Module :

CGS / CPRS-DRS / Steel Pipeline

 CGS

• CGS is the location of Custody Transfer from Transmission Company to

Distribution Company

• Basic Function of CGS is to

 Filteration
 Pressure Reduction
 Custody Transfer metering
 Odorization
 Preheating of NG if required
 CGS – Design Criteria

• Upstream Pressure
• Downstream pressure requirement
• Downstream flow requirements including peak flow rates
• Future projections of volume growth / flow-rate
• Future expansion
• Consider safety at all stages
• Reference Standards : IGE/TD/13
 Major Elements of CGS

• Suitable Land
• Below facilities with a hot stand by mode :
– Filtration (Knockout drum, Filter Cum Separator)
– Let Down Skid (PCV or PRV, SSV, CRV/SRV, Pressure Gauges)
– Metering (Turbine / Ultrasonic / Orifice)
– Odorization
• Pre-heating
• Ball Valves
• Station Piping & Supports
• Electrical Work
• Instrumentation work (SCADA / Control Panels)
Typical City Gate Station
Typical City Gate Station
 Pipeline

• Type of Pipelines:

– Steel Pipeline

• Transmission Pipeline (Up to CGS)

• Distribution Pipeline (CGS Downstream, Ring)

– Poly Ethylene Pipeline

• Medium Pressure (4 Bar)

• Low Pressure (110 mBar)

 Requirement / Considerations for Steel Pipeline

• Delivering Natural Gas at required pressure to :

– CNG Stations
– CPRS
– DRS

• Covering entire City / Town by forming a RING in the periphery of the

city/town, to cater existing and forecasted demands
• Consideration of future load of outskirts areas / developing areas
• Future need of Looping / Interconnections
 Steel Pipeline – Reference Standards

Standard / Code Title

PNGRB T4S Technical Standards and Specifications including Safety Standards - CGD

ASME B 31.8 Gas Transportation and Distribution Piping Systems

ASME B 31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids

OISD-141 Design & Construction Requirements for Cross-Country Hydrocarbon Pipelines

OISD-214 Cross-Country LPG Pipelines

OISD-226 Natural Gas Transmission Pipelines and City Gas Distribution Networks

API 5L / ISO 3183 Specification for Line Pipe

API RP1102 Recommended practice for Rail and Highway crossings

API 1104 Standard for welding pipeline and related facilities

API 6D / ISO 14313 Pipeline Valves

DNV OS-F101 Submarine pipeline systems

Other References Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN
 Stages of Steel Pipeline Project

• Conceptualization
– Market surveys for deriving basic assumptions on demand
– Study Alternatives
– Initiation of Feasibility Study for Commercial / Technical viability
• Feasibility Report
– Route Selection & Surveys
– Hydraulics / Simulations
– Estimation of Project Cost
– Market Demand Assessment
– Project Approval
• Engineering & Planning
– Design & Sizing
– Specifications & Tender Document preparation
– Material Procurement / Release of Word Orders & Contracts
– Acquire RoU / Permissions
– Project Execution & Commissioning
• Operation & Maintenance
– As per AOMP
 Route Selection / Surveys

• Considerations / Detailing Required

– Pipeline Length
– Type of Terrain
– No of Crossings / Type of Crossings
– No of Valves (Section/Tap off/Future Extension)
– Obstructions / Limitations
– Identification of Authorities for permissions

• Type of Surveys
– Topographical
– Geo-Technical
– Population Density Index (Location Class)
– Soil Resistivity
– Cadastral
 Design / Hydraulics / Simulation

• Process
– Simulation for Network Hydraulics is done in the SYNERGEE software
– This is basically required to derive diameter of pipeline in such a way that
required pressure at all locations can be achieved and future load
projections can be ascertained
– Formulae used for hydraulics : Colebrook White / Fundamental pipe
equation with flow dependent friction factor

– Roughness:

Type of Material Roughness (microns)

Steel – new pipe (</= 10 Yrs old)
With internal coating 10 – 15
Without internal coating 35 – 40
Steel – old pipe (> 10 Yrs old)
With internal coating 15 – 20
Without internal coating 40 – 45
 Design / Hydraulics / Simulation

• Process
– Efficiency factor: 0.85 – 1, factor shall be determined by duly
calibrating actual field data in the approved flow equation
– Velocity: Max. allowable velocity of the gas in the steel pipeline
section of CGD network shall be 30 m/s
– STP:
• Standard pressure : 1.01325 Bar (a)
• Standard Temperature : 15.5 Deg C
– Design Life:
• Steel pipeline : 30 Years
• PE Pipeline : 50 Years
 Design / Hydraulics / Simulation

• Location Class:
Class I 10 or fewer buildings in 1mile section
Class II 10 – 46 buildings
Class III 46 or more buildings
Class IV areas where multistoried buildings and heavy
underground utilities

• Basic Design Factor:

Location Class F (design factor)
Class I 0.72
Class II 0.60
Class III 0.50
Class IV 0.40
 Design / Hydraulics / Simulation

• Location Class:
Class I 10 or fewer buildings in 1mile section
Class II 10 – 46 buildings
Class III 46 or more buildings
Class IV areas where multistoried buildings and heavy underground
utilities
• Wall Thickness calculation for steel pipeline
P = 2St FET
D

where
P Design pressure
S Specified minimum yield strength
D Nominal OD of pipe
t Nominal wall thickness
F Design factor
E Longitudinal joint factor
T Temperature de-rating factor
 Line Pipes – Selection / Specifications

• Type
– ERW
– Seamless
– LSAW
– HSAW

• Material Grade
• Nominal Diameter and Wall Thickness
• Length (single random / double random)
 Coating

Coal Tar Enamel Coating (BS 4164, AWWA C203)

• Primer
• Two layers of coal tar enamel & glass fiber Inner wrap
• One layer of coal tar impregnated outer wrap
• Coating thickness 4.7mm

3 Layer PE/ PP Coating (DIN 30670)

• First layer of Fusion bonded epoxy
• Second layer of extruded adhesive
• Third layer of extruded PE/ PP
• Coating thickness 2.0 to 3.7 mm

Fusion Bonded Epoxy Coating (CSA Z245.20)

• 350-500 micron thick single layer coating
• 600-800 micron thick dual layer coating
 Fittings & Components in Pipeline

• Fittings:
– Elbows & Bends
– Flow Tees
ASTM A 234
– Insulating Joints ANSI B 16.5 & 16.11
– Weldolet / Sockolet
– Flanges
– Gaskets
– Fasteners
• Valves:
– Sectional Valves
– Tap Off Valves (future API 6D
provisions)
 Construction Stages

• Pre-constructional Activities

• Construction Activities

• Testing and Commissioning

• Handover to Operations
 Construction Stages

• Pre-constructional Activities
Activity Description / Steps

Planning • Resource & Equipments

• Scheduling of activities & milestones
Scheduling
• Material Ordering / Delivery schedule
Mobilization • Mobilization of Manpower & Equipment

• Approval of procedures for various activities

Procedures /
• Welding Preparedness (WPS/PQT, EQT, Welders Qualification)
Qualifications
• Insulators’ qualification
• Safety Trainings
Training
• Site Briefing
Readiness to Start
• Kick off Meeting
Construction
 Construction Stages

• Construction Activities

Activity Description / Steps

Grading • RoU clearance, Marking and cleaning
• At Correct depth
Trenching
• With the help of Machines or Labors as per site requirement
Stringing • With the help of Hydra or Side Boom
• Welding as per approved procedures by qualified welders
Welding & NDE
• Non Destructive Testing – X-ray/UT/MPT/DPT
• Heat Shrinkable sleeves or R-95 (Material TC required)
Joint Coating
• By qualified insulator
• Lowering of pipe section
Lowering
• Tie-in Joints
• River/ Drains/Railway/ Highways/ Canals
Special Crossings
• By HDD or Push Jack Boring
Backfilling & • Backfilling & Crowning
restoration • Manually / with Machine as per site requirement
 Construction Stages

• Testing & Commissioning, Handover to O&M

Activity Description / Steps
Cleaning • Cleaning of pipeline prior to start hydrostatic testing
Hydrostatic • Water filling, Air volume calculation before pressure holding
Testing • Pressure Holding & Monitoring (min.24 hours after temp. stab.)
• Dewatering & Cleaning
Valves • Installation of Valves
• Construction of Valve chambers
TCP • Installation of TCP
• Review readings
Readiness • Readiness review of pipeline jointly by Projects/O&M team including
review of documents/records/deviations, route visit, etc
• Preparation of punch points, Compliance to HOTO procedure
• Intimation to Local Authorities prior to Gas in.

Purging & • Purging with Nitrogen. Ensure <2% O2 before gas in

Commissioning • Commissioning
Hand over • Handover to O&M for routine operations / maintenance
 Project Management in GSPC Gas

• Execution by Contractor
• Inspection & Certification for quality by TPIA
• Project Management by PMC
• Overall monitoring by GSPC Gas
Photo : Steel pipeline site
CPRS/DRS : typical schematic
Photo : DRS/CPRS
 Components

• Filter : filter cartridge, DP Gauge

• Two streams of :
– Active regulator
– Monitor regulator
– Slam Shut off Valve
– Creep Relief Valve
• Pressure Gauges
• Pilot regulators
• Ball Valves
 Design Parameters

• Maximum inlet pressure: 49 BarG

• Differential Pressure (Min.) : 0.5 BarG
• Outlet pressure range: 4 BarG
• Flow rate @ min inlet pressure: 2000 SCMH/ 5000 SCMH
• End Connections : 4”/6” depending upon capacity

Land Requirement
• 30-36 Sq. Meter
• No overhead electric lines / min. Distance 6 mtrs from HT/LT
• Land should not be in a water logged area
• Safe distance from Garbage collection/storage point
 Installation & Commissioning

• Proper platform to be constructed

• Inlet/outlet piping Installation as per the approved layout
• Maintain proper alignment of installations
• Proper support to inlet/outlet piping
• Earthing to be provided
• Vent height should be at least 3 meter from the ground level
• Fencing of area recommended
• Caution Board to be provided
• Site Acceptance Testing before commissioning
• Readiness review / HOTO with O&M
• Gas in
Photo : Steel Valve Chamber
Thank You…