The Commission voted 5-0 to adopt the Recommended Decision of PUC Administrative Law Judge Jeffrey A. Watson – which recommended approval of a Joint Petition for Approval of Settlement filed on March 14, 2025, between the PUC’s Bureau of Investigation and Enforcement (I&E) and Columbia Gas.
The PUC action resolves a formal complaint filed by I&E on Nov. 21, 2023, alleging that in 2019 and 2020 Columbia Gas and its contractor, Infrasource, violated state and federal regulations relating to visually unacceptable socket fusions along multiple main line replacement projects in Allegheny and Washington counties.
Gas service line fusion is a permanent method of joining plastic polyethylene (PE) gas pipes using controlled heat to melt and blend the materials into a single, continuous piece.
I&E Investigation and Formal Complaint
In 2020, I&E launched an investigation as the result of a failed fusion at the company’s Tropical Avenue Project in Pittsburgh.
Subsequent integrity validation digs at the Tropical Avenue Project, as well as at four additional Columbia Gas projects across Allegheny and Washington counties, discovered a much larger number of alleged violations related to fusion work, including--
-- Failure to identify no less than 220 visually unacceptable fusions and saddle tee fusions on service lines and main lines. These visually unacceptable fusions lacked a complete impression of the cold ring clamp and/or were mitered.
-- Failure to mark, label, or sign no less than 552 fusions according to Columbia Gas Standards.
-- Allowing an unqualified contractor employee to perform and inspect plastic fusions.
-- Failure to properly install no less than 44 saddle tee taps to a gas main line.
-- Failure to capture and maintain accurate records of the pipeline components and personnel performing work on the pipeline.
Following discovery of these safety violations, the settlement notes that during 2021 Columbia Gas completed replacement of all visually unacceptable fusions at the five locations and discontinued the use of socket fusion as a joining method.
Settlement Terms and Conditions
Terms of the settlement between I&E and Columbia Gas include:
-- Payment of a $875,000 civil penalty, which will not be tax deductible nor passed through as an additional charge to Columbia Gas’ customers in Pennsylvania. In addition, the company may not recover the costs associated with the plastic fusion investigations and subsequent remediations for the projects identified in the formal complaint.
-- Implementation of corrective actions, to include replacement of all visually unacceptable fusions and designed to reduce risk associated with plastic pipe fusions, enhance contractor oversight, assure the production of quality fusions, and enhance knowledge of Columbia Gas’ system.
-- Amending company procedures to require the submission of a Facility Failure Report for all legacy production joints which are removed following a failure of a legacy plastic fusion visual inspection.
-- Development of a process to incorporate the findings and locations of visually unacceptable fusions removed from service into the annual Columbia Gas Distribution Integrity Management Program review.
-- Implementation of a fusion inspection documentation process to be used by Columbia Gas Construction Coordinators when evaluating fusions witnessed in the field.
-- Company notification to the PUC’s Pipeline Safety Division when a leak occurs at a plastic fusion as soon as practical, but not to exceed the next business day following discovery.
Columbia Gas is owned by NiSource and has approximately 448,000 customers in 26 counties across the Commonwealth.
Documents related to this case can be found at PUC Docket No.: C-2023-3044398.
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[Posted: September 10, 2026] PA Environment Digest
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