Welcome To

Presentation
AMPY Pipeline Solutions LLP
Adding Values through Audits & Inspections
Critical Observations / Findings (PPL)
 Non-availability of construction related documents

 No evidence of taking earth quake consideration while designing the pipeline

 HCDs not covering the entire area

 Pipe supports not meeting the requirement of Cl.1.8.7 of the Regulation

 The detail of dwelling unit or permanent structures is available for ROW but
not for 15M either side of the pipeline

 Non-availability of road around the facilities especially at old locations

Critical Observations / Findings (NGPL)

 No pigging in some of the pipelines due to operating at

low pressure

 Non-availability of construction related documents

 Passing of the first and last station valve i.e. valve on

scrapper barrel

 Non-availability of road around the facilities especially

at old locations
 Recommendations
 The audit check-list contains some construction related points – not
relevant to operation; may be dropped

 There is no provision of station limit valve in NGPL like PPL to isolate the
complete station during any emergency- Regulation is to be amended

 All critical valves above 8-inch size in pipelines should be remote

operated so that in case of any emergency it can be operated from
remote – It will eliminate a person going to filed during any hydrocarbon
leak which could be dangerous to him – Regulation is to be amended
 Way forward
 Clarity is required regarding inspection of all the stations (PS/IPS/Terminal) or
on a sample basis especially for a pipeline having multiple station

 Standard Terms and Conditions of Inspection or Certification is to be framed

which should be a part of the tender floated by the entity

 The auditing should be on concept of self-auditing followed by TPIA auditing

 A time limit should be fixed for first audit from the date of Notification of a
T4S Regulation
6th Capability Building workshop on
PNGRB T4S and IMS Regulations for
Empanelled TPIAs

Move Forward with Confidence

Major Observations / Findings of IMS Audit
- Awareness among management, employees and customers regarding PNGRB IMS
regulation is not adequate.
- Regular preventive maintenance procedures, checklist, SOP’s & action plans are not kept
systematically. Relevant information is not passed on to the concerned persons.
- Statutory permissions documents for laying and operations were not provided for review.
- ERDMP manual, HAZOP & QRA study documents not provided for review.
- As built alignment drawings were not available & piping layout drawings are not revised as
per onsite modifications.
- Internal audit mechanism to ensure continual improvement is not properly addressed.
- Consequence, Impact Analysis and Identification of High Consequence Area (HCA) are not
been addressed. Quantification of risk is not done with respect to above.
- Data management is big concern. Asset related design, manufacturing, inspection and
maintenance data is not easily traceable.
 Recommendations
- Improve & demonstrate awareness among management, employees and customers regarding
PNGRB IMS regulation.
- Effectiveness of communication plan shall be evaluated on regular basis.
- Employees & customers should be made aware of every possible risk and prevention measures
included in CGD Network.
- Records for the odorant dosing to be presented during next schedule of audit.
- All pending documents to be provided during next schedule of audit.
- Drawings shall be submitted after necessary revision. GIS based asset management system shall
be inplace.
- Extensive use of Internal audit tool to ensure continual improvement.
- Quantification of Consequence, Impact Analysis and Identification of High Consequence Area
(HCA) shall be done on priority.
Major Observations for IMS CGD

• Integrity assessment to be done for pipeline sections by suitable technique as

planned.
• In the SCADA system for CNG stations, Supervisory control is yet to be
established as presently only data acquisition is available..
• GIS mapping being not done in totality.
• Pipeline is protected by TCP in some of locations in NCR region.
• Odorant is presently being batch dosed (1cm3/18 sec). Dosing is not being
recorded and volume of dosing in ppm is not evaluated wrt regulation (Max
12ppm as per T4S). FBD & Khurja
• CNG Station inlet valve handle damaged and could not be manually
operated. In CNG stations that door interlock for simulation of CO2 fire
suppression system inside compressor has been kept in bypass mode.
Major Observations for IMS CGD

• Inside compressor following observed:-Gas detector sensor cover not

removed & Compressor door limit switch connection and cable tied with
clothes leading to bypass of CO2 Flooding system without proper
interlock bypass authorisation.
• Each isolation valve must be covered in preventive maintenance plan
including its operational & functional checks and observation must be
recorded.
• Non sparking tool not used during maintenance and emergency
• Surge Diverter to be provided across IJ.
• Periodic inspection of fire extinguisher not done, safety seal and hose
found damaged at locations visited.
• Compressor panel spare cable entry points are not plugged. They to be
plugged as per area classification.
 SINCE 1950

Dr. Amin Controllers Pvt. Ltd.

6th WORKSHOP ON CAPACITY BUILDING OF
EMPANELED THIRD PARTY INSPECTION AGENCIES
15 JANUARY 2020
Observations / Findings – for 2019-20
SINCE 1950


Entity has not confirms Impact value for 2 NPS Pipe

At Railway crossing, observed TLP PSP reading was taken
on one side as second side not accessible.

Domestic consumers, condition of rubber hose to the burners
was found very bad and in brittle condition. Also, observed
validity of the rubber hose has expired.

Laid steel network at CGS including DRS - Material & NDT
records not traceable to ascertain integrity of pipeline
sections in conformity to design standards.
Observations / Findings – for 2018-19
SINCE 1950


For PE fittings, test certificates following records not evidenced,
1. Polyethylene resins used for thermoplastic fittings is virgin,
2. Cadmium free pigmented compound.
3. Anti-oxidant and UV Stabilizers should not exceed 0.3 and
0.5 percent respectively
Recommendations
SINCE 1950

 Sampling plan to be finalized for T4S Audit.

 PNGRB empaneled IBs should be mandatory for certification of
construction activities of CGD.
 Daily inspection activities report should be finalized for an entity
to cover the essential content of T4S regulations.
 A joint workshop should be initiated on the latest national and
international standards as per the site applications.
 Associates with CGD entity (i.e. Manufacturer, contractor) should
be covered under accreditation/ Empanelment norms who
engaged with CGD construction activities respect to the T4S
Regulation the PNGRB.
Way forward
SINCE 1950

 FAQS portal to be developed for better understanding

and to promote an ideology of better productivities.
HERTZ INSPECTION & SERVICES PVT. LTD.

“Safety protects people, Quality protects jobs.”

SR.NO. OBSERVATIONS RECORDED DURING T4S AUDIT FOR CGD NETWORK

1 Timely commissioning of permanent cathodic protection (PCP) in place of

temporary cathodic protection (TCP) Unit for protection of U/G Steel PL.

2 Early mitigation of DC interference in M/L when observed.

3 Encroachment should be removed from ROW in M/L (if any) at the earliest for the
safety of people around Pipelines.
4 Monitoring of current density annually to see the current requirement of U/G Steel
PL.
5 Scheduled checks of Insulating Joints are required to ensure its function.

6 Short bolting found in vent filter system.

“Quality over quantity.”
SR.NO. OBSERVATIONS RECORDED DURING T4S AUDIT FOR CGD NETWORK

7 Earth pit resistance i.e. for individual electrode and for grid was mentioned on the cover plate.
The grid resistance was different on different Plates. It could not be verified on site.

8 Double earthing was not found on 3-phase, 415 V Motor connected to Air Compressor.

9 In Odourisation Unit , Vent system/pipe found inside roof shade.

10 N2 cylinder found in horizontal position in place of Vertical position in Odourisation Unit.

11 SOP displayed near the facility was not readable.

12 Odoriser dosing rate at CGS found non constituent. To ensure to get desired ethyl mercaptan
smell at the farthest point.
13 Approach road from road to CGS station not properly maintained.

“Build quality in upstream.”

SR.NO. OBSERVATIONS RECORDED DURING T4S AUDIT FOR CGD NETWORK

14 No Fire Extinguisher was placed in Battery Room.

15 No double earthing connection provided to both Air Compressor Motors.

16 Thickness Measurement validity date of Air Pressure Vessel had expired.

17 Hydrotesting validity of 75 kg DCP Fire Extinguishers had expired.

19 Operating Pressure Limits of CNG Compressors not mentioned in Compressor log book.

20 Review of CNG Compressor Log Book data are not evident.

“Quality means doing it right when no one is looking.”

SR.NO. OBSERVATIONS RECORDED DURING T4S AUDIT FOR CGD NETWORK

21 DMP Organogram with roles & responsibilities not displayed at CNG Station.

22 Charge jumpers at inlet flanges of Compressors are in damaged condition.

23 Identification of Emergency push button of compressor-1 and compressor-2 was not mentioned
at CNG Station Control Room.
24 Hydro test plate on all the CNG Vehicles not checked for validity of Cylinders before filling gas.

25 First Aid box not properly maintained. List of items not available.

26 Emergency numbers not getting displayed on DRS.

27 Fire Extinguisher not available in DRS.

“Quality is remembered long after the price is forgotten.”

SR.NO. OBSERVATIONS RECORDED DURING T4S AUDIT FOR CGD NETWORK

29 The pipe through wall was not passing through sleeve in many Commercial Customers.

30 Gas detectors with hooter/siren not provided in DRS located in residential area.

31 Electrical isolation permit was not found per OISD-105 standard.

32 Mutual aid agreement to include validity of agreement, meeting frequency etc.

33 Safety manuals and operating manuals are not reviewed periodically.

34 CO2 Cylinders of both CNG Compressors at some of CNG Station -Weight Gauge Glass is
blurred and needs replacement.
35 Cross-over to be provided over the Incoming header PL to DRS Inlet.

36 In the Battery Room lot of unwanted materials were lying.

“Quality is never an accident; it is always the result of intelligent effort.”

SR.NO. OBSERVATIONS RECORDED DURING T4S AUDIT FOR CGD NETWORK

37 In the Electrical Room, Insulation Mats are in damaged condition.

38 List of Authorised personnel for operating Electrical Panel was not displayed.

39 Identification mark for U/G Valve chamber not available.

40 Identification mark for P/L route marker and TLP not available.
41 House keeping of MRS of some of Industrial Customers was found poor. Outlet pipe had
been corroded and repainting required.
44 Calibration records of Safety Devices and Pressure Relief devices found expired at some
locations.

“Quality is never an accident; it is always the result of intelligent effort.”

 DMP Organogram with roles & responsibilities should be displayed at CNG Station.
 Safety manuals and operating manuals should be reviewed periodically.
 Fire Extinguisher should be placed in battery room.
 List of Authorised personnel for operating Electrical Panel should be displayed.
 Calibration records of Safety Devices and Pressure Relief devices should be properly
maintained.
 Gas detectors with hooter/siren shall be provided in DRS located in residential area.
 Operating Pressure Limits of CNG Compressors shall be mentioned in Compressor
log book.
 Scheduled checks of Insulating Joints shall be required to ensure its function.

“Safety begins with team work.”

 Meenaar Global Consultants LLP
Presentation

Petroleum & Natural Gas Regulatory Board on

Workshop for Capability building of the TPIAs empaneled
under PNGRB T4S and IMS Regulations
 Observations / Findings
 Critical observations for CGD-

 GIS BASED ASSET MANAGEMENT SYSTEM

GIS based Asset management system not implemented.

 Operation & Maintenance of CGD Network

Installation of Gas Detectors and earthing of various equipment’s like compressors,
DRS etc not evident.

 HSE Management System

Training programs not covers contractors and utility companies on
hazards associated with leaks/damages.

 Markers / Warning Signs – Not installed in urban areas and industrial parks.
 Observations / Findings
 Critical observations for CGD-
 At City Gas Station:
•Online odorization equipment is installed and maintained by OEM. As per record, 10 ppm is
dozed but display is not available. Shade is not provided for online odorization equipment.
Odorant absorber such as activated carbon saw dust and odorant neutralizer are not available.

 Common points for all CNG stations:

• Traceability to NABL was not evident for agency performing calibration.
• No earthing to the Gate and fencing of compressor
• Double earthing for lightening arrestor is not provided. Building is also not earthed.
• Double earthing is not provided for compressor foundation.
• Storage cascade is not earthed.
 Observations / Findings
 Corrosion Control & External Corrosion Control
ON/OFF Potentials – only ON potentials are recorded. Instant OFF potential is not being
recorded which is must to ensure ICCP system is protecting the pipelines as per OISD 233 –
Guidelines of non piggables pipelines.
Electrical interference at foreign pipeline crossings not being measured.
 Internal Corrosion Control
No monitoring regarding internal corrosion on steel pipeline is being implemented.

 Industrial Consumers :
• Fencing is not provided for IPRS installation.
• Warning sign board is not provided.

• Fire extinguisher is not provided

• Rust is observed on the GI pipe entry to the building

• Approval of IPRS installation by certified TPIA is not available.

 Recommendations
 Active monitor combination should be provided at CGS.

 Meter should be provided for gas measurement at DPRS.

 Fencing should be provided at IPRS installation.

 Fully equipped emergency vehicle should be available all the time.

 Sound pressure level monitoring should be evident at CGS and DPRS.

 Way forward
 PNGRB should start allocating the T4S audits on rotational basis to all the
authorized and empanelled TPIA so that they should have equal opportunity to
conduct the T4S audits / inspection as private entities could allocate their
favourite TPAI for T4S audits without considering competency level and on lower
rate rather than going for tendering process.

 Instead of City Gas entities float their separate tenders, PNGRB should provide
the single platform or web portal to all the City Gas entities where they can share
the requirement for conducting the T4S audit.

 Audit duration (number of days) should be specific for each entity based upon the
the assets available. Some methodology should be developed to calculate the
minimum number of days required to conduct the T4S audit.
MOODY INTERNATIONAL INDIA PVT. LTD.
INDUSTRY SERVICE DIVISION
Third Party Inspection Service in T4S Audit of CGD &
NGPL
by:
SIBENDRANATH ROY, J N AGRAWAL & AJAI SRIVASTAV
28 Jan 2021
 Major Recommendations for CGD
Sl No Recommendations
1 Gas detectors should be provided inside DRS/IDRS installations
2 GIS based asset management system should be available for CGD network
4 Off potential measurement should be taken once in a year for steel pipeline
5 Earthing of chain link fencing and gate should be done at installations
6 Valves should be placed at an interval of 1 Km for PE pipe
Boundary wall height should be extended to minimum 3 meter and 0.3 meter barbed wire on top of
7
boundary wall should be provided
8 Surge diverters should be provided across IJ
NABL accreditation for outsourced agencies engaged in calibration of instruments and masters should be
9
available with the entity
10 Coating repair should be done on the basis of CIPL and DCVG survey
 Major recommendations for NGPL
Sl No Recommendations
1 Continuity of flanges should be maintained
3 The minimum distance of 5 meter should be maintained from boundary wall to QOEC and scrapper
barrel.
4 Painting of above ground piping should be done

5 QOEC line should be replaced or risk assessment should be done for pressure classification as it is
lesser than minimum one third of main line.
6 Point support for piping should be rectified
7 NABL accreditation for outsourced agencies engaged in calibration of instruments and masters should
be available with the entity
8 Gate and barbed wire fencing should be earthed.
9 LEL detectors should be provided at IP stations and terminals
10 Pipe of thickness lesser than minimum 6.4 mm is required to be replaced.
Key concerns and suggestions for strengthening the
certification/ compliance process
Sl No Concerns Suggestions
Time is a constraint for quality audit as Benchmark should be made for minimum time to carry out
1 schedule is not mentioned in tender by clients audit of installations

A time bound rectification measures is not at A time bound rectification process or taking deviation
2 place. Audit observations are carried forward should be in place and carried out before next audit.
or no deviation is taken Defaulter entity should be penalized.

Design documents and records are mostly not In such cases, guidelines may be issued or amended as
3 available for old pipelines per requirement.

Extent of checks ( % of Qty ) of the installation In such cases, guidelines may be issued or amended as
4 is not mentioned by Clients in most of the cases per requirement.

Non-compliance to T4S regulations emerge TPIA engaged in supervising construction work should also
5 from lapses in TPIA supervision of construction be checked by PNGRB for quality output
work
PHISTREAM CONSULTING PRIVATE
LIMITED

PNGRB Empanelment Renewal

 NON – CONFORMITY
36

• The Pressure Reduction skid at CGS does not have Active/monitor combination with a minimum 50% redundancy
•NC- including slam shut valve for over-protection (Ref Schedule 1D, iv) of PNGRB T4S Standards).
01:
• The On-line odourization equipment designed to minimize fugitive emissions during loading, operation and
NC- maintenance is not installed at the CGS (Ref Schedule 1D, iv) of PNGRB T4S Standards).Hence, the 2.7 Km Steel
02: Pipeline is without odorant.

• Gas Detectors are not installed at CGS (Ref Schedule 1D of PNGRB T4S Standards, Network
NC- Design Requirements, City Gate Stations)
03:

NC-
04:
• Gas Detectors, Flame Detectors and Carbon-di-oxide flooding system installed in the CNG
NC-05 Compressors at Mother Station are not in working condition.
(a):
37
NON – CONFORMITY

• Gas Detectors and Flame Detectors are not installed at the CNG Booster Compressors. Carbon-di-oxide flooding system at CNG
NC-05 Booster compressors is not in working condition (Ref Point No 12 of PNGRB Approved Check List TPCA for CNG Stations).
(b):
• No evidence of external safety audit found (Ref Point No 13 of PNGRB Approved Check List
NC- TPCA for Safety).
06:
• Internal Audit observations of internal audit are not closed (Ref Point No 12 of PNGRB
NC- Approved Check List TPCA for Safety).
07:
 AREA OF IMPROVEMENT
38

• The TCP system of the 2.7 Kms Pipe line needs to be converted to PCP system for better control of the CP system

• As the Pipeline is more than 15 years old Caliper survey, CAT/DCVG survey are required to be done for assessment of
internal condition & external Coating condition of the Pipeline

• General housekeeping & condition of Electrical panel room in dealer maintained DBS (inspected by the Audit team) needs to
be improved

• Critical F/F equipment i.e. CO2 flooding system is not operational, requires immediate restoration
• Gas Detectors and Flame Detectors are not installed at the CNG Booster Compressors. Carbon-di-oxide flooding system at
CNG Booster compressors is not in working condition (Ref Point No 12 of PNGRB Approved Check List TPCA for CNG Stations).
Quality Services and Solutions Pvt Ltd
By Jayant Nabar

Presentation to PNGRB on status of QSSPL as TPIA

 Quality Services and Solutions Pvt Ltd

Observations / Findings
• Critical Observation for PPPL
1. Few valves at inlet manifold of Booster pump house and pig launching valves (HOV)are with welded ends
in Pump Station

2. It has been observed that mitre bends are used at suction line of booster pump area in PL. Since, Pipeline
is old pipeline before PNGRB T4S regulations.

3. As per test record of DCP Fire extinguisher no. D1, D6, D7, D13 & D19 failed in HT, carried out on
17.01.19.

4. Test record for radiography, ultrasonic test or other applicable NDT methods (as carried out before
commissioning) was not available.
Hydro-test (as carried out before commissioning) Report was not available.

5. Inter distance between Booster Pump Shed and Scrapper Launcher or Receiver not maintained as per
PNGRB regulation also found two nos. air receiver vessels between these two sheds, making the area mostly
hazardous.
 Quality Services and Solutions Pvt Ltd

7. LPBS for MOV 211, MOV 104., 63 Amp Welding switch socket Body earthing is provided, but terminated at
LPBS Canopy instead of LPBS BODY; It is not effective earthing for the LPBS. More over LPBS Canopy is badly
corroded, earth connections are badly rusted.

8. Three Marshalling JBs are installed & are in service, Flame Proof /EXD Type. No any tag identification on the
JBs. Middle JB, One No cable entry is open/unplugged. One of the JB Cover is half closed

9.JB cover for all the JBs are almost 75 % open, No earthing Provided, No any type tags provided for identification
and supporting frame is badly rusted.

10. All other Electrical Motors, MOVs in the same area Power cables are connected without any kind of straight
through joint. The MOVs located are hardly 350-400 Meter distance from Electrical Substation.

11. Amp flame proof Switch socket installed near MOV 305 , found with No Identification Tag , Input power source
also not mentioned , Allen bolts missing, Spare cable entry hole found unplugged.
 Quality Services and Solutions Pvt Ltd

• Critical Observation for NGPL.

1.Gas detectors have not been provided at terminals

3.The minimum distance of 5 meter is not maintained from boundary

wall to scrapper barrel.

4.QOEC line has been observed lesser than 1/3rd of main line.

5.None of the earth pits were painted with the test date every 6 months with date and resistance value ,
so could not be identified.

6.No spare bank available at CO2 flooding system

8.Thickness measuring locations on the piping and pressure vessels are not marked and numbered

9.Pipeline flanges of PCV -102 ,kickoff line are short bolted and one stud of PSV -102 flange is missing
 Quality Services and Solutions Pvt Ltd

• Critical Observation for CGD

1. Air Compressor rooms within Fenced area of CGS’s, and other electrical
fittings are with Non FLP equipment and accessories.
2. Original Pipe Book pertaining to the commissioning of GA’s not available
3. Most of the Cascade LCVs in all GA areas not fitted with spark arrestors
4. Fire Extinuishers maintenance and records are grossly inadequate
5. ERDMP manuals are required to be LOCATION specific not GA specific
6. Gas receipt /dispatch balancing not being done at all
7. Odourant reconciliation not being done/ records not available
8. Lightening arrestors provided at are in adequate. Equipment protection not
available. To be provided in line with IS 2039
9. For domestic connections , in buildings , Secondary pressure of approx. 4 bar
is taken upto the building, UG, and crimped to risers upto the regulator
reducing pressure from 4 bar to 21 mbar with no regulator inside the customer
premises. This is unsafe , and pressure at appliance should be ensured a
pressure of 21mbar , even if only 5 floors height are involved. As per PNGRB
tertiary lines to be of 100mb only
10. Boundary walls at all location not as per MHA guidelines
11. Checking of gas leakages in Steel/MDPE pipelines in congested areas not
being done .
12. All Equipment earthing not at two independent points , with proper earthng
strip and not flexible.
 Quality Services and Solutions Pvt Ltd

Major Recommendations for CGD,NGPL,PPPL,

1. Diploma holder engineers with 10 years of domain experience may be acceptable
2.Only 2 auditors team may be acceptable for less than 50-100 km spur, branch pipelines without
any critical equipment
3.More clarity on mitigation for very old pipelines to be discussed.
4. Criteria for Fitness for Purpose certificate to be clarified
 Quality Services and Solutions Pvt Ltd

WAY FORWARD

 New regulations of PNGRB for empanelment.

 Welcome To
SANMARG Engineering
SEVA
A TPI Service Provider
Validation and Assessment
Pvt. Ltd.
6th Workshop for Capability building
of the TPIAs empaneled under
PNGRB T4S and IMS Regulations
Observations & Recommendations

Sr No Observations & Recommendations

1. In CGD networks PCP has not been installed even after completion of 2 years.

2. Proper maintenance of API 6D/ API 600 Gate/ Ball/ Plug valves is not carried out.

3. Emergency Control Rooms are not identified in the installations.

4 Work Permit System to be followed strictly in line with the regulatory requirements.

5 Assembly Points to be properly marked in the installation.

6 QRA recommendations to be complied.

48
Way Forward

• Standard guidelines and empanelment of agencies for QRA &

HAZOP , Document Preparation to ascertain the quality of risk
assessment and documentation.
• PQ Criteria for TPIA bidders should not be restricted. It should be
open to all PNGRB empaneled TPIAs.
• Training on T4S , IMS , ERDMP Regulations and QRA and HAZOP.

49
 SGS Presentation
WORKSHOP ON CAPACITY BUILDING OF
THIRD PARTY INSPECTION AGENCIES

Petroleum and Natural Gas Regulatory Board

New Delhi: January 15th 2021
Key Observations/Findings of T4S audit

■ Temporary encroachments on steel pipe line observed at Railway crossing

near TLP Unit.
■ At domestic connections wrinkles observed in the bend area of copper tubing.
Copper tube to be checked after commissioning at bend area.
■ Rusted Fastners (Studs, nuts, bolts) in CGD networks shall be replaced with
hot dipped galvanized as per ASTM A 153 or equivalent.
■ For all underground DRS/DPRS, Gauges and other safety instruments calibration
plan not available, also not calibrated as per frequency since long time
Key Observations/Findings of IMS audit of NG
Pipeline Networks
■ Preventive maintenance schedule followed by the Bases is different from the
IMS Manual. It was informed that few schedules have been changed in the
recent Past and the data is also not maintained in the formats given.
■ Gas leakage survey of underground pipelines is not carried out as per IMS Manual.
■ Gas Test results from all supplies are not available at the Master Control Rom/ Bases.
Major Criteria of H2S and moisture control needs to be monitored.
■ The sludge analysis report indicates high sulphate.
■ Frequency of cleaning of filters is not documented and varies at Bases.
■ Pipeline Thickness for aboveground pipelines is carried out but co-relation study
with previous data is not done.
■ Out of 371 TLPs, 71 TLPs are missing and no action plan is drawn for replacement.
Key Observations/Findings of IMS audit of CGD
Network
■ Odorization Unit:
■ Neutralization Kit is incomplete

■ SOP for Odorization Unit, Do’s and Don’ts at Odorization Unit is not displayed.

■ PPEs is not available at All Odorant Station as per PNGRB T4S Requirements.

■ GAP Analysis of CGD System of Gasified Areas are not done after commissioning.
■ High Consequential Areas of Various GAs are not identified location wises.
■ No internal audit has been done after commissioning.
 Key Observations/Findings of IMS audit of CGD
Network
■ Most of the MDPE Valve Chamber observed without any Tagging on it. Valve Chamber tagging to
be done as GIS Mapping and Final As-Built Drawing.
■ Fire Mock drill with fire in tea shop opposite RO was carried out and major observations are given
below:
■ Action to be taken in such scenario was not known to the In-charge of RO.
■ There is no role clarity.
■ Such Mock Drill has not been carried out by BPCL / SGL any time in the past.
■ ERV response time: 45 mins.
■ Incoming vehicle entry barrier placed after 10 mins.
■ Fuel filling was not stopped.
 Recommendations for CGD
 Entities shall impart T4S & IMS related awareness training to all his
employees as well as Contractor’s employees also
 Regular monitoring shall be done for pipeline corrosion, painting of
aboveground p/l & replacement of galvanized fasteners.
 Entity should use megaphone at every CNG Station for communication
during emergency.
 Entity should provide proper technical training to all contractor’s operators
as well as evaluating their skills after training completion.
 Highly congested areas shall be surveyed using gas detectors at least once
in 03 months.
 Continuous monitoring shall be done to avoid temporary encroachment on
P/L route & near railway crossings.
Recommendations for CGD
 CGD shall ensure the 100% usage of Reinforced
rubber hoses conforming to IS 9573 Type II for all
domestic, commercial customers.
 CNG Filling operators shall be rigorously trained to
verify CNG kit nameplate & hydrotest due date of
CNG cylinder.
 Safety Guards shall be provided for the dispenser units
at CNG stations.
Recommendations for NG Pipeline
 Entities shall ensure continuous monitoring to avoid temporary
encroachment on P/L route & near railway crossings.
 Entities shall maintain Cathodic Protection system for complete
pipeline.
 Required distance shall be maintained between two isolation valves.
 Pipeline construction records i.e. RT films, pipe book, as-built
drawings, hydrotest reports shall be maintained in all respect.
 Way forward
Key suggestions for strengthening the certification/
compliance process

 TPIA should have enough past experience in Pipeline laying of CGD/NG(Cross Country),
Procurement inspections of CGD/NG network.

 Follow-up audits of T4S compliance audits shall be conducted strictly.

 TPIA should follow the competency criteria set by PNGRB/NABCB for audit team.

 TPIA to make the empanelment as per various regulations of PNGRB.

 TUV India – Expertise For your success
TÜV INDIA with PNGRB
28.01.2021
5
Observations / Findings of audit Conducted(1/5)
 Erection of CGD lines was being done as per vendor’s prepared
unapproved drawings/ Sketches.
 Un-calibrated or calibrated measuring Instruments/ Testing equipment
from Non-NABL Accredited Lab like pressure Gauges, Meters etc. are
being used by vendor’s ,by which accuracy of measurements or
observations cannot be ensured.
 Formats used by vendors for records, do not carry any evidence of
Approval / Consent of Client.
 Vendors are carrying out erection work, without Approved ITP/QAP,
Erection, Welding, Testing, Commissioning procedures.
 Observations / Findings of audit Conducted(2/5)
 Vendors are not observing, in some cases, the requirements of PNGRB
Pipelines should not be laid within specified distance from Electrical
Wires/ Installations. In such cases, they are putting Insulation material
around pipeline and offering installation for clearance. There is no
PNGRB guidelines to resolve such situations.
 Welders deployed by vendors in CGD Pipelines, are having cards in
which details like Position, Diameter, Procedure , welding parameters
used during their qualification, are missing.
 Observations / Findings of audit conducted (3/5)

 Vendors are generally avoiding the stage of Hydro test before

installation under Railway Lines, Road crossings etc. as per PNGRB
regulations.
 Vendor is not arranging Pressure and Time recorder for TPI review
during 24 HRS. Hydro testing of NGPL Pipelines, which is a requirement
as per PNGRB regulations.
 Vendor tend to use ASME Section IX for welding whereas specified as
per PNGRB , API Code is applicable.
 Pneumatic Testing of RF pads is generally not specified in drawings
and also not in procedures, which should be tested to ensure leak-proof
sound material below RF Pad Plates at branch locations.
General Observations / Findings /Recommendations

 Erection of CGD lines is being done as per vendor’s prepared

unapproved drawings/ Sketches.
 Un-calibrated or calibrated measuring Instruments/ Testing equipment
from Non-NABL Accredited Lab like pressure Gauges, Meters etc. are
being used by vendor’s ,by which accuracy of measurements or
observations cannot be ensured.
 Formats used by vendors for records, do not carry any evidence of
Approval / Consent of Client.
 Vendors are carrying out erection work, without Approved ITP/QAP,
Erection, Welding, Testing, Commissioning procedures.
General Observations / Findings /Recommendations

 Vendors are not observing, in some cases, the requirements of PNGRB Pipelines
should not be laid within specified distance from Electrical Wires/ Installations.
In such cases, they are putting Insulation material around pipeline and offering
installation for clearance. There is no PNGRB guidelines to resolve such
situations.
 Welders deployed by vendors in CGD Pipelines, are having cards in which
details like Position, Diameter, Procedure , welding parameters used during
their qualification, are missing. These details are required to be verified during
progress,of actual erection work.
General Observations / Findings /Recommendations

 Vendors are generally avoiding the stage of Hydro test before installation
under Railway Lines, Road crossings etc. as per PNGRB regulations.
 Vendor is not arranging Pressure and Time recorder for TPI review during 24
HRS. Hydro testing of NGPL Pipelines, which is a requirement as per PNGRB
regulations.
 Vendor tend to use ASME Section IX for welding whereas specified as per
PNGRB , API Code is applicable.
 Pneumatic Testing of RF pads is generally not specified in drawings and also
not in procedures, which should be tested to ensure leak-proof sound material
below RF Pad Plates at branch locations.
 Way forward
 More workshops on auditing as per requirements of PNGRB and it’s
revisions.
 Spread more awareness about PNGRB regulation requirements in
industry.
 Add requirements for training and qualification of contractor’s
personnel regarding PNGRB and Standard requirement.
 Providing structured document flow / linkage information about various
PNGRB , Code and Standard requirement.
 Indian industry should come with indigenised products for gas networks.
 6th Workshop on Capacity Building
TÜV SÜD South Asia 21-01-11 Slide
 Recommendation / Suggestion

 Inspection during construction carried out either by PMC or Inspection

Agency should be PNGRB approved agency.

 As per GSR512 (a) & as per PNGRB approved guidelines for

“Gas supply to industrial commercial customer” clause 9(9)
consumer shall ensure recertification for 3 years for commercial
& Industrial Services . Majority of the entities do not have
mechanism to ensure compliance of this requirement and also
same is not being complied by consumer as well So way out for
this is be done.
Key suggestions or concerns for strengthening the
certification/ compliance process

 Interactions of PNGRB with TPIA shall be increased through

training sessions / workshops / meetings for exchange of
experience.

TÜV SÜD South Asia 21-01-11 Slide 69

 ICSPL

Well Come you all

in PNGRB Workshop

Date – 15th January 2021

Major observations for NGPL T4S audits -

• Earth cover monitoring records not available for

HDD at Yamuna river crossing.
• Isolation valves across Yamuna river not considered
in design and not provided
• Jumpers were not provided across all flange joints
of gas vent.
Major observations for NGPL T4S audits -
 line and few locations at station piping.
• Leak detection System of pipeline is not functional.
• Calibration due date found expired for
Hand held gas detectors. Calibration is
not done of PRVs installed at pressure reduction
skids/metering skids.
• Fire proximity suit was not available.
 Major observations for NGPL T4S audits -

• Mandatory stock for spare hoses, nozzles & DCP are not
available.
• CP monitoring records for Cathodic protection was not made
available.
• Report on effect of interference of Pipelines on Pipelines and
was not made available.
 Key Concerns for T4S CGD Audit -

• Audit Man days estimation is concern for T4S audits for some of the CGD
networks more than 10 years old because of their size of operations.

• The T4S CGD audit scope for construction activities is a concern. For auditing
Construction scope, whether to audit construction activities only for the
period from the last audit or from the start of CGD.

• The verification of the last audit observation compliance status

need to be included in the audit scope.
6th Capability Building workshop on PNGRB T4S and IMS Regulations for
Empanelled TPIAs
 Observations and Recommendations– LNG Sector
Ship-Shore Compatibility Checking before Ship Arrival
Ship Berthing Safety Checks in field
Unloading Arm Hook/Emergency Release Coupler fixing as per
Standard SOP
Avoid Roll over during filling into LNG Tanks by density
measurement
Emergency Shutdown System Checking before unloading for Jetty
Operations
Valve passing in the pig launcher/ receiver barrel
Piping external corrosion at locations of pipe support
Compliance of Statutory requirements
Incident reporting / Investigation/ Analysis/ Safety Interlocks
Hydro Carbon Detections / Calibrations
Signal of field gas detector not available in control room
Cleaning pigging to be done as per recommended periodicity
gas discharge through vent lines are to be made vertically upwards
Alternate communication for remote valve isolation in case of OFC
Cable snapping .
Station venting QOEC piping to be made of atleast 1/3rd of Station
maximum dia piping
Surge divertors at IJ to be tested for its working condition
SOP for various field equipments to be displayed at field
Process Hazard Analysis
Change Management Procedure and P & ID updation
Fire equipment facilities
 Observations and Recommendations of PPPL–
Observations and Recommendations–
PPP Sector PPP Sector
Current consumption by the Cathodic Protection system as per weekly readings
Anode based resistance of the CP anode bed as per CP weekly readings
After carrying out pigging of the line, reviewing the pig mug test report results to assess the condition of the internal
corrosion of the line
Intelligent Pig Survey report & based on the report rectification of the anomalies in the pipeline.
DCVG survey report to find condition of the coating damage exact location of the pipe
Cathodic protection impressed current system need to be maintained well
Earthing and bonding practices to be monitored/maintained
Solar power/ Battery system at remote locations to be monitored/maintained
Communication with Security staff at remote PL locations thro' CCTV/mobile/landline is required( generally one person
provided per shift by cos. to save expenses) for his effective response and for his own safety in case of emergency. At some
location security person was found dead by reliever as the person was bitten by snake in night

Any metal pipeline waiting for commissioning filled with pressurized water dosed with corrosion inhibitors (Cathodic
protection in service) should be monitored by 2 different departments so that line integrity is maintained till full
commissioning takes place
 Observations and Recommendations– CGD Sector
Observations and Recommendations– CGD Sector
Gas detectors are to be installed at DRS.
At Odorisation unit & industrial connection, observed that the electric cable was laid on the walkway – Cable tray to be provided.

Fire call point in UPS room should be placed at visible location.

Display of Emergency medical Services should be available in ECC.

.
On Hydro test Reports conclusion like (Accepted / Not Accepted / OK / Not OK / Satisfactory ..) not mentioned.
Pressure Gauges installed at down stream of CGS & Odorant Equipment – are not having Calibrations Tags
In Commercial connection electrical cables & the Gas supply line pipes will be together.
Internal & external corrosion thickness check records need to be incorporated with required thickness values.

Rubber mat to be replaced near control panel area.

No emergency exit observed Administrative building

 key concerns & suggestions for strengthening the certification
key concerns & suggestions for strengthening the certification
Some Entities are taking their own sweet time to close non Conformities raised during Audits, PNGRB should fix particular no.of days
within which NCs to be closed otherwise TPIA should be authorized by PNGRB to Revisit entity if entity delays in complying.
Existing process of manual adequacy review is to be shifted along with onsite Visit, one day for Onsite visit should be increased to
two where one day for Onsite and One day for manual adequacy to mandated by this faster closure of NCs takes place and
certification will be completed as soon as possible.

PNGRB not defined guidelines on mandays to be spent sector wise during onsite visit for T4S and IMS audits
PNGRB should allow TPIAs if they want to depute full time working employee of mutual aid firm of client of TPIA to visit and
carryout onsite visit on behalf of TPIA.
Recertification Period of three years is long period it should be reduced to as much as possible to strengthen certification
process.

Entities are not able to approach TPIAs as their contact details are not posted on PNGRB website.

What is the minimum price to be quoted

PNGRB should directly give work order to TPIAs to cross audit or carryout surprise Audits if they feel that particular entity is not complying to
safety minimum safety standards
THANK YOU