TORRENT GAS TRAINING

MODULE
 Technical Standards and Specifications
Including
Safety Standards for City Gas Distribution
Networks (T4S)
 SCOPE
‒ Design, materials, fabrication, installation, inspection and testing, commissioning,
operation, maintenance, modifications and abandonment of CGD network for domestic,
commercial and industrial users.
‒ It covers all pipelines, distribution mains and piping facilities downstream of inlet isolation
valve of city gate station (CGS) up to and including consumer meter for commercial or
industrial customer and up to final isolation valve including connecting hose to gas
appliance for domestic consumer.
‒ The CNG Mother Station, On-Line Station and Daughter Station shall be designed, operated and
maintained in line with the requirements of the CCoE as per Gas Cylinders Rule, 2004. This
includes compression, handling and transportation activities of compressed natural gas.
‒ These regulations also cover safety aspects of operation and maintenance of CGD network and
the requirements covered herein are meant to supplement the safety requirements already covered
under ASME B 31.8.
 Intent
‒ It is intended to apply these regulations to all new and already existing networks as design,
fabrication, installation, testing at the time of construction and commissioning.
‒ However, if an entity has laid, built, constructed or expanded the CGD infrastructure
based on some other standard or is not meeting the standards specified in these
regulations, the entity needs to carry out a detailed technical audit of its infrastructure
through PNGRB authorized or approved third party agency. The entity thereafter shall
submit the recommendations made by the third party along-with its time-based mitigation
plan and implementation schedule to PNGRB.
‒ The continuation of operation of existing CGD network shall be allowed only if it meets the following
requirements:
• The CGD system downstream of city gate station shall have been tested initially at the time of
commissioning in accordance with ASME B 31.8 Chapter IV (with minimum test pressure of 1.4 times of
MAOP for steel network and 1.4 time MAOP or 50 PSI whichever is higher for PE network). The entity
should have proper records of the same.
• The CGD system has leak detection system in position and is operative. For pipeline network it shall be
odorisation based and for enclosures such as CGS, above ground DPRS, it shall be gas leak detection
based.
• The CGD system has in position necessary pressure relief valves.
• There shall be protection of the system against third party damages both in respect to steel pipe, PE pipe and
GI Pipes.
 THE STANDARD
‒ Technical standards and specifications including safety standards for city or local natural gas
distribution networks are as specified in Schedule–I which covers:
• Material and equipment (Schedule–1A),
• Welding (Schedule–1B),
• Piping system components and fabrication (Schedule–1C),
• Design, installation and testing (Schedule–1D),
• Operating and maintenance procedures (Schedule–1E),
• Corrosion control (Schedule–1F)
• Miscellaneous (Schedule–1G).
LIST OF CRITICAL ACTIVITIES
IN CGD NETWORK
Time period for
Sr. No. Critical infrastructure/ activity/ processes Implementation plan
implementation
Pressure reduction skid CGS (active/monitor combination)
Modification of CGS
1 with a minimum 50% redundancy including slam shut valve 1 year
skid
for over pressure protection and creep relief valves.
Automated
On line odorisation equipment designed to minimize fugitive
2 1 year odorisation systems
emissions during loading, operation and maintenance.
to be used
Height of the vent shall be minimum 3 meters above working Increase height of
3 6 months
level vent
Install gas detectors
4 Gas detectors shall be installed at critical locations 1 year
in the CGS and DRS
Pressure reduction for DRS (active /monitor combination)
skid with minimum 50% redundancy including two safety
Modification/
5 devices at least one of them shall be a slam shut valve for 2 years
replacement
over pressure protection/under-pressure and inlet and
outlet isolation valves.
 Cont.
Time period for
Sr. No. Critical infrastructure/ activity/ processes Implementation plan
implementation
Replacement of all rubber
6 Steel reinforced rubber hose conforming to IS 9573 Type IV 6 months * hoses @ fifty thousand per
year
Pipeline test record and joint radiography and cover in the form
7 3 months Can be submitted in stages
of pipe book
8 HSSE Management System 6 months To be implemented

Emergency Response Plan, Disaster Management Plan and

written emergency procedures. Also, provide for an Emergency
Control Room, manned round the clock and equipped with
9 effective communication system and emergency vehicles fitted 6 months To be implemented
with communication facilities, first aid equipment, fire
extinguishers, gas detectors, repair kits and tools, maps, plans,
material safety data sheets etc. at its disposal.
 Schedule – 1A
MATERIALS AND EQUIPMENT
• Materials for Use in Cold Climate :
– Materials to be used in facilities exposed to low ground or low atmospheric temperatures or low
operating temperatures shall have adequate impact properties to prevent brittle fracture at low
temperatures.

• Material Specifications :
– In addition to standards and specifications covered in ASME B 31.8, standards and specifications
listed in Annexure-I shall also be acceptable for manufacturing of various piping components
forming part of the CGD network.
– Steel Pipe :

• Carbon steel used in CGD networks shall meet following requirements:

Carbon Equivalent

For pipes having Carbon Content > 0.12%

CE(IIW) = C + Mn + Cr+Mo+V + Ni+Cu
6 5 15
CE (IIW) value shall be ≤ 0.43%.

For pipes having Carbon Content ≤ 0.12%

CE(Pcm) =C + Si + Mn + Cu + Ni + Cr + Mo + V + 5B
30 20 20 60 20 15 10
CE (Pcm) value shall be ≤ 0.25%.
– Ductile Iron Pipe :
• Use of ductile iron pipe is not permitted for CGD networks for transport of natural gas.

– Plastic Pipe and Components :

• Thermoplastic pipes, tubes and fittings are recommended for use in city gas distribution networks.
• Polyethylene (PE) pipes conforming to IS 14885 or ISO 4437, and PE fittings conforming to ISO
8085 Part 3 shall be acceptable.
• Reprocessed material shall not be used.
• Color of pipes used for gas service shall be yellow for PE 80 grade and Orange for PE 100 grade.
• PE pipes shall be permanently marked (either impressed or embossed to a depth / height of 0.02 to
0.15 mm).
 Cont.
– Pipes and tubing for above ground service lines up to meter:
Galvanized Iron (GI) pipes shall be used in above ground service lines up to consumer meter or meter
control valve. Use of non-galvanized pipes should be restricted as far as possible; however, in case
they are used they shall be properly protected and painted. PE pipe shall not be used for above
ground gas pipes.
– After meter, GI pipes or Copper tubing shall be used up to gas tap.
– After Gas tap, Steel reinforced rubber hose shall be used to connect customer appliance which shall
conform to IS: 9573 Type IV
 Cont.
‒ Conditions for reuse of Plastic Piping :

Reuse of plastic pipes is permitted subject to the following.

• Its original and manufacturing specifications are known and documented.
• It meets the requirements of new pipes conforming to its manufacturing
specifications.
• The pipe is free from visible defects.
• It is installed and tested in accordance with requirements of this standard. All testing
shall be carried out at recognized independent laboratory and records of the same are
maintained.
 Schedule – 1B - WELDING
‒ General

These requirements apply to steel pipe and components only.

Notches or laminations on pipe ends are not permitted and must be removed by cutting
the pipe as a cylinder and re- beveling of pipe end prior to welding.

‒ Qualification of Procedures and Welders

Welding procedures and welders for welding of gas pipelines shall
be qualified as per API 1104 and shall include toughness testing requirements as
applicable for the line pipe.
 Cont.
• Welding procedures and welders, for station piping shall be qualified as per ASME Boiler
and Pressure Vessel (BPV) Code Section IX or API 1104.
• When welders qualified under API 1104 are employed for station piping, their
qualification shall be based on destructive mechanical testing as per API 1104.
‒ Inspection of Welds

• All Non Destructive Testing (NDT) including radiographic examination shall be

performed in accordance with the requirements of API 1104 except that no root crack
shall be permitted.
 Cont.
• Regardless of operating hoop stress as well as location class all carbon steel butt welds shall be 100%
radiographed. In case radiography is not possible due to safety reasons, weld shall be examined by using
ultra sonic techniques.
‒ Repair or Removal of Defective Welds

• Welds having defects shall be removed or repaired in accordance with API 1104 or ASME BPV code
Section IX as applicable. Welders employed for repairs shall be qualified in accordance with
“Qualification of Procedures and Welders”.
• Weld repair areas shall be subjected to additional radiography or ultrasonic testing after repair.
 Schedule – 1C
PIPING SYSTEM COMPONENTS AND
FABRICATION DETAILS
‒ Valves and Pressure Reducing Devices
• Valves body, bonnet, cover and/or end flanges components made of cast iron and/ductile iron (as
per ASTM A 395) shall not be used in CGD networks.
• Valves used in service lines of size NPS 2 and below shall conform to BS EN 331.
‒ Flanges
• Flanges made of cast iron, ductile iron and non-ferrous materials (brass or bronze) shall not be
used in CGD networks.
• Use of flanges in natural gas transmission and distribution piping is not permitted except for
station piping e.g. CGS, DRS,MRS etc.
• For piping class 150 or above all the flanges shall be with raised face.
 Cont.
‒ Bolting

• All stud bolts and nuts used in CGD networks shall be hot dipped galvanized as per ASTM A 153 or
equivalent.
‒ Fittings other than Valves and Flanges

• All plastic fittings used in CGD networks must have been type tested by an internationally
recognized testing agency prior to their use.
• Thermoplastic/thermosetting fittings shall not be used in above ground piping system. Thermoplastic
fittings conforming to ISO 8085 Part 3 shall be acceptable and shall meet following requirements:
 Cont.
• Grade of PE compound used for the fittings should not be less than that of PE pipes. In case fittings are
of different grade than that of pipes, compatibility of the same with pipes shall be established prior to
their use. However, in case of higher grade fittings separate compatibility test shall not be required.
Heating element shall not be exposed and all coils are embedded into the body of the fittings.
• Color of fittings shall be yellow or black.
• Electro-fusion fittings complying with ISO 8085 Part 3/EN- 1555-3 shall be used for all sizes of PE
pipes. Fittings fabricated from pipe shall not be used. Only injection molded fittings are recommended.
 Cont.
• For fusion fitting up to 63 mm, pipe fixation device shall be an integral part of the body of the fitting
and for size above 63 mm external alignment clamp shall be used.
• Each Electro Fusion fitting shall be bar coded. Fusion fittings shall have permanent fusion indicator or a
data card conforming to ISO-7810/ISO-7811.
• The fusion jointing shall be carried out as per the procedure outlined in the standard DVS 2202 or
equivalent.
• Carbon steel part of transition fittings used for connecting PE system with Carbon Steel system may
have butt weld/plain/flanged ends.
 Cont.
‒ Special Fittings

• Mechanical fittings for making hot taps on pipelines and mains shall not be used. Fittings
for hot taps shall be welded type (for steel pipelines and mains) and electro fusion type
(for thermoplastic mains and service lines).
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING

‒ General
The selection of design for CGD network shall be based on the gas properties, required
flow rates, operating pressures and the environment.
• City Gas Distribution Network
A typical CGD network comprises of one or more or all of the following:
1. Primary Network:
A medium pressure distribution system comprises of pipelines, gas mains or
distribution mains normally constructed using steel pipes and connects one or more
Transmission pipeline to respective CGS or more CGS to one or more DRS. Max.
Velocity in the pipeline shall be limited to 30 m/sec. as far as possible, primary
network should fed through more than one CGS.
 Cont.
2. Secondary Network
A low Pressure Distribution System comprising of Gas Mains or Distribution Mains usually
constructed using thermoplastic piping (MDPE) and connects DPRS to various service regulators at
commercial, industrial, and domestic consumers. The network shall be sized for maximum flow
velocity of 30 m/sec.
3. Tertiary Network
A service Pressure Distribution System comprising of Service Lines, Service Regulators and
customer/consumer Meter Set Assemblies constructed using a combination of thermoplastic (MDPE)
piping and GI/copper tubing components.

4. City Gate Station

Typically comprises of, but not limited to, the following facilities:
a. Filters
b. Separators (if required).
c. Metering facilities.
 Cont.
d. Heater (if required)
e. Pressure reduction skid comprising active and monitor combination with a minimum 50%
redundancy with stream discrimination arrangement, including slam shut valve for over and under
pressure protection and creep relief valves (stream redundancy shall not be less than 2+1).
f. Online odorization equipment designed to minimize fugitive emissions during loading, operation and
maintenance.

5. Distribution Pressure Regulating Station :

Located at various demand centers for domestic / commercial users typically consists of:
a. Gas filter
b. Heater (if required)
c. Pressure reduction skid comprising active and monitor combination with minimum 50% redundancy
with stream discrimination arrangement, including slam shut valve for over and under pressure
protection with additional feature of under pressure protection if required(stream redundancy shall not
be less than 2+1).
d. Inlet and outlet isolation valves.
 Cont.
6. Individual Pressure Regulating Station (IPRS):

Located at the premises of an individual customer and having facilities similar to DPRS however,
monitor regulator may or may not be provided. Metering facilities may or may not be part of this
station.

7. Service Regulators:

Usually located at customer premises for maintaining supply pressure and designed to maintain safe
condition even in the event of rupture in the regulator downstream section.
 Network Design Requirements

‒ The design of CGD Networks and its components shall be such that it ensures:
• Supply of gas at constant volume into a system, which fluctuates in pressure between pre-determined upper
and lower limits in the distribution network, or
• Supply of gas at a constant pressure at consumer end, and
• The design should recognize the need for safe guard against malfunction of any equipment and provide
sufficient redundancy to ensure that the supply is secured against such malfunctions.
‒ Facilities forming part of CGD networks shall be designed considering:
• Range of flow rates and pressures required in various sections of the network
• Quality of gas, including cleanliness in respect of both solid and liquid particles.
• Metering requirements.
• Noise control and
• Corrosion Protection
‒ Necessary calculations shall be carried out to verify structural integrity and stability of the pipeline for the
combined effect of pressure, temperature, bending, soil/pipe interaction, external loads and other
environmental parameters as applicable, during all phases of work from installation to operation. Such
calculations shall include, but not limited to, the following:
• Buoyancy control and stability of pipeline in areas subjected to flooding /submergence,
• River crossing to be installed by trench less techniques, wherever soil data is favorable for such
installations,
• Damage potential for steel pipeline from hazards associated with earthquake, if applicable.
‒ Layout of Station Facilities :
• The following aspects are to be considered in deciding layout of facilities at CGS, DPRS, IPRS, etc.
• Type and size of equipment.
• P&IDs
• Utility requirement.
• Venting wherever required.
• Operation and Maintenance philosophy.

‒ As far as possible the city gate station (CGS) shall be installed at the periphery of populated area. The entity
should make best endeavor to have more than one CGS for supply security.
 – Inter distance between various facilities required at CGS shall be as below:
Table – 1 : Inter-distance between Facilities at CGS
Sr. No. From / To 1 2 3 4 5 6

1 Compound Wall - 6 6 6 6 6

2 Control Room/Office Building / Store 6 - 12 12 2 15

Pressure Regulation and / or Metering 6 12 - 2 12 15
3
4 Odorant System 6 12 2 - 12 15
5 Electrical Sub Station - 2 12 12 - 15
#
Gas fired heaters 6 15 15 15 15 -
6
• Buried piping inside the CGS area shall have a minimum depth of cover of 1.2 m. Where buried pipes
come out of the ground, the underground coating on the pipe will continue for a length of at least 300
mm above ground.
• Platforms and crossovers shall be provided.
• Provision should be made for venting, purging and draining all sections of pipe work and
equipment.
• All vents shall be routed to a safe area and in a manner that gas vented out is blown away from the
nearest building. Height of vent shall be minimum three (3) meters above working level.
• DRS facilities can be located above ground or below ground. In case DPRS is located below ground,
the facilities shall either be inside a enclosed chamber with a provisions for entry of authorized personnel or
be a buried hermetically sealed (air tight) module type with proper cathodic protection.
• For below ground installations, the vent line shall be terminated at a minimum height of three (3) meters
above the ground level.
• IPRS shall normally be located above ground.
• DRS/IPRS installed above ground shall be provided with proper security fencing.
‒ Electrical Equipments:
• All electrical equipment /installations shall meet following requirements:
• Electrical area classification of Installation, as basis for selection of Electrical Equipment, shall follow
IS-5572.
• The specification of Electrical equipments shall be in line with IS -5571, “Guide for selection of Electrical
Equipment for Hazardous Area”.
• All electrical equipment, systems, structures and fencing, etc. shall be suitably earthed
• Lightening protection shall be provided
‒ Steel Pipe :
• Wall Thickness
• Designing should consider following factors as per ASME B 31.8
•Overburden loads
•Dynamic and seismic loads
•Cyclic and vibratory loads
•Internal pressure fluctuations
•Geo-technical loads (including slides, differential settlement of piping, loss of support, and thermal
effect of the pipeline on soil properties)

• In any case minimum thickness of pipe permitted as per this standard shall not be less than 6.4mm,
irrespective of the grade of the pipe material.
‒ Pipelines or Mains on Bridges :
• Pipeline on bridges should be avoided. Under unavoidable conditions, pipeline installed on railroad,
vehicular, pedestrian, or other pipeline bridges, a design factor of 0.40 shall be used for Location Class 4.
• In cities where crossing the river through HDD crossing is not possible, pipeline laying on river bridges
is permitted.

‒ Metering Facilities :
• Upstream dry gas filter(s) shall be installed when rotary or turbine meters are used.
‒ Pressure / Flow Control Facilities :
• Protection against over pressure of pipeline or mains downstream of city gate station (CGS) shall be
provided as follows:
• The provision of Active / Monitor Regulator System (i.e. monitor regulator in series with a controlling
(active) regulator) shall be the principal method of controlling pressure.
• Adequately sized pressure relief valve(s) could be used for overpressure protection downstream of
controlling regulator(s) provided Quantitative Risk Assessment is made for environmental hazards (fire /
explosions) associated with large release of gas volume of gas release and the risks are found within
acceptable level.
• Pressure relief valve(s) should be carefully sized to meet their required duty and to minimize the volume
of gas released.
• Over pressure shut-off valve(s) or Slam-Shut Valve(s) upstream of the controlling regulators are preferred
as overpressure protective devices instead of pressure relief valves.
• The isolation valve of the sensing lines of regulators and slam shut valves should have provision for locking
in open position.
• Additionally suitable gas heaters upstream of regulators / control valves/ pressure reduction system should
be provided in case after pressure let down operating conditions would result in low temperatures beyond
design conditions of downstream facilities.
• Sound pressure levels shall be limited to the values prescribed by Environmental Authorities but in no
case it shall exceed 110dbA.
• Gas velocities in piping up to 20 m/sec before filter and 40 m/sec (120 ft/sec) after filter, at peak flow
conditions, may be permitted provided care is taken to ensure that allowable sound pressure values are not
exceeded and materials selected are suitable to prevent erosion at such high velocities.
• Gas filtration facilities with 100% redundancy shall be provided.
• In order to prevent over pressurization of piping downstream of regulators/control valves, creep relief valve
should be provided, if required.
• For isolation of the CGS during emergency, quick closing valve (with remote operation facility in case of
unmanned station) shall be installed at the inlet of CGS
 Cont.
– Cover, Clearance and Casing Requirements for Buried Steel Pipelines and Mains
Minimum depth of cover for buried steel pipelines shall be as per the table given below:
Table – 3 : Minimum Cover Requirements for Steel Pipelines
Location Min. Cover (m)
Normal / rocky terrain 1. 0
Minor river/unlined canal/nala crossings, tidal areas and other water courses 1. 5
Major river crossings 2.5
Rivers with rocky bed 1.5
Lined canals / drains / nalas etc. 1.5
Drainage ditches at roadways and railroads 1. 0
Rocky Areas 1. 0
Cased/uncased road crossings 1. 2
Cased railroad crossings 1. 7
‒ Clearance between Pipelines or Mains and other underground structures :
• When a buried steel pipeline or main has to cross any existing underground pipeline, cable, drain or
other services, the pipeline shall be laid at least 300 mm below from such services.
• When laid parallel to any existing underground cable, drain or other utilities, the pipeline or main shall
be laid with a clear distance of at least 300 mm from existing utility.
• As far as practical, a minimum separation of three (3) meter should be maintained between the steel
pipeline or main and footing of transmission tower.
• A clearance sufficiently large to avoid electrical fault current interference shall be maintained between
the pipeline and the grounding facilities of electrical transmission lines.
• Clear distance between new steel pipeline or main running parallel to existing pipeline should be minimum
5.0 meters when heavy conventional construction equipment is expected to be utilized. This distance may be
reduced, after careful assessment of construction methodologies, to three (3) meters, provided it does not
result in unsafe conditions during construction.
• While laying more than one new hydrocarbon pipelines or mains in the same trench, clear separation of
minimum 500 mm shall be maintained between adjacent pipelines.
• No steel pipeline or main should be located within three (3) meters of any habitable dwelling or any
industrial building unless it is provided with at least 300 mm of cover over and above minimum cover
‒ Casing Requirements under Railroads, Highways, Roads or Streets
• Steel casing at road/railway crossings, when provided to meet statutory requirements, shall be designed in
accordance with API 1102. Casing pipe diameter shall be minimum two pipe sizes bigger than carrier pipe.
In case of PE, the casing can be RCC pipe of min NP3 class.

‒ Bends, Elbows and Miters in Steel Pipelines and Mains

• Miters bends and wrinkle bends are not permitted in pipelines and mains used in CGD networks regardless
of operating hoop stress.
• Cold field bend radius for pipes of size NPS 20 and larger shall be minimum 40 times the pipe diameter.
• As far as possible use of short radius elbows should be avoided.
‒ Hot Taps :
• Split tees designed to fully encircle the pipe shall be used for making hot taps. The split Tees shall be
designed considering a minimum design factor F = 0.40.
• In case of Hot taps of size up to 1/4th of the nominal bore of the main pipeline, use of weldolets is
permitted in place of split tees.
• Full bore ball valve shall be used when making branch connections using hot taps.
• Recommendations as per API RP 2201 - Recommended Practice for Safe Hot Tapping Practices in
the Petroleum and Petrochemicals Industry shall be followed while carrying out hot tapping works.
 Testing after Construction

‒ General Provisions :
• Proper Communication
• Inspection and calibration of testing instruments /equipments.
• Test to prove strength of pipelines to operate at Hoop Stresses of 30% or more of SMYS.
• All the buried steel pipelines shall be hydro pressure tested at 1.4 times of MAOP.
• Test procedure as per ASME B 31.8 Appendix N “Recommended Practice for Hydrostatic Testing of
Pipelines in Place”
• Pressure hold up time shall be 24 hrs. for underground and 4 hrs. for above ground minimum.
‒ Safety during testing:
• Warning signs to be displayed
• Test area shall be properly cordoned
• ERP must be in place and emergency numbers are clearly visible
‒ Commissioning of facilities
• Work permit should be issued
• Fire fighting equipments should be available
• Proper communication facilities
• ERP must be in place and emergency numbers are of relevant agencies are available.
‒ PLASTIC PIPES :
• Plastic pipe shall not be used for Pipeline and Distribution Mains operating at pressure in excess of 100
psig. (6.8 Bar-g)
• Use of thermosetting plastic piping is not permitted as per this standard.

‒ Plastic Pipe and Tubing Design Formula :

• Nominal wall thickness of plastic pipe shall be calculated as per following formula:
• P = 2S * (t / (D-t)) * 0.32
Where
D = Specified outside diameter in mm
P = Design pressure in psig
t = Nominal wall thickness in mm
S = Long term hydrostatic strength in bar-g (psig) determined in accordance with applicable pipe
specification at temperature equal to 73°F, 100°F or 120°F.
‒ Thermoplastic Design Limitations :
• The design pressure shall not exceed 100 psig (7 kg/cm2).
• Thermoplastic pipe, tubing and fittings shall not be used where operating temperature of the
materials will be:
•Below 0 degree centigrade or
•Above 50 degree centigrade
• Minimum thickness shall not be less than 2.3 mm.
• Pipe wall thickness selected shall be such that it corresponds to Standard Dimension Ratio (SDR).
Pipes with non standard SDR should not be used.
 Wall Thickness and Standard Dimension Ratio for Thermoplastic pipes
Nominal Outside Diameter Minimum wall thickness in mm for Standard Dimension Ratio, SDR
in mm
D 17.6 13.6 11 9
16 2.3 2.3 2.3 2.3
20 2.3 2.3 2.3 2.3
25 2.3 2.3 3.0 3.0
32 2.3 2.3 3.0 3.6
40 2.3 3.0 3.7 4.5
50 2.9 3.7 4.6 5.6
63 3.6 4.7 5.8 7.1
75 4.3 5.5 6.8 8.4
90 5.2 6.6 8.2 10.1
110 6.3 8.1 10.0 12.3
125 7.1 9.2 11.4 14.0
140 8.0 10.3 12.7 15.7
160 9.1 11.8 14.6 17.9
180 10.3 13.3 16.4 20.1
200 11.4 14.7 18.2 22.4
‒ Design Pressure of Plastic Fitting :
• All fittings used shall be electro fusion type. Other types of fittings are not permitted. All PE fittings
shall conform to ISO 8085 –Part 3. The wall thickness of the fittings shall be more or equal to the
wall thickness of the pipe jointed.
‒ Plastic Pipe and Tubing Joints and Connections
• General Provisions :
• Threaded joints in plastic pipe are not permitted.
• Plastic piping joints shall be made by Electro Fusion fittings only.
• All electro fusion fittings shall be bar coded and the control unit shall be equipped with bar code
reader to directly transfer fusion data to control unit.
‒ Installation of Plastic Piping :
Installation Provision
• Use of thermoplastic piping in above ground piping is not permitted unless the piping is
completely protected against deterioration (e.g. high temperature, ultra violate degradation)
by corrosion protected metallic or reinforced concrete or Glass Reinforced Plastic (GRP)
enclosure.
‒ Direct Burial :
• Directly buried thermoplastic pipe shall have a minimum thickness of 2.3mm.
• Trench width shall be at least 300 mm.
• The bed of the trench shall be free of sharp objects, stones etc. In rocky areas trench shall
be padded with soft soil or sand to minimum depth of 150 mm below the pipe.
‒ Branches :
• Branch connections shall be made only by socket type electro fusion tees or electro fused
Saddle connections.
‒ Testing Plastic Piping after Construction :
General Provisions
•Testing instruments and equipments must be properly inspected and calibrated.
•Proper communication facilities must be available.
‒ Test Requirements :
• Thermoplastic piping shall not be tested at material temperature above 50 degree centigrade.
• Test medium shall be air or nitrogen for test pressure up to 100 psig. For test pressure higher than 100
psig, water shall be used as test medium.
• Test duration shall be minimum 24 hours for plastic distribution mains of length greater than 1 km
and minimum 4 hours for length shorter than 1 km.
‒ Safety during Testing :
• Relevant Warning Signs shall be displayed
• The test area should be properly cordoned
• A proper Emergency Response Plan shall be in place and emergency contact numbers of relevant
agencies should be available
 Valves

‒ Valves should be installed below ground with the valve operating device readily
accessible.
‒ Valves of size 4 inches and above shall be fitted with double block and bleed facility.
‒ Spacing between valves on distribution mains shall be as follows:
• High Pressure Distribution System, valves may be provided on:
• Either side of water body crossings.
• Strategic take-off points including future developments.
• Based on risk associated with emergency situations requiring speedy isolation and
resulting number and type of customers affected by such emergencies etc.
• In steel distribution mains valve spacing should normally not be more than 3 kms.
• In plastic distribution mains valve spacing should normally not be more than 1 km.
• The above spacing, however, may be increased or decreased based on risk assessment and to allow
location of valve at an easily accessible location.

‒ Low Pressure Distribution System:

• Valves in low pressure distribution system may be provided at locations requiring isolation for ease of
maintenance in addition to those required as per following Para.
‒ Meter and Regulators :
• Preferably be located on the wall outside kitchen, however it is located inside, it must be located in well
ventilated area.
‒ Gas Service Lines :
• Service lines shall be sized for max. flow velocity of 15 m/sec.
• Installation of Service Lines
• All plastic pipe and fittings shall be laid underground and shall be provided with a minimum cover of
1.0 m. Where it is impractical to provide 1.0 m cover due to physical constraints, additional
protective measures shall be installed at least 300 mm above the service line. In no case the depth of
cover shall be less than 600mm.
• For transition from plastic pipe to GI pipe, transition fittings shall be used. Plastic part of transition
fitting protruding above ground shall be protected by encasing it with concrete guard.
• In case of carbon steel section beyond TF is below ground, it shall be protected with min. 400 Micron
thick epoxy coating.
 • Above ground service piping shall be GI or Copper or Carbon Steel.
• Whenever risers are installed in confined space, welded risers must be used. The gap between riser and
wall shall be minimum 25 mm to and shall be supported at every 2 m. Ventilators shall be provided in
confined space.
‒ Design of Plastic Service Lines :
• Only electro fusion fittings shall be used in plastic service piping including pipe to pipe joints.
• Installation of Plastic Service Lines
• Installation of plastic pipe above ground is not recommended. In case any section of plastic pipe extends
above ground, it shall be completely encased in a concrete casing.
• Whenever steel to PE connection to be made, it must be through TF only.
‒ Piping beyond meter to gas appliance :
• Piping must be GI or copper up to last valve of the appliance.
• Appliance shall be connected to gas line with a flexible and wire braided hose as per IS 9573.
• Length of this hose shall be kept minimum. However, in no case the length shall be more than 1.5 meters.
Both ends of the hose shall be firmly clamped on the nozzle by metallic clamps.
 Schedule – 1E
O&M PROCEDURES
‒ Basic Requirements :
HSE Management system, which covers
• HSE Policy Statement
• Organizational objectives to ensure implementation of the policy
• Set of detailed processes supporting each activities of the HSE management system
• Implementation of control and monitoring activities
• Periodic monitoring, review and reporting of performance
• Audit of internal and external activities
Following processes shall be prepared as part of HSE Management System

• Emergency Management System to safely handle emergencies with minimal risk.

• Disaster Management Plan encompassing offsite and onsite emergency response plans and mutual aid system
• Hazard Identification Processes such as HAZOP
• Risk Analysis and Risk Assessment Process such as QRA
• Safety and Technical Competency System.
• An Operational Health and Safety Legal applicability and compliance Matrix
• An Environmental Legislative Register
• Carrying out periodic Work Place Inspection of all Critical Activities by senior management team,
implementation of Behavior Based Safety Programs and implementation of Safety Intervention System.
‒ GIS based asset management system :
• The entity operating a CGD network shall put in place a GIS (Geographical Information System) based
system with the intention of capturing the entire underground gas network and customer database. This
system shall include details of the entire pipe network. All the pipelines laid shall be identified in GIS
through geo- referenced co-ordinates. All failures in the pipelines shall be mapped in GIS for
investigations.
• The system shall include the following features:-
• Entire network view ability on one platform to manage the huge database.
• All network extensions and expansions to be mapped and updated in GIS with geo-referenced co-
ordinates for better identification.
• Immediate availability of the new constructed pipeline locations and customer base information to the
user groups allowing related analysis, planning and future projections of new possibilities of pipelines,
customers, gas volumes and revenue including jobs to be undertaken by third party.
• GIS shall be used during the entire life cycle of the asset.
‒ Essential Features of O&M Plan:
• Preventive maintenance plan and procedures required in accordance with recommendations of Original
Equipment Manufacturer.
• Periodic Inspection of all facilities
• Calibration plan for Meters, Gauges and other instruments.
• Plan for functional testing of pressure regulation and control equipment (Active/Monitor Regulator,
Slam Shut Valve, Pressure Relief Valves, control valves etc.)
• Isolation scheme (complete with drawings showing the orientation of the facilities, location of major
services, power switches, entry and emergency exits, fire assembly points etc.)
• Limits of operating parameters (pressure, temperature, flow, levels etc.)
• An Alarm Management System
• “Work Permit” procedures
• Procedures to log operation and maintenance activities.
• Personal Protective Equipments
• Do’s and Don’ts and safety precautions during operation and maintenance
‒ Accident /Emergency reporting procedures :
• In house accident reporting procedure and its response plan for all kind of accidents / emergencies
such as …
• near miss accidents
• accidents without loss of production, supply or human life
• accidents with loss of production, supply or human life
• Fire and explosion or other emergencies leading to disaster effecting outside public.
• Last two accidents shall be reported to PNGRB with remedial actions taken for avoiding recurrence.
‒ Written Emergency procedures :
• “Do’s and Don’ts” during and emergency and other safety instructions.
• Telephone numbers of emergency response team members, emergency services, mutual aid industries,
district authorities, law enforcing agencies, contractors/vendors, fire services, district civic authorities, etc.
• Actions to be taken during an emergency including warning /cordoning off of affected area.
‒ Training :
The training program should cover following:
• Hazardous characteristics of Gas.
• Familiarization with commissioning, operation and maintenance procedures.
• Hands on experience on operation of emergency and manual shut down systems.
• Effective isolation of any gas leak.
• Safety regulations and accident prevention.
• Firefighting equipment operation and its upkeepment.
• First Aid and Housekeeping.
• The training process should be subjected to regular internal audit to ensure effective implementation and
improvement.
• Training shall include Mock Drills, at least twice a year.
• Training program shall include all the employees and contractors of other utility companies sharing them
with learning and hazards involved with Natural Gas.
‒ Liaison :

• Entity should have designated personnel to liaison with other existing utility companies, district local
administration and gas supplying companies.A utility co-ordination team consisting of
representatives from all other utility companies and civil authorities can substantially improve safety
records.
‒ Educational Programs :

• Entities shall undertake a comprehensive public awareness program for consumers and general
public. The educational material shall be prepared in local, Hindi and English language. Local audio
visual media available should be used for such educational programs.
‒ Pipeline Failure Investigation :
• damage to the environment and third party property shall also be recorded.
• Failure investigating team shall comprise personnel trained in failure investigations
• The data from all failure occurrences should be analyzed for trends so that proper initiatives including
training could be taken to minimize failures.
‒ Prevention of Accidental Ignition :
• Site Specific Risk Assessment should be carried out.
• No hot work should be undertaken without proper work permit issued by authorized personnel.
 Distribution Piping Maintenance

‒ Markers :
• Markers shall be positioned along entire network at a maximum spacing of 100 meters in urban area
and 200 meters within industrial parks for steel mains.
• Additional warning signs or markers shall be installed to indicate the presence of a pipeline at road,
highway, railroad, stream, canal, nala crossings and other locations where there is a possibility of
damage or interference.
• Marker shall include: NGD operating company, Contact telephone no. to report emergency, location
area code, Warning, etc.
‒ Patrolling :
• Patrolling schedule shall be such that entire primary network is inspected at least once in three (3)
month and secondary network is inspected at least once every month to observe surface conditions,
construction activity, encroachments, soil wash outs and any other factors that may affect the safety
and operation of the network.
‒ Leakage Surveys :
• Highly congested areas shall be surveyed using gas detectors at least once in three months. Other less
congested areas shall be surveyed at least once a year.
• Leakage Surveys using gas detectors shall be done in accordance with the requirements of ASME B
31.8.
‒ Plastic Pipe Maintenance :
The following safety precautions shall be ensured
• All naked flames, sources of ignition and mobile phones shall not be allowed in the
immediate work area.
• Gas level should be monitored during the repair work with gas detectors. The repair
shall not be carried out in atmosphere which contains natural gas.
• Adequate fire extinguishing equipment shall be available during such repair.
‒ Repair of Plastic Pipe :
• Damaged or defective plastic pipe shall be cut and replaced with new pipe.
• Repair of damaged plastic pipe by using repair patches is not permitted.
‒ Records :
• CGD Network Company shall also maintain following records/ documents
• Design specification
• Alignment sheets for primary network of steel pipeline and associated pipe book and other
installation and test records
• Surveillance inspection and maintenance records
• Material certification including dimension, metallurgy, destructive and non-destructive testing records,
performance and functional test reports
• Welding records including PQR, WPS and welder qualification records
• Commissioning reports
• Non-conformance / deviation records
• Calibration records of Inspection, Measuring, Metering and Test equipment
• Audit compliance reports
• Statutory clearances(contd.)
• Approved drawings /documents.
• HAZOP / Risk Assessment reports and compliance to recommendations of such reports.
• All operation and maintenance manuals.
Thank You