prior to
trenching. All necessary precautions would be taken to protect the structures from damage by
construction work. Praxair would use the Underground Services Alert (USA) System to identify
other existing underground structures. The owners of all underground structures would be
notified by the USA System in writing and again by telephone prior to excavating near their
facilities. Underground structures would be crossed by ditching under them unless the owner
would allow the natural gas and/or hydrogen pipeline to be installed over them. The trench
would be hand-dug in areas in close proximity to existing pipelines. A minimum clearance of
1 foot would be maintained, where feasible, between such lines or structures and the line being
laid, unless otherwise required. Where this clearance is not feasible, special procedures would be
followed to protect existing structures. Pipe and/or pipe coating damaged by the construction
work would be repaired. Special care would be taken to protect other pipelines and coatings in
the vicinity of the new pipeline construction.

As described in Section 3.4.8, Construction Safety, Praxair would follow the requirements of
California Senate Bill (SB) 1359 (Chapter 651, Statutes of 2006) to identify and delineate high-
priority subsurface installations prior to construction activities occurring near these installations.

The construction contractor would excavate the trench along staked lines established by Praxair.
The end of the trench would be sloped to enable animals that inadvertently enter the trench to
escape. For construction on EBRPD property, trench plates would be placed over the open trench
at night. The finished trench would be free of rocks, hard clods, stumps, roots, or other debris
that may injure the coating when the pipe is lowered into the ditch. A licensed professional
arborist, approved by Contra Costa County, would cut and seal all tree roots flush with the
sidewall and bottom of the ditch to prevent contact with the pipe. The bottom of the trench would
be graded and dressed so that the pipe would have substantially continuous and uniform bearing
or supports, such as sandbags (or equivalent). In open grassland areas, a trenching machine may
be utilized. In areas near creeks and on roads, a backhoe would generally be used.

To minimize the number of bends required to lay the pipe, the construction contractor would cut
the trench slightly deeper at the crest of ridges and gradually cut the trench deeper in approaches
to areas such as road crossings, terraces, and water courses. At such locations, the trenching
machine would be operated at various depths rather than grading the ditch by other means.
Where overbends or sidebends are required, the trench would be excavated to provide proper
clearance between the inside bend of the pipe and the bottom or side of the trench. Soil removed
from the trench would be used to backfill the trench once the pipeline has been installed.

Any water that requires removal and disposal during trenching would be tested to determine if it
is contaminated. If the water is nonhazardous, it could be used for dust suppression along the
right-of-way and/or irrigation with land owner and appropriate regulatory approvals.

STRINGING, BENDING, LINEUP, WELDING, AND RADIOGRAPHIC INSPECTION

Pipe would be transported to the rights-of-way by truck, laid on wooden skids, and strung
alongside the trench. A portable bending machine would be used to bend the pipe to fit the

3.0 Project Description_May2009 Draft.doc 3-31

CONTRA COSTA PIPELINE PROJECT DRAFT EIR • MAY 2009

contours of the trench. For sharper angles, pipe bends would be prefabricated. Following bending
and lineup, pipe would be welded in accordance with approved specifications and procedures for
the particular material and service involved. The welding procedure would meet applicable
American Petroleum Institute (API) Standards. All welders would be qualified and welds
inspected in accordance with API 1104. A radiographic inspection of 100 percent of all pipeline
butt welds, tie-ins, and isolation block valves would be performed by an independent qualified
radiographic contractor.

EXTERNAL COATING
Pipe would be delivered to Project staging areas with the external coating applied. Field
application of external coatings would be required only on those pipes improperly coated,
damaged during transportation or construction, or left bare for welding. Field-applied coating
materials would match or equal the original coating. All coatings would be checked for defects
prior to lowering the pipe into the trench.

LOWERING OF THE PIPE

No pipe would be lowered into the trench until it is free from loose rocks, hard clods, roots, or
debris, which could damage the coating. Necessary flexibility in the pipeline is obtained by
lowering sections into the trench while sections are held above the ditch on skids.

BACKFILLING
After the pipe is properly positioned within the trench, excavated material that has the
appropriate geotechnical characteristics would be placed into the trench. If the excavated
material does not have the appropriate characteristics, then imported fill material would be used
to augment it. First, the subsoil would be backfilled and compacted by rolling with one tread of a
tractor or by other suitable means. Colored pipeline warning tape would be placed in the trench
approximately 12 inches above the pipeline. After all subsoil is placed and compacted and the
pipeline warning tape installed, the remainder of the ditch would be filled with topsoil. All
topsoil would be spread in an even layer over areas where topsoil was removed. The
right-of-way disturbance would be left rough, where practical, to assist rehabilitation.

Backfill operations would be performed within a reasonable time of the lowering-in operation to
ensure the trench is not left open for more than 24 hours, or 36 hours in special cases. For
roadway and railroad construction the trench would be covered with metal plate(s) at the end of
construction each day. For construction on EBRPD property, fencing would be placed around the
open trench at night. In all construction areas, the end of the strung pipe would be capped to
prevent animals from crawling in. The end of the trench would be sloped to enable animals that
may inadvertently enter the trench to escape.

HYDROSTATIC TESTING
After the pipeline has been backfilled, the line would be tested in accordance with ASME B31.8
(Chapter IV, Design, Installation and Testing) to establish the integrity and strength of the
pipeline. In accordance with 49 CFR Part 192.919 – 192.921, Praxair would use a hydrotest to

3-32 3.0 Project Description_May2009 Draft.doc

 CHAPTER 3
PROJECT DESCRIPTION

establish the baseline assessment for the pipelines. In hydrostatic testing, the hydrogen pipeline
and Segments 3 and 5 of the route, which would use Chevron Line #2, would be filled with
water, sealed, and pressurized at 1,050 psig (1.5 times the maximum allowable operating
pressure of 700 psig). This test provides physical proof that the pipeline would safely operate at
the anticipated lower operating pressure of 350 psig. For the hydrotest of the gas pipeline, it
would be filled with water, sealed, and pressurized at 2,160 psig (1.5 times the maximum
allowable operating pressure of 1,440). The estimated operating pressure of the gas pipeline is
expected to be 800 psig.

East Bay Municipal Utility District (EBMUD) would provide water to Praxair for hydrostatic
testing. Praxair would draw water from city and/or county fire hydrants. The estimated volumes
of water used, by segment, for hydrostatic testing are proposed in Table 3-2:

Table 3-2: Water Volumes Used for Hydrostatic Testing

Segment Gallons
1 None
2 130,000*
3 60,000
4 53,000
5 136,000
6 290,000
7 43,200
8 15,000.
Total 727,200
* The water for hydrotesting the pipelines in Segment 2 would be used for both
the hydrogen pipeline and the gas pipeline.

EBMUD would set the draw points and place water meters for the construction contractor’s use
along the pipeline route. The construction contractor would give EBMUD the estimated daily
water consumption rate for the area of current construction activity and acquire the water from
the location closest to the ongoing work area.

The construction contractor may elect to move water from one segment to another, thereby
decreasing the overall water volume used in the test. During the hydrotest activity, the
construction contractor would place holding tanks at the hydrotest fill site, fill the tanks with
water, and prepare to test the section and perform the hydrotest. Once the entire pipeline has
been successfully hydrotested, the test water would be pushed from the pipeline into the holding
tanks. The test water would be sampled and analyzed for contaminants. Depending on the results
of the analysis, the test water would either be disposed off site in a properly regulated facility or
treated on site by being pumped into an on-site portable infiltration system consisting of two
10,000-pound tanks, an integrated lead-lag pipe rack with backwash capability, and a work
platform all mounted on a compact skid (BakerCorp 10K Specialty Media System). The system
is designed to remove contaminants from water to nondetectable levels. Following treatment in
the Baker system the water would be used for dust suppression or would be discharged into an

3.0 Project Description_May2009 Draft.doc 3-33

CONTRA COSTA PIPELINE PROJECT DRAFT EIR • MAY 2009

existing storm drain, per agency approval and specifications. This process would be repeated for
each segment of the pipeline requiring hydrostatic testing. Temporary approval for test water use
and permits for discharge would be obtained as required.

CLEANUP
After construction of the pipelines is completed, the right-of-way would be restored by removing
any construction debris, grading to the original grade and contour, and revegetating and repairing
where required. Restoration of temporarily disturbed areas would begin as soon as possible after
the topsoil is replaced over the new pipeline segments and when laydown areas are
reconditioned. Seed drilling would be the preferred method of reseeding on flat ground. On
slopes and other areas inaccessible to seed drilling, a seed mix would be broadcast and then
covered by weed-free straw. The straw would be crimped into the ground to a depth of 2 inches
using a crimping disc or similar device. Alternatively, instead of crimping, a tackifier may be
applied using hydroseed equipment.

3.4.2 Jack and Bore

The jack and bore construction method would be used to make moderately short crossings under
roads, railroad tracks, and drainages. Bore pits would be dug on each side of the crossing. On
one side, a boring machine with an auger would be used to dig under the crossing and install the
pipe. (See Figure 3-4, Typical Jack and Bore Detail.) At most jack and bore crossings, the
dimensions of the bore pits would be approximately 25 to 40 feet long by 10 feet wide by
approximately 5 to 8 feet deep. At Pinole Creek, the bore would be approximately 140 feet long
at a minimum depth of 5 feet below the creekbed (Praxair 2009a). At Alhambra Creek, the bore
would be approximately 215 feet long at a minimum depth of 5 feet below the creekbed (Praxair
2009b). It is unlikely that drilling fluids would be used with jack and bore construction; however,
if it would be necessary to do so, the Drilling Monitoring and Emergency Response Plan
discussed in Section 3.4.3, Horizontal Directional Drilling, would apply.

Once the pipe is installed, the pits would be backfilled with the soil that was removed. Any soil
unsuitable for use would be disposed of pursuant to applicable laws and regulations. The jack
and bore areas would be cleaned and restored as described in Section 3.4.1, Conventional
Pipeline Trenching.

3.4.3 Horizontal Directional Drilling

The HDD construction method would be used for large crossings and where the jack and bore
construction method is not appropriate. HDD involves the drilling of a pilot hole beneath the area
to be crossed, followed by a pilot hole drill string. A reaming device is attached to the drill string
and pulled through the pilot hole. The reaming device enlarges the diameter of the pilot hole.
Drilling mud, consisting of bentonite, would be used to lubricate and cool the drill. Bentonite is
an inert, nontoxic, natural material. The pipe is then welded, radiographed, hydrotested, and
pulled through the enlarged hole (see Figure 3-5, Typical Horizontal Directional Drilling Detail).

3-34 3.0 Project Description_May2009 Draft.doc

 Source: Praxair 2007

E N T R I X E N V I R O N M E N T A L I M P A C T R E P O R T
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E n v i r on m e n t a l a n d N a t u r a l R e s ou r c e M a n a g e m e n t C on s u l t a n t s
Contra Costa Pipeline Project
TYPICAL JACK
AND BORE DETAIL
FIGURE 3-4
 Source: Praxair 2007

E N T R I X E N V I R O N M E N T A L I M P A C T R E P O R T
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E n v i r on m e n t a l a n d N a t u r a l R e s ou r c e M a n a g e m e n t C on s u l t a n t s
Contra Costa Pipeline Project
TY P I C A L H O R IZ O N TA L
D I R EC TI O N A L D R I L L I N G D ETA I L
FIGURE 3-5
 CHAPTER 3
PROJECT DESCRIPTION

To conduct HDD, an approximately 100-foot-square drill pad is needed on each end of the
crossing. A drilling mud collection pit would be dug within the 100-foot-square area. Upon
completion of the HDD, the drilling mud would be removed, and the drill pad area would be
cleaned and restored as described in Section 3.4.1, Conventional Pipeline Trenching.

As part of the HDD activities, a Drilling Monitoring and Emergency Response Plan would be
developed to address the inadvertent return of drilling mud (most often referred to as a “frac-
out”) through fissures in the soil structure. The main components of the plan are:

 Stop drilling when return of drilling mud slows/ceases or a spill is observed by the driller or
biological monitor.
 Contain the spill (often with silt fencing/hay bales).
 Pump drilling mud from the containment area to a drill rig or frac truck.
 Do not resume drilling until containment is completed. (On EBRPD property, HDD drilling
would not resume until approved by EBRPD’s construction inspector or designate.)

The contingency plan is discussed in more detail in Section 4.4, Biological Resources.

Once the pipe is installed, the pits would be backfilled with the soil that was removed. Any soil
unsuitable for use would be disposed of pursuant to applicable laws and regulations. The HDD
pit areas would be cleaned and restored as described in Section 3.4.1, Conventional Pipeline
Trenching.

3.4.4 Avoidance and Minimization Measures during Construction

The following protective measures would be implemented to protect sensitive species found
during preconstruction surveys and construction monitoring activities:

 Provide Worker Environmental Awareness Training to instruct construction personnel in

identifying sensitive biological resources and the measures required to minimize Project
impacts and protect species in habitats adjacent to the alignment and work areas during
construction activities.
 Provide on-site monitoring by a Qualified Biological Monitor familiar with the species in the
Project area. The monitor would implement and/or oversee protection and mitigation
measures developed for the construction activities near sensitive habitats (wetlands, creeks,
marshes, stock ponds, trees, and nesting areas).
 Avoid sensitive habitats and species during construction by retaining the existing boundary
fenceline, developing construction exclusion zones, and fencing around sensitive areas as
needed.
 Conduct additional preconstruction surveys for sensitive species in potential impact areas
during the winter and spring before construction grading begins, particularly within areas that

3.0 Project Description_May2009 Draft.doc 3-39

CONTRA COSTA PIPELINE PROJECT DRAFT EIR • MAY 2009

have nesting substrate (trees, shrubs, and tall vegetation). Surveys would focus on ground
nesters such as killdeer, burrowing owl, northern harrier, and others.
 Restore all areas that are not required for permanent easements and development to
preconstruction conditions, including topography, hydrology, topsoil, and, if appropriate,
revegetation designed to control erosion. Final restoration requirements would be determined
by the property owners.

The majority of the pipeline would be constructed by the conventional open cut trenching
method. This method requires an approximately 4-foot-wide, 5-foot-deep trench. Because many
wildlife species are attracted to confined spaces such as covered trenches, trenches would be
covered at night only in areas where potential exists for human access to the site. All trenches
that are not covered at night would have appropriate egress (sloped trench walls) to allow
trapped wildlife to escape. Trenches would be inspected by a Qualified Biological Monitor prior
to the start of each day’s activities. If an animal is in the trench and cannot escape, the biological
monitor would be called for guidance and/or to relocate the animal.

3.4.5 Right-of-Way Access

Existing public and dirt roads would provide access along the construction right-of-way. Specific
access routes to the pipeline right-of-way have been determined for construction along private
property, including railroad tracks, and on public property (such as property owned by the
EBRPD). The right-of-way access locations for these areas are identified below and depicted on
Figure 3-6, Access Roads and Laydown Areas. The locations for right-of-way access along the
pipeline route include:

 EBRPD trail in Pinole, accessed via Pinole Shores Drive

 Charles Street off San Pablo Avenue (UPRR Property)
 Collier Meter Station along private ranch road
 EBRPD Gate 15 off Cummings Skyway
 Eastern side of Cummings Skyway
 Western side of McEwen Road at ranch gate
 Western side of McEwen Road near valve station location
 Eastern side of McEwen Road at ranch gate
 Carquinez Scenic Drive
 Martinez Shoreline Park

3-40 3.0 Project Description_May2009 Draft.doc

 L AY D O W N A R E A S A C C E S S R O A D S
§
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80

L1 Hammond Property off Gertrude Avenue A1 EBRPD trail in Pinole accessed via Pinole Shores Drive
§
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780

L2 South of Wildcat Creek A2 Charles Street off Pablo Avenue (UPRR Property)

!
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L3 North of Wildcat Creek
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(
A3 Collier Meter Station along private ranch road

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(
L4 Along the BNSF tracks west of Walter Avenue
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(
A4 EBRPD Gate 15 off Cummings Skyway

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L5 Along the EBRPD trail in Pinole
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A5 East Side of Cummings Skyway

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(
L6 BNSF rail road tracks west of Tennent Avenue
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A6 West side of McEwen Road at ranch gate

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L7 UPRR property off Charles Street in Pinole
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A7 West side of McEwen Road near valve station location

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L8 Collier Meter Station parking lot
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(
A8 East side of McEwen Road at ranch gate L1.05
L1
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L9 North of Collier Meter Station
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A9 Carquinez Scenic Drive
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L10 At the top of Franklin Hill above the City of Martinez
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A10 Martinez Shoreline Park Map 5
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A4 14 Map 6
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680

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L11 Alhambra Industrial Park
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L0, 12.22 (
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A6
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L8 (
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Map 4 L9 (
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9 10
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L10 !
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A9 Map 10
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Map 9

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Map 2
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( Map 3 A2

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1 2
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( L3 Map 1

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L2
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0
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( L1

E N T R I X Map Pr ojec tion Map Location Legend E N V I R O N M E N T A L I M P A C T R E P O R T

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Contra Costa Pipeline Project
E n v i r o n m e n t a l a n d N a t u r a l R e s o u r c e M a n a g e m e n t C o n s u l t a n t s NAD_1983_StatePlane_California_III_FIPS_0403_Feet

¯
!
Projection: Lambert_Conformal_Conic

.
0 3,500 7,000 14,000 False_Easting: 6561666.666667 Proposed Pipeline Alignment A1 Access Road Location
ACCESS ROADS AND LAYDOWN AREAS
False_Northing: 1640416.666667

!
(
N Central_Meridian: -120.500000
Contra Costa
Scale in Feet Standard_Parallel_1: 37.066667 1 L4 Laydown Area Location
Standard_Parallel_2: 38.433333
County !
( Milepost
Latitude_Of_Origin:
Linear Unit: Foot_US
36.500000
Foot_US
FIGURE 3-6
GCS_North_American_1983 INDEX MAP
Datum: D_North_American_1983
 1 PI T T SB U R G AV E
(
!
L AY D O W N A R E A S

!
( L1 Hammond Property off Gertrude Avenue

!
( L2 South of Wildcat Creek

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( L3 North of Wildcat Creek
DA VILLA

D E C A R L O AV E

!
(
L3
V E R D E AV E

2ND ST
RICHMOND PKWY

3RD ST
DR
EN

W A RR

HARROLD ST
M A R KE T AVE

N JADE ST

TRUMAN ST

4TH ST
1ST ST
S I LV E R AV E

2ND ST
!
( L2
GR O VE AV E

MARCUS AVE

DR

E
AV
M ARTIN

R U BY
C H E S L E Y AV E

!
(
MALCOLM DR
L1

FILBERT ST
0 (
! W G E RT R U D E AV E
GE RT R U D E AV E

YORK ST
ALAMO AVE

E N T R I X Map Projection Map Location Legend E N V I R O N M E N T A L I M P A C T R E P O R T

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E n v i r o n m e n t a l a n d N a t u r a l R e s o u r c e M a n a g e m e n t C o n s u l t a n t s NAD_1983_StatePlane_California_III_FIPS_0403_Feet

¯
Contra Costa Pipeline Project

!
Projection: Lambert_Conformal_Conic

.
0 250 500 1,000 False_Easting: 6561666.666667 Proposed 16" Natural Gas Line Existing Chevron #2 Line
N
False_Northing:
Central_Meridian:
1640416.666667
-120.500000 Contra Costa
Drill Line Proposed 12" Diameter Hydrogen Line ACCESS ROADS AND LAYDOWN AREAS
Scale in Feet Standard_Parallel_1: 37.066667 Coun ty 1 Right-Of-Way Access
Standard_Parallel_2: 38.433333
(
! Milepost
Latitude_Of_Origin: 36.500000 FIGURE 3-6
Linear Unit: Foot_US Foot_US Laydown Area MAP 1 OF 10
GCS_North_American_1983
Datum: D_North_American_1983