Professional Documents
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GSPC GAS
The Pathway
GSPC Gas Company Ltd., a group company of the Gujarat State Petroleum Corporation has been
established to complete the presence of GSPC in the Energy Value Chain. GSPC Gas always
works towards a principal aim to supply natural gas to retail customers, i.e. Domestic,
Commercial/Non-Commercial, Industrial and CNG. GSPC Gas is playing a vital role to cater to
the natural gas demand up to the last mile of the retail network. GSPC Gas is envisioned to be
complementary to Gujarat State Petronet Ltd. (GSPL), which is evident from the presence of
GSPC Gas retail network starting at every point and location that the GSPL network ends.
Core Philosophy
The GSPC Group's foray into Gas Distribution in a big way bears testimony to the core
philosophy of being 'A Complete Energy Company'.
GSPC Gas is supplying natural gas to more than 4, 96,138 domestic households, 1,918
commercial and non-commercial segments and 1,897 industrial customers. GSPC Gas also
supplies natural gas in the form of Compressed Natural Gas (CNG) through 159 CNG
stations across the state that caters to more than 89,000 vehicles per day.
II. Industrial Usage: It is used to treat waste material, for incineration, drying,
dehumidification, heating and cooling, and cogeneration. It is used as an input to
manufacture pulp and paper, metals, chemicals, clay, glass and to process certain foods.
III. Commercial Purpose: Main commercial centers which use natural gas are Hotels,
healthcare facilities and office buildings for cooking, cooling and heating purposes.
IV. Natural Gas Vehicles (NGVs): It can be used as a motor vehicle fuel – as CNG
(Compressed Natural Gas) and as LPG (Liquefied Natural Gas). Natural gas vehicles
fleet accounts for about one and a half million vehicles worldwide. Concerns about air
quality in most parts of the world are increasing the interest in using natural gas as a fuel
for vehicles. Cars using natural gas are estimated to emit 20% less greenhouse gases than
gasoline or diesel cars. In many countries NGVs are introduced to replace buses, taxis
and other public vehicle fleets. Natural gas in vehicles is inexpensive and convenient.
1. Green Fuel
Commonly referred to as the green fuel because of its lead and Sulphur free character, CNG
reduces harmful emissions. Being non-corrosive, it enhances the longevity of spark plugs. Due to
the absence of any lead or benzene content in CNG, the lead fouling of spark plugs and lead or
benzene pollution are eliminated.
4. Safety
CNG is less likely to auto-ignite on hot surfaces, since it has a high auto-ignition temperature
(540°C) and a narrow range (5%-15%) of inflammability. It means that if CNG concentration in
the air is below 5% or above 15%, it will not burn.
5. Low Operational Cost
At the prevailing price of fuel in Gujarat, operational cost of CNG vehicles is 68% lower than
petrol and 36% lower than diesel.
2.2. Piped Natural Gas (PNG)
Natural gas which is maintained at low pressure less than 4 bar and carried by poly ethylene
pipeline mainly used for cooking in houses and various industrial purposes.
The ratio of carbon to hydrogen is least in methane and hence it burns almost completely making
it the cleanest fuel. It is procured from the oil / gas wells and transported through a network of
pipelines across the country.
1. Uninterrupted Supply
PNG offers the convenience of ensuring continuous and adequate supply of NG through pipeline,
without any storage of gas in cylinders.
2. Unmatched Convenience
The domestic consumers have to take upon themselves the tiresome task of booking an LPG
cylinder; refill time and again start the wait for the deliveryman to deliver the cylinder. Switching
over to PNG renders this entire exercise unnecessary. PNG also eliminates the tedious routine of
checking LPG refill cylinder for any suspected leakage, or it being underweight, at the time of
delivery. Precious space, occupied by LPG cylinders is also saved.
3. Safety
The combustible mixture of natural gas and air does not ignite if the mixture is leaner than 5%
and richer than 15% of the air-fuel ratio required for ignition. This narrow inflammability range
makes NG one of the safest fuels in the world.
Natural gas is lighter than air. Therefore, in case of a leakage, it just rises and disperses into thin
air given adequate ventilation. But LPG being heavier will settle at the bottom near the floor
surface.
A large quantity of LPG is stored in liquefied form in a cylinder. With PNG, it is safer since PNG
installation inside your premises contains only a limited quantity of natural gas at low pressure
i.e. 21 millibar.
On leakage, LPG expands 250 times, which is not the case with PNG. Supply in PNG can be
switched off through appliance valve and isolation valve, which fully cuts off the gas supply.
4. Billing
The user is charged only for the amount of PNG used, and no pilferage is possible with PNG as
the billing is done according to the meter. A unique feature is that the user gets to pay only after
consumption of gas. The domestic consumer pays the PNG bill only once in two months.
Moreover, there are no minimum consumption charges i.e., if there hasn’t been any consumption,
there shall not be any bill.
The user pays the gas consumption charges based on the exact consumption reading provided by
the meter installed at his premises. The bill is delivered at the user’s doorstep.
5. Customer Support
Round-the-clock customer support is assured through 24 hours toll free number backed by
control rooms, which are manned by engineers and trained technicians. Thus complaints, if any,
are promptly redressed.
6. A Versatile Fuel
Natural gas is being used predominantly as a versatile fuel in many major cities catering to
domestic and commercial applications, as a cooking fuel, for water heating, space heating, air
conditioning, etc.
7. Environment Friendly
Natural gas is one of the cleanest burning fossil fuels, and helps improve the quality of air,
especially when used in place of other more polluting energy sources. Its combustion results in
virtually no atmospheric emissions of Sulphur dioxide (SO 2), and far lower emissions of carbon
monoxide (CO), reactive hydrocarbons and carbon dioxide, than combustion of other fossil fuels.
8. No Daily Liasioning
The consumer is spared the task of liasioning with oil companies and co-coordinating with them
for ensuring the daily supply of fuel, because PNG is supplied directly through pipes. The daily
bills, settlements and reconciliation are also avoided as the consumer is billed once a month, and
that too as per the meter reading.
Currently the CGD segment constitutes 10 percent of the total gas consumption in India. It is
worth noting that this has been achieved in the past five years itself. It is expected to reach a
share of 20 percent by FY20. The supply of natural gas for CGD is around 13 mmscmd in FY11
against the demand of 15.83 mmscmd in the country. Increasing demand from commercial and
small industrial customers within the city limits, in addition to the automotive and residential
demand, are the key drivers of growth in this segment. Much of the demand in future will
continue to be as a result of customers finding natural gas to be more competitive than other
fuels coupled with ease of handling and lower pollution.
On the supply side expectation of large volumes of gas being made available within the next few
years, though both new domestic finds and imports, has created greater compulsions for
developing the CGD market. With an estimated demand of 100 mmscmd by FY 20, CGD market
is expected to grow by leaps and bounds.
Table 3
S. Name of the CGD
Area Covered Entity Authorized
No. Network
1 Sonipat CGD Network Sonipat Gail Gas Limited
2 Meerut CGD Network Meerut Gail Gas Limited
3 Kakinada CGD Network Kakinada Bhagyanagar Gas Limited
4 Dewas CGD Network Dewas Gail Gas Limited
5 Kota CGD Network Kota Gail Gas Limited
6 Mathura CGD Network Mathura JV of M/s DSM Infratech Pvt. Ltd. &
M/s Saumya Mining Pvt. Ltd.
7 Chandigarh CGD Network Chandigarh M/s IOCL-AGL
8 Allahabad CGD Network Allahabad M/s IOCL-AGL
9 Jalandhar CGD Network Jalandhar M/s Jay Madhok Energy Pvt. Ltd.
10 Jhansi CGD Network Jhansi M/s Central UP Gas Ltd.
11 Bhavnagar CGD Network Bhavnagar M/s Gujarat Gas Company Ltd.
12 Jamnagar CGD Network Jamnagar GSPC Gas Company Limited
13 Firozabad Geographical Area Firozabad GAIL Gas Ltd.
Geographical
Area (U.P.)
14 Agra CGD Network Agra Green Gas Ltd.
15 Hyderabad CGD Network Hyderabad Bhagyanagar Gas Ltd.
16 Indore CGD Network Indore including Avantika Gas Ltd.
Ujjain
17 Gwalior CGD Network Gwalior Avantika Gas Ltd.
18 Gandhinagar, Mehsana, Gandhinagar, Sabarmati Gas Ltd.
Sabarkantha CGD Network Mehsana,
Sabarkantha
19 Pune City including Pimpri, Pune City Maharashtra Natural Gas Ltd.
Chichwad CGD Network INCLUDING
Pimpri,
Chichwad
20 Kanpur CGD Network Kanpur GA Central U.P. Gas Ltd.
21 Bareilly CGD Network Bareilly GA Central U.P. Gas Ltd.
22 Delhi CGD Network National Capital Indraprastha Gas Ltd.
Territory of Delhi
- A typical CGD Network shall comprise of one or more or all of the following:
3.) Regulating Stations – District Regulating Stations (DRS), Service Regulators, Domestic/
Commercial/ Industrial Regulators
Fi
gure 3 – Basic System Flow Diagram (Schematic)
The main Components of City Gas Station and their function is as follows –
5.1.1. Filtration Skid: Dust particle and liquid coming with the gas stream are separated by
high efficient filters in KOD. Gas is maintaining same pressure from the inlet to the filtration
skid. After the filtration two streams are dividing from the main line using a header. Line which
is in function is known as active line where another one is called passive line.
5.1.2. Pressure Reduction Unit: A pressure reduction valve is installed for the reduction
of the gas stream pressure from 40-45 bars to 25-30 bars. Creep relief valve and Slam Shut off
valve is being installed in this skid for the safety purpose.
5.1.3. Metering Skid: Metering skid is installed for the gas flow measurement. Orifice meter
is used in this metering skid; because of the large pressure drop requirement. The various
parameters such as temperature in the various sections of the line pressure at the inlet & outlet
joints, flow inlet & outlet are monitor by the SCADA systems in the control room.
5.1.4. Odorization Unit: An Odorization unit is installed for addition of ethyl Mercaptan in
the gas stream. The dozing unit of the ethyl Mercaptan should be of 9 mg/m3. This unit consists
of mainly two cylinders of capacity of 160 kg, pneumatic panel, level indicator and a filter. This
unit is directly connected to the main line after the metering skid.
5.2. Steel Pipeline – It is the Primary Network in the form of Transmission Pipeline (Up
to CGS) and Distribution Pipeline (CGS Downstream, Ring).
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.
Velocity: Max. Allowable velocity of the gas in the steel pipeline Section of CGD
network shall be 30 m/s.
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
5.2.2.1. Type:
5.2.3.3. Welding:
1.) Fillet weld: A weld of approximately triangular cross section joining two surfaces
approximately at right angles to each other in a lap joint, tee joint, or corner joint.
2.) Butt weld: It is used to connect the parts which are nearly linear and does not overlap.
3.) Girth weld: It is a complete circumferential butt weld joining pipe or components.
4.) Seam weld: The longitudinal or helical seam in pipe, made in the pipe mill for the
purpose of making a complete circular cross-section.
5.2.4. Cathodic Protection - There are two main types of cathodic protection systems:
galvanic and impressed current.
5.2.4.1. Galvanic system: Makes use of the corrosive potentials for different metals.
Without CP, one area of structure exists at a more negative
potential than another, and corrosion results. If, however, a much less inert object (that is, with
much more negative potential, such as a magnesium anode) is placed adjacent to the structure to
be protected, such as a pipeline, and a metallic connection (insulated wire) is installed between
the object and the structure, the object will become the anode and the entire structure will
become the cathode. That is, the new object corrodes sacrificially to protect the structure.
Galvanic anodes are usually made of either magnesium or zinc because these metals have higher
potential compared to steel structures.
5.2.4.2. Impressed current systems: Use same elements structure and is protected by
applying a current to it from an anode. The anode and the structure are connected by an insulated
wire and current flows from the anode through the electrolyte onto the structure, just as in the
galvanic system. The main difference between both systems is that the galvanic system relies on
the difference in potential between the anode and structure, whereas the impressed current
system uses an external power source to drive the current. The external power source is usually a
rectifier that changes input A.C. power to the proper D.C. power. Impressed current cathodic
protection system anodes typically are high-silicon cast iron or graphite.
Table 13
Table 14
3.) Pressure reduction (active / monitor combination) skid with minimum 50%
redundancy including slam shut valve for over pressure protection.
The flow capacity of DRS is in range of 5000-10000 SCMH. The inlet line of DRS is steel
pipeline and outlet is polyethylene pipeline carrying a pressure of 4 bars.
The plug movement is controlled by the diaphragm 10 by the following forces acting on it:
1.) Downwards: the force of spring 16, the thrust deriving from the regulated pressure Pa in the
top diaphragm chamber and the weight of the diaphragm assembly;
2.) Upwards: the thrust deriving from the motorization pressure Pm in the bottom diaphragm
chamber, supplied by the pilot.
Filter 41 filters gas and is subjected to initial reduction in the first stage pilot, composed
essentially of a plug 37, a spring 28 and a diaphragm 34A to a value, which depends on
the pressure set point of the regulator.
The pressure then passes to second stage pilot that controls pressure by plug 35, a main
spring 28 and a diaphragm 34B to the motorization pressure Pm, which is supplied to
bottom diaphragm chamber of the main regulator.
The regulation of Pm is obtained by the comparison of the force exerted by setting spring
28B of the pilot and the action of the regulated pressure Pa, acting in the chamber below
the diaphragm 34B.
The control mechanism (Pilot 1) has a latching arrangement holding main valve stem in
open position. The sensing element is pilot regulator (Pilot 2) continuously monitors the
line pressure to be safeguarded.
This pilot spring diaphragm type valve, in case of over pressurization gives signal
pressure to control mechanism which in turn trips off main valve.
In normal condition the Pilot-2 remains in close position. The main valve remains in open
position by holding the plug rod 14 by rack 21 through ball catch arrangement in Pilot-1.
Whenever the pressure monitoring by Pilot-2 exceeds above its set intervention value the
diaphragm 48 moves upward displacing the plug 47.
Thus the pressure passes to Pilot-1 diaphragm 27 pressing it along with push rod 25,
pressing the ball 41.
The rack 21 latched by the ball gets released resulting in downward movement of plug 7
and plug rod 14 closing the valve. The visual indicator 32 will indicate the position as
CLOSE.
The valve can also be shut off manually by pressing knob 33 on pilot-2.
The controlled pressure is generally set to a pre-determined designed value using adjusting
screw. This is the maximum pressure which pressure-gauge (installed on upstream side of control
valve) indicates when the fluid is not flowing through the valve. Any accumulation of the gas
results in increase in controlled pressure. This result in increase in the compensation force, which
balances the controlling force, hence valve opens. This releases the rise/build up in the upstream
pressure. Thus, it is clear that the pressure will not be the same during no-flow and during flow-
passing through valve. Hence rise in the controlled pressure, during operation/flow through the
valve, is to be accepted in principle and one should not try to re-set the valve/pressure because of
the draw of fluid. The controlled pressure is expected to rise to allow for discharge to the
downstream side of the valve.
5.3.4. Non Return valve (NRV) - It is also known as check valve. It maintains
unidirectional flow and restricts reverse flow. It operates by itself by application of pressure
present in line, minimum pressure range is required to operate this valve.
A. The distribution pipe is with standard dimension ratio (SDR 9) for 20 mm, (SDR 11)
from 32 mm upto 63 mm and (SDR 17.6) for above 63 mm. The term SDR is defined as
the normal outside diameter (DN) divided by the minimal wall thickness.
B. It is standard practice in India to have a minimum 1 m cover. All MDPE Pipe back filled
with sand around it to protect the plastic material.
5.4.1. Specifications
Tech. Spec.: IS 14885:2001 & ISO 4437
Material Grade & Color: Internationally approved resins of PE 100 grade of Orange color
Minimum Required Strength (MRS) of PE 100 Grade pipe: 10 MPa
Operating Pressure: 4 Bar, Operating Temperature Range: -10°C to +40°C
High resistance to corrosion and Low Heat Conductivity (low thermal loss).
5.5. PE Laying
‒MP Network
1. The MP PE network starts from downstream of DRS/CPRS and distributes the Natural
Gas till the different Service Regulator located nearby a cluster of domestic customers or
a main commercial customer or Industrial Customers upto MRS/IMS.
2. The PE mains are subdivided into sections by means of adequately located manually
operated valves (Note: As per PNGRB in MP network minimum one at every 1 Km).
‒LP Network
1. The LP Network in PE starts from the downstream of Service Regulator (SR) and brings
the natural Gas to domestic customers.
4. To check underground utilities with a minimum clearance of 25cm. from PE pipe. If not
maintain min clearance distance to cover pipe by using RCC half round / PVC sheet.
5. When two PE pipeline (MP & LP) to be laid in same trench then min. 300mm distance to
be maintained between two pipes. Also MP pipeline is to be laid at Road side and LP
pipeline to be laid at extreme side of the road.
6. Pipe laying at the center of the trench for proper sand padding surrounding PE pipes.
7. 75mm sand bedding below pipe in case of normal soil and 150mm in case of rocky
terrain and 75mm sand padding above pipe.
8. Stone free soil backfilling above sand padding upto 0.5 mtr. Of PE pipes.
10. Backfilling entire Trench, Watering and Compaction, Excess soil scrapping.
Figure 16 - Trench Dimension for PE Pipeline: Size – 32mm. Similar for other Pipe Sizes
ii. 90 mm dia. PE pipes can be used without any EF joint in between if the crossing length is
less than 100 mtr.
30 City Gas Distribution by Sarthak Kishore| GSPC GAS
CITY GAS DISTRIBUTION
I. The pipes ends to be welded must be cut at right angle by using proper pipe cutters.
II. Visually check that the pipe/fitting surface is free of defects such as cuts, abrasion etc.
III. Avoid using excessive ovalized pipes. Remove Ovality by using Re-round tool. Clean the
pipe ends from dust, grease, dirt etc.
IV. Mark the scraping area with an indelible marker pen. The scraping area must be 10mm
larger than the insertion depth of the fittings.
V. Remove the oxidized surface from the pipe, by scraping it. Remove an uniform surface
for a depth of approximately 0.1mm for pipe diameter upto 63mm and 0.2 mm for pipe
diameter higher 63mm.
VI. AVOID ABSOLUTELY other scraping equipment such as abrasive paper, rasp, emery
wheels, saw blades, etc. other than Mechanical/Manual scrapper.
VII. Before inserting the fitting on the pipe, clean the scraped surface using isopropyl alcohol.
VIII. Clean with the same chemical the inner surface of the fitting, which has to be removed
from its protective wrapping only at the moment of use.
X. The aligning clamp must be used for all diameters to be welded which, Protects, during
the electro-fusion and the subsequent cooling, mechanical stresses on the jointing.
XI. Allows revising possible off-centering between both ends to be welded and to recover the
out-of-round of parts, it ovalized.
XII. In case of EF coupler welding, sign a mark using an indelible pen on the two ends to be
welded corresponding to the depth of insertion, equal to half length of the coupler.
XIII. Insert the coupler up to the location mark and fasten the pipe into the aligning clamp.
XIV. Connect the plugs of the control unit to the terminals on the fittings and proceed with the
set-up of the welding parameters, strictly following the instructions of the welding unit.
XV. When the fusion cycle is completed, verify the fusion indicators coming out. The fusion
indicators are located near the terminal connection of the fitting.
XVI. Cooling, in order to avoid possible stresses on the jointing, strictly respect the cooling
time indicated on the bar-code and do not remove aligning clamp of the fittings.
These are installed before tertiary PE lines, generally located at customer premises for
maintaining supply pressure and designed to maintain safe condition even in the event of rupture
in the regulating downstream section. It reduces the pressure from 4 bars to 110 mbar to the
service device.
Table 15
2.) Min. Distance to be maintained - 10.0 Mtr. from any turning / junction of the road, 15.0 Mtr.
from Bus stand or public gathering spot, 15.0 Mtr. from any above ground electrical installations
i.e. Transformer, Junction box, Pole etc.
3.) Water logged area, In front of Entry / Exit of building / Shop/Garbage collection area is avoided.
5.6.2. Installation of SR
A. Installation of Service regulator module shall be done as per the foundation drawing
/specification.
B. 90 degree EF elbow shall be used for hook-up of the Service Regulator for 63mm and
above size pipeline.
5.6.3. Testing of SR
I. Pre-commissioning testing for performance of safety devices i.e. UPSO, OPSO, and
Relief valve, which is integral part of Service Regulator, shall be done.
II. The set pressure of Service Regulator for different features are as per the below:
–Set Pressure: 100 – 110 mbar
–UPSO: 50 mbar
–OPSO: 150 mbar
- All electro-fusion joints (SR Hook up joints) shall be checked with soap solution before
commissioning of Service Regulator.
5.6.4. Commissioning of SR
A. Ensure all installation and pre-commissioning activities are completed. Inlet and Outlet
valves shall be kept in closed position.
C. Leak test shall be carried out upto upstream of inlet valve. If no leakages found, open
inlet valve of Service Regulator and ensure no leakages upto outlet isolation valve.
D. Monitor Outlet pressure of Service Regulator for 5 min. before opening outlet valve.
E. Ensure positive lock-up pressure (to confirm no leakages or open end during
commissioning) in downstream network before opening outlet valve.
F. Ensure that not a single domestic connection has been connected through downstream of
the network which is to be commissioned.
G. Release lock up pressure before opening outlet valve of SR and by keeping inlet valve
closed.
H. Slowly open inlet valve first and subsequently outlet valve of Service regulator to allow
Gas – in the downstream network.
A. Isolation valve to be installed at every 1.0 km on 90mm dia. and above PE pipeline
Medium Pressure network. Where tapping of 90mm and above on Medium Pressure PE
network, PE isolation valve to be provided immediate after tapping.
B. Isolation valve to be installed before 2.0 meter of end cap for 125mm and higher dia.
Medium Pressure PE pipeline.
C. The valve shall be supported on a bed of firmly compacted by using fine sand.
E. Isolation valves shall be provided in PE pipe line at both ends of major crossing carried
out with Steel pipeline.
5.6.6. PE Testing
5.6.6.1 MP Network Testing: The MP Network will be tested at 7.0 bars for
C. Suitable Relief Valve set at 5% higher than i.e. 7.9bar test pressure shall be fitted at the
test to avoid over pressurization during testing.
D. The DRS/CPRS, Service Regulator and service line must be disconnected during testing.
The section to be tested must be completely isolated.
The procedure to follow the pneumatic testing and flushing of a LP network is similar to the
procedure for the MP network. Except for the following:
B. The Contractor will test network by section starting from the Service Regulator till all the
sections of the concerned area have been tested satisfactorily.
A. Pipe line marker shall be installed at every 200 mtr. distance on sizes of 63mm and above
PE pipelines. Also pipe line marker shall be installed at both sides of Main road crossing,
river crossing, railway crossing and any other locations as specified by GSPC GAS.
B. Marker installation shall be done as per GSPC GAS approved diagram. Ensure marking
on Pipeline Marker is as per approved drawing of GSPC Gas. Installation of Pipeline
route marker as per approved drawing of GSPC Gas.
5.6.8. Commissioning
C. Ensure pneumatic test report. Check and assure that the positive pressure in the pipeline
stayed equal as the pressure measure after testing.
E. Ensure that EF welding machine with ELCB (Earth leak circuit breaker).
G. The gas should be vent continuously by crack opening of valve until two reading confirm
a concentration of gas by methane detector.
B. Inlet Pressure Range – 1.5 Bar to 4 Bar, Outlet Pressure – As required by customer.
CRV - It is used here to relief excess pressure in line in case of over pressure.
PRV in customer premises - Same as PRV in CGS skid and CPRS skid it
reduces pressure as required. It operates without pilot valve.
36 City Gas Distribution by Sarthak Kishore| GSPC GAS
CITY GAS DISTRIBUTION
- The connection between consumer meter set assembly and gas appliance may be made by GI
Pipes or Copper Tubing or Steel Rubber Hose.
- Commercial Connection has same components as domestic connection but some customers
may have larger diameter GI Pipeline and higher pressure meter.
- The quantity of gas consumed by an average domestic consumer will remain almost same for
all customers. Basic data sheet is prepared based on practical assumption & past experience of
similar gas distribution industries. For estimating/calculating the peak demand of domestic
consumer we consider following assumptions.
1” GI pipe riser for connecting more than seven floors and up to sixteenth floor from
single riser & single connection on each floor.
Pipe shall not be installed on un-plastered wall or in the house under construction or in an
unventilated void space.
Route shall be selected that maximum length of the pipeline shall be installed outside.
Route of the pipeline shall be planned for the shortest possible length.
The gas pipeline and meter shall be away (minimum distance of 300mm) from the
electrical line and heat source. There shall be minimum change of directions and
minimum no of threaded joints.
Maximum two Point in the single kitchen for gas stove only.
Compound gate or doors and windows inside the house shall not hit the Gas pipeline, if
no alternative route found installs proper pipe protection guard.
Riser Isolation Valve: For apartments, one riser isolation valve shall be provided at a
height of 2 meter from the ground level.
Customer wise individual main isolation valve shall be installed. Brass made Regulator
and Meter adaptor shall be used.
Regulator shall be installed in such a way that it reduces the length of H.P. Line (Max.
pressure 0.1 Bar) to minimum possible. Wherever possible meter Regulator shall always
be installed outside residence and at a convenient height.
It is advisable to install Gas Meter shall in such a way that it shall be protected from
direct rain or waterfall on the meter. Location of the Gas meter shall be decided during
the route selection.
The position of the appliance valve shall be convenient to operate and it shall keep the
rubber tube at a safe distance from the heat source.
The orientation and distance from cooking platform/ground shall be maintained in such a
way that the Bending Radius of the Rubber Tube shall be more than 100mm.
Appliance valve shall be installed in ventilated space and the lever of appliance valve
shall not foul with the wall during the on-off operation.
After site and route clearance, the measurements for pipe cutting shall be taken and pipes
shall be cut accurately as per the required lengths.
Installed piping threaded connections / joints shall be tightened in such a way that all the
joints shall be free from heavy stresses and misalignments due to incorrect pipe length.
Cutting fluids (oils) shall be used while thread cutting.
The condition of thread die and pipe vice jaws shall be checked regularly and shall be
free from defects. BSP taper thread dies to be used for threading and shall be checked
with “GO” and “NOGO” gauge.
Threaded pipes shall be handled carefully so that the threaded oily portion shall be free
from dust, mud, water and any damage due to impact of any object.
Cutting burrs on the pipe shall be removed from the edges. The edges shall be straight
and free from Knife-edge formation.
Teflon tapes of approved make shall be wrapped on threaded portion of the pipe with
minimum three overlaps.
The pipeline portion containing the Regulator and Meter, either horizontal or vertical,
shall have clamps on both side of the regulator and meter. Clamps shall be fitted in such a
way that they do not create misalignment of pipes.
The clamp shall be installed by drilling 6 mm hole in plastered wall and screwed using
rowel plug. The clamps should be fixed properly on the walls and grip pipe in position.
Distance between two clamps shall not be more than 1.0 meter. Clamps shall be installed
in a straight line and shall be parallel to each other.
Self-adhesive anti-corrosive tape shall be wrapped on the pipe with 50% overlap. Casing
sleeve shall be installed in wall for wall crossing.
Wherever compound gate, house door or window may hits the G.I. pipe, protection clamp
shall be installed to protect the pipe. Concealed piping shall not be done.
All the pipes shall run on walls with clamps. Pipe should not be overhung and shall not
be installed without pipe clamp.
PE to GI (transition fitting) threaded joint shall be provided above ground. PE pipe length
should be 1.5 meter of transition fitting.
Before carrying out the pneumatic test of the whole installation; testing assembly, air foot
pump with pressure gauge / manometer shall be checked its calibration and proper
functioning.
Before pneumatic testing of the installed connection spacing between two clamps,
tightening of the clamps thread joints, alignments of the whole piping shall be checked.
Valve shall be kept in open position and the appliance valve shall be kept in close
position.
Calibrated pressure gauge shall be used having the range of 0 – 1 Bar. Position of the
pointer of the pressure gauge shall not be marked with the marker pen on the glass. It
should be recorded in the test records.
Table - 16
After pressurization of the whole piping section shall be checked for the leakage with the
help of soap solution.
During the testing, air should reach up to the appliance valve. After completion of testing,
pressurized air shall be released from appliance valve only.
All the appliance valve and riser isolation valve shall be kept in closed position. Ensure
that meter and regulator adaptor shall be leak proof.
Open the burner knob and remove the plug from the hot plate.
Clean the simmer hole. Make the simmer hole of 0.6 mm with the help of simmer drill.
At the time of drilling the hole, ensure that it should not be inclined. Remove the dust
from plug.
After greasing, plug and knob should be properly positioned at their original position.
Remove the burner from hot plate and clean it. Open the existing jet (LPG) and replace it
by 125 no jet if it is big burner or 110 no jet if it is small burner.
Place the burner on its original position and connect the nozzle with appliance valve
using flexible and braided SURAKSHA rubber hose.
The length of rubber hose shall not exceed 1.0 mtr. Both the ends of the rubber hose shall
be clamped by metallic clamps on the nozzle.
Check all the joints with soap solution and ensure that the flame color should be blue.
Meter Job card to be prepared duly signed by Contractor, Customer & Third Party Inspector and
to be submitted to GSPC Gas immediately on completion of conversion.
I. Finalize the location of Industrial Metering Skid as per safe installation distance:
Table - 17
equipments
Boundary wall 2 meter
Bore well or sock pit/underground septic tank 6 meter
III. Installation of mounting pole to be done by customer within 3 to 5 meter from IMS.
IV. Installation of brick Chamber near hook up portion of skid and filling with fine sand to
protect PE pipe as per GSPC Gas requirement.
V. Chain link fencing to be done surrounding the Industrial Metering skid for restricted un-
authorized entry. Minimum distance to be maintained 1.5 meter from the foundation.
II. Supply and Installation of Regulators, Isolation valves, pipe fittings, fasteners and
consumables shall be done by the customer as per individual equipment flow and
pressure requirement.
III. Supply and installation of Gas train with safety interlocks, Gas Burner and equipment
conversion. Pneumatic testing of Internal Piping.
6.2.2.3. Electrical:
I. Un-interrupted AC power supply for Metering purpose and two separate earthing for IMS
to be provided and done by customer.
I. Internal piping installation shall be done through competent steel pipeline contractor.
II. Underground steel pipeline shall not be allowed inside the premises.
III. Jointing of Internal piping shall be done through welding method only. No threaded joints
shall be allowed for internal piping installations. Welding spatter should be removed by
grinding.
IV. Pipe should not be routed through heated zone like bhatthis / tandoor / furnace etc. For
wall crossing the pipe should be protected with anti-corrosive wrapping tape.
VI. Pipe support should be firmly fixed on wall and Pipe should be firmly tightened on
support with U bolt or to be installed on proper fabricated structure on ground.
VII. Pipeline shall not rest on support directly. Rubber sheet piece to be kept between pipe and
support to avoid erosion and leakage.
VIII. A safe gap of minimum 1" should be maintained between pipe and wall. Pipe support
should not be provided on temporary wall/shed/trees etc.
IX. Main Isolation Valve to be provided immediately after entering into industrial premise
and branch Isolation ball valve at each tapping from main header.
6.2.4. Testing:
I. Pipeline should be flushed with air or nitrogen to remove dust, dirt, welding spatter etc.
Meter and regulator should be removed before flushing. Flushing should be done from
each tapping.
II. Once flushing is completed entire pipeline shall be tested at min. of 1.5 x design pressure
(MOP) or 7 bar whichever is higher with air or nitrogen for 06 Hrs. Testing shall be done
with all isolation valves semi open. Pressure should not drop during testing hours.
III. Once testing is found OK, pressure should be vented out till pipeline pressure becomes
0.5 bars. Positive pressure shall be kept hold till pipeline commissioning.
6.2.5. Painting:
I. Selection of proper paints to be made depending on the environment conditions.
II. Entire pipe should be cleaned with wire brush. It should be free of welding spatter, dust,
dirt, rust and moisture.
IV. Primer and finished coat shall be done as per paint manufacturer recommendations. Final
coat shall be “Golden Yellow” color for gas pipeline identification.
V. Direction of gas flow should be marked along the pipeline at the interval of 2 meters.
II. Portable Fire Extinguisher of ABC type -10 kg. (ISI marked) to be placed nearby
Industrial Metering skid by customer before commissioning of Internal Piping.
III. “NO SMOKING”, Safety Instruction Board and other safety signage near Industrial
metering Skid.
IV. Customer internal piping with electrical bonding at joints.
VI. Intimation to GSPC Gas in case of plant shutdown/ No usage of NG for long time.
I. GSPC Gas engineer shall ensure undertaking from customer for successfully testing of
internal pipeline on their letterhead.
II. GSPC Gas representative need not to certify testing of customer premises internal piping.
I. GSPC Gas engineer shall ensure undertaking from customer for successfully internal
pipeline testing on their letterhead.
II. Tool-Box talk shall be conducted in presence of Industrial customer covering Do’s and
Dont’s.
III. Ensure positive lock pressure in internal piping before opening of Industrial Metering
Skid outlet valve to industrial customer.
IV. Ensure internal piping of Industrial metering skid up to equipment connected before
commissioning of metering skid, and no inter connection with other fuel system.
V. Ensure oil level in case of RPD meter before Industrial metering skid commissioning.
VI. Ensure all required accessories of meter are installed prior to commissioning.
VII. Ensure GSPC Gas engineer presence during commissioning of internal piping.
VIII. Industrial Metering skid commissioning report shall be prepared after commissioning.
Table -18
Commercial Meter: Pressure Rating: Suitable to withstand Max. Working Pressure of 200 mBar
Specifications:
V. Accuracy +1%
VI. Not sensitive against Disturbances, Not sensitive against fast changes against flow rates
A ball valve shall have a spherical closure member which rotates about an axis which is
perpendicular to the direction of flow. It is easier to obtain a tighter seal with a sphere
than with other shapes.
The valve shown has flanges end parts, which connect to the piping and are held to the
main body by bolting arrangement. The valve is operated by turning the spherical plug
(ball) a quarter turn in the clockwise (for closing) or anti-clockwise direction (for
opening).
48 City Gas Distribution by Sarthak Kishore| GSPC GAS
CITY GAS DISTRIBUTION
A check valve shall have a closure member(s) (as ball or a flapper) permit fluid to flow in
one direction only. Lift-check and swing-check are the two major types of valves used in
process work.
The lift-check, or ball-check, is most often used in 2- inch and smaller sizes. It has a ball
or guided plug which is lifted by fluid pressure and does not have a tendency to slam - as
the swing-check type does. For this reason, the lift-check valve is preferable for services
having irregular or frequent reversals of flow.
For sizes larger than 2-inch, the swing-check valve is most often used.
Table - 19
Sr. Description Frequency Responsi
No. bility
1. PNG Connection
3. Odorant System
3.1 Monitoring of Odorant Level/Smell Daily
3.2 Odorant transfer from Barrel to Tank When required
3.3 Monitoring/Inspection of Odorant Storage area
3.4 Leak Check of all joints and at the time of every Half Yearly PE/PNG
odorant filling
3.5 Pneumatic Test of Odorant Tank If Wall O&M
thickness varies Team
3.6 Calibration of Pressure Gauge Yearly
51 City Gas Distribution by Sarthak Kishore| GSPC GAS
CITY GAS DISTRIBUTION
transmission line and supplies the same to the customers/vehicles after filtration,
compression (upto 250 Bar) and check metering.
II. CNG is stored at compression stations which are directly connected with the gas pipeline.
Here the gas is compressed to a required pressure and aids fuelling. CNG can also be
transported to other retail outlets by cylinder trucks. These trucks carry a number of
cylinders which provide CNG to fuel stations which are not connected by pipelines.
III. The system has major assets like, Odoriser Unit, CNG Compressor, Storage facility,
Dispenser, LCV/HCV Filing Point, Mobile cascade vehicle, Electrical Installations, DG
set and Air Compressor. The size, rating and type of the major and sub assets are selected
based on the pressure rating, capacity and other applicable criteria considered for
refueling station for meeting the current and future customer potential, health and safety
of employees, customers and public at large, environmental protection and complying the
statutory, legal requirements, national and international technical and safety standards/
practices.
IV. Various operation and maintenance activities, as per annual operation and maintenance
plan are carried out for ensuring safe and uninterrupted gas supply.
1. Mother Station: A CNG station provided with whole set up (compressors, dispensers,
cascade etc.) along with a LCV filling point is known as a mother a CNG station.
2. Online Station: This CNG station has same set up as a mother station but LCV connection is
not provided for filling.
3. Daughter Booster Station: Daughter station provided with the compressor (known as
boosters) to compress the gas we are getting from the mother station are known as daughter booster
station.
4. Daughter Station: Daughter stations are established in those areas where laying a pipeline is
not possible. In that case gas is delivered from mother station to daughter station; via mobile cascade
van. The gas from mother station is filled in mobile cascade by a LCV filling point.
Steel line of 2 inches dia. coming to compressor as a suction line (25 bars). Suction line is
provided with isolation valve followed by a strainer for removing of foreign particles.
After strainer comes the suction filter of size 5 micron. From here the suction line is
divided into two lines, one is inlet to 1st stage of compressor and another one is
instrument line for operating actuator valves in the compressor.
Instrument line having a pressure of 25 bar it goes to a PRV which reduces pressure upto
6-8 bars for the SOV which provide functioning of actuator.
Now the main suction line goes in Non Returning Valve (NRV) which provides only
forward movement of gas. From NRV it goes into Blow down Vessel. We have two
interconnected Blow down vessels. In these, gas is stored which is mainly used during
startup of compressor.
Now from NRV it comes to main PRV & then first Suction volume bottle. From here it
enters to compressor.
Valve and Piston means in other compressors valve and piston are provided separately
but here valve is provided in the piston so function of both is performed by piston only.
The first stage is double acting stage; here compression is affected from both the ends of
the cylinder of the compressor. Then gas is sent to the intercooler for the cooling of the
gas.
Now gas from intercooler enters to second stage for the compression and again same it
goes to intercooler for air cooling of the compressed gas.
Finally it reaches to third stage for final compression from intercooler for the desired
final pressure of gas. At every stage, the gas pressure and temperature is:
Table -20
Final discharge line goes to separator first and then filter of size of 1 micron. Now gas
enters to mass flow meter for measurement. Water cooling is provided for the cooling of
the oil used in compressor. From mass flow meter gas comes to priority panel.
The following codes and standards (version/revisions valid on the date of order) are referenced to
& made part of specification -
API-11P (latest edition), API 661:1997, ASME VIII Div. 1999, API 618
BS 5514 - 1996.
ISO 3046/1
NFPA-37, OISD 179 and NFPA-52: 1995 or equivalent.
NFPA- 12, IS: 6382, Gas Cylinder Rule-2004
IS: 5571, IS: 5572, IS: 5580
Indian Electricity Rules, Indian Explosive Act
Standard specifications of Bureau of Indian Standards
Specification/Recommendations of IEC
Discharge line coming out from the compressor is splitting into five lines in sequence as:
3. Followed by medium pressure line divided into two lines one goes to cascade and
other to dispenser medium pressure bank.
4. Followed by low pressure line divided into two lines one goes to cascade and
other to dispenser low pressure bank.
Each line is provided with Non returning valve and pressure transmitter respectively.
Priority system having the following set points:
- High Bank - 220 Bar
- Medium Bank – 210 Bar
- Low Bank – 200 Bar
10.2.4. Cascades
A bank of cylinders used for buffer stock of compressed natural gas is known as cascade.
Stationary cascade is used to store the gas when vehicle is not there at the dispenser then
the gas from compressor flows into a cascade.
The cascade having horizontal cylinders and sited parallel to other cascade, cylinder
fittings should be arranged so that they do not face cylinder fittings of other cascade.
Cascade with horizontal cylinders shall have the valves fitted on the same side within the
cascade opposite to the refueling point and arranged in a manner that any gas leakage is
discharged upwards.
Gas storage facility shall be protected from the effects of the weather by a roof or canopy
designed to facilitate the dispersion of free or escaped gas.
Only dedicated trailer, truck or any other vehicle to be used for transportation of CNG
storage units. These units should have lugs fitted for lifting and in no case magnetic
device to be used for lifting purposes.
The vehicle with the cascade there own, shall be placed with easy access and egress on a
low platform or hard compacted ground, which shall extend to at least another one meter
on all sides and this platform or hard ground shall be under a light roof or canopy.
The trailers/ vehicle carrying CNG should be made immovable by application of brake
and wheel choke prior initiation of filling or dispensing operation. We have two types of
Cascades:
1. Stationary Cascade: These are fixed cascades established on CNG station for the storage of
CNG. It has a direct inlet from compressor and outlet to line connected
to dispenser.
2. Mobile Cascade: Cascade is mounted over an LCV and it carries CNG from Mother station
to Daughter station or Daughter booster station as per the requirement.
IS 7285
IS 3224
OISD-179
Gas Cylinder Rules-2004
Indian Explosive Act
10.2.5. Dispenser
Working of a Dispenser:
Gas from dispenser will dispense in the sequence: - low bank, medium bank and high
bank.
A PRV is connected to main line coming to the dispenser which is reducing the pressure
for the operation of Actuator.
It has filters (size of one micron) where oil and other foreign particles are removed.
I. A Natural Gas leakage without associated with fire from potential leakage sources e.g.
flange and valves in the DRS, CNG stations (Cascade connections), Valve Chambers,
MRS and customer premises.
II. A leak from the main Steel pipeline section (15-25 bar pressure) could be well damaging
and requires quick isolation of gas supply.
III. Any fire in customer premises (not a very credible scenario because of very low pressure
in the domestic section of pipeline) or a fire explosion in the gas/leak.
V. Preventive shutdown action during any Natural calamities, e.g. flood, earthquake,
epidemic, storm etc.
Level 1
Level 2
Level 3
On site emergency plan: A responsive plan to contain and minimize the effects due to
emergency within the installations.
Off-site emergency plan: A responsive plan to control/ mitigate the effects of catastrophic
incidents.
This is prepared by district management based on the data of the installation(s) given by all the
owners.
I. Site Incident Controller (SIC) or Incident Controller - means the person who
goes to the scene of the emergency and supervises the actions necessary to overcome the
emergency at the site of the accident.
- The City Managers / technical in charges at respective locations will be the Incident Controller.
II. Chief Incident Controller - means the person who assumes absolute control of the
unit and determines the action necessary to control the emergency.
- Respective Zonal Head of GSPC Gas is CIC for GSPC Gas Company Ltd.
III. Duty Manager - means the Manager nominated from time to time at corporate office
of GSPC Gas at Gandhinagar, on duty, whose role is to provide incident management
support during and outside working hours.
I. HSE Policy
V. Permit to Work ( Hot Work, Cold Work, Working at Height, Boring, Electrical Isolation
and Energization)
VII. HIRA (Hazard Identification Risk Assessment), QRA (Quantitative Risk Analysis)
X. Personal Protective Equipment (PPE) – Gloves, Safety shoes & glasses, Face Shields, etc.
XI. Tool Box Talks, Life Guards (focus on High Risk Activities)
XV. ERDMP (Emergency Response & Disaster Management Plan) – Each Zone has its own.
To define and assess emergencies, including risk and environmental impact assessment.
To control and contain incidents and their effects within the shortest possible time.
To inform employees, the general public and the authority about the hazards/risks
assessed, safeguards provided, residual risk if any and the role to be played by them in
the event of emergency.
To be ready for ‘’mutual aid’’ if need arises to help neighboring unit. Normal jurisdiction
of an OEP is the own premises only, but looking to the time factor in arriving the external
help or off-site plan agency; the jurisdiction must be extended outside to the extent
possible in case of emergency occurring outside.
Classification of Emergencies
Medical facilities
Incident reporting
The Regulations for Access Code was passed in June 2007 by PNGRB for Natural Gas
transmission Pipeline and City or Local Natural Gas Distribution Network. The main objectives
of this access code are –
1.) Promote the development of a competitive gas market by establishing uniform principles for
owners and users of gas pipelines to allow transport and non-discriminatory access to the gas
pipelines and CGD Network.
3.) Ensure that a Pipeline/CGD Owner provides minimum service of access to available capacity
on a “Firm Service” basis and/or on “Interruptible Service” basis.
Market Exclusivity
The entity winning the right to set-up CGD Network in a city will have 5 year marketing
exclusivity. After 5 years, the network will be thrown open to competition but a fresh entrant will
not be allowed to lay a new pipeline. It will have to use the network for which it will have to pay
a fee to the CGD Company.
However, a company that has operated a CGD Company for 3 years or more prior to the
appointment of PNGRB, i.e. 1st October, 2007 will have a marketing exclusivity for 3 years
compared to 5 years.
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CITY GAS DISTRIBUTION
Infrastructure Exclusivity
The CGD Company will have a lifetime exclusivity of 25 years for the pipeline network.
Eligibility Criteria
Those who want to obtain rights to set up a CGD network would need to meet the following
eligibility criteria:
Should have experience of laying aggregate of over 300 Km of oil and gas pipelines or
form a Joint Venture with a company which has that experience.
The entity should have experience of at least one year in operation and maintenance of a
CGD Network or should have a Joint Venture with 11% holding with another entity
having such experience.
Appropriate technical assistant agreement for at least one year with another party having
experience of operating and maintenance of CGD Network for at least a period of one
year.
An entity interested in developing a particularly City gas project needs to submit “Expression of
Interest” to PNGRB with Rs 8-12 Lakh as fee depending upon population of the city (Non-
Refundable), Geographical Area, market potential of CNG and PNG, business plan.
Developing CGD specific safety standards and developing & multiplying their
monitoring by the third party
Developing & multiplying core competence of skilled manpower to handle the operations
in cities after cities.
Proper understanding of regulatory act & mechanism to avoid contradictions for synergy.
iii. Too much control not to dampen the spirit of free competition.
i. Gas availability / allocation to all CGD entities, which are not gas
producer or marketer.
ii. Gas purchase pricing for CGD at affordable price for public good.