Institution of Gas Engineers and Manager

INSTITUTION OF GAS ENGINEERS AND MANAGERS IGEM/TSP/12/123
Founded 1863
IGEM/UP/2 Edition 3 Royal Charter 1929
Communication XXXX Patron
Her Majesty the Queen
INSTALLATION PIPEWORK ON INDUSTRIAL AND

COMMERCIAL PREMISES
DRAFT FOR COMMENT

1 This draft Standard IGEM/UP/2 Edition 3 has been prepared by a Panel under the
chairmanship of Richard Marrow.
2 This Draft for Comment is presented to Panel PUP/2 for its consideration.
3 This is a draft document and should not be regarded or used as a fully approved and
published Standard. It is anticipated that amendments will be made prior to
publication.
It should be noted that this draft Standard contains intellectual property
belonging to IGEM. Unauthorised copying or use by any unauthorised person
or party is not permitted.
4 This is a copyright document of the Institution of Gas Engineers and Managers.

Enquiries should be addressed in the first instance to:
Peter Hurst
IGEM
IGEM House
26-28 High Street
Kegworth
Derbyshire, DE74 2DA
Tel: 0844 375 4436
Fax: 01509 678198
Email: peter@igem.org.uk
I GEM / UP/ 2 Edit ion 3
Com m u n ica t ion X XXX
I n st a lla t ion pipe w or k on in du st r ia l

a n d com m e r cia l pr e m ise s
Dra ft for Com m ent
Founded 1863
Royal Chart er 1929
Pat ron: Her Maj est y t he Queen
I GEM / UP/ 2 Edit ion 3
Com m u n ica t ion X XXX
I n st a lla t ion pipe w or k on in du st r ia l

a n d com m e r cia l pr e m ise s
Dra ft for Com m ent
Price Code: C6S

© The Institution of Gas Engineers and Managers
IGEM House
26-28 High Street
Kegworth
Derbyshire, DE74 2DA
Tel: 0844 375 4436
Fax: 01509 678198
Email: general@igem.org.uk
Copyright © 2012, IGEM. All rights reserved
Registered charity number 214001
All content in this publication is, unless stated otherwise, the property of IGEM. Copyright laws
protect this publication. Reproduction or retransmission in whole or in part, in any manner,
without the prior written consent of the copyright holder, is a violation of copyright law.
ISBN 978 1 905903 XX X

ISSN 0367 7850
Published by the Institution of Gas Engineers and Managers
Previous Publications:
Communication 1598 (1994) – 1st Edition
Communication 1729 (2008) – 2nd Edition
For information on other IGEM Standards please visit our website, www.igem.org.uk
IGEM/UP/2 Edition 3 – Draft for Comment
CONTENTS
SECTION PAGE
1 Introduction 1
2 Scope 4

3 Legislation and standards 6

3.1 Health and Safety at Work etc. Act (HSWA) 6

3.2 Management of Health and Safety at Work Regulations (MHSWR) 6

3.3 Gas Safety (Installation and Use) Regulations (GS(I&U)R) 6

3.4 Gas Safety (Management) Regulations (GS(M)R) 7

3.5 Electricity at Work Regulations 7

3.6 Control of Substances Hazardous to Health Regulations (COSHH) 8

3.7 Control of Asbestos at Work Regulations 8

3.8 Gas Appliances (Safety) Regulations 8

3.9 Gas Cooking Appliances (Safety) Regulations 8
3.10 Reporting of Injuries, Diseases and Dangerous Occurrences

Regulations (RIDDOR) 9

3.11 Provision and Use of Work Equipment Regulations (PUWER) 9

3.12 Confined Spaces Regulations 10

3.13 Building Regulations 10

3.14 Construction (Design and Management) Regulations (CDM) 10

3.15 Pressure Systems Safety Regulations (PSSR) 11
3.16 Dangerous Substances and Explosive Atmospheres Regulations

(DSEAR) 11
3.17 Pressure Equipment Directive (PED) 12

4 Planning and design 13

4.1 Planning 13

4.2 Design 15

4.2.1 General 15

4.2.2 Gas quality 15

4.2.3 Gas flow rate 15

4.2.4 Gas pressure 15

4.2.5 Gas velocity 17

4.2.6 Calculation of flow, pressure drop and velocity 17

4.2.7 Temperature variations 17

4.2.8 Pressure test and purge points 17

4.2.9 Facilities for hydrostatic testing 18

4.2.10 Gas filers 18

4.2.11 Equipment and pipework installation components 19

4.2.12 Valves and connections 19

4.2.13 Gas supply line diagram 20
4.2.14 Hazardous areas classification considerations 22

5 Materials 23

5.1 General 23

5.2 Protection of components prior to construction 23

5.3 Selection 23

5.3.1 General 23

5.3.2 Carbon steel 23

5.3.3 Stainless steel 24
5.3.4 Polyethylene (PE) 24
IGEM, IGEM House, High Street, Kegworth, Derbyshire, DE74 2DA. Website: www.igem.org.uk
1


5.3.5 Copper 25

5.3.6 Corrugated stainless steel tube (CSST) 25

5.3.7 Sleeving 25
5.3.8 Corrosion 26

6 Jointing 27

6.1 General 27

6.2 Carbon and stainless steels 28

6.2.1 General 28

6.2.2 Welding 29

6.3 Polyethylene (PE) 31

6.3.1 General 31

6.3.2 Fusion jointing 31

6.4 Copper 33

6.4.1 General 33

6.4.2 Brazing and soldering 33
6.5 Corrugated stainless steel tube (CSST) 33

7 General principles for installing pipework 35

7.1 General 35

7.2 Location of pipework 35

7.3 Hazardous area considerations 36

7.4 Connection to the meter installation 36

7.5 Construction and sleeving 36

7.6 Provision for expansion and flexibility 37

7.7 Protection of pipework 37

7.7.1 General 37

7.7.2 Stored pipework 37

7.7.3 Installed pipework 38

7.8 Clearances 39
7.9 Electrical safety 39
• 7.9.1 General 39
• 7.9.2 Electrical isolation 40

• 7.9.3 Earthing 40

7.10 Associated components 41

7.10.1 Additional emergency control valves (AECVs) 41

7.10.2 Additional manual isolation valves 42

7.10.3 Non-return valves (NRVs) etc. 43

7.10.4 Traps 43

7.10.5 Purge points 43

7.10.6 Pressure test points 43

7.10.7 Secondary and check meters 43

7.10.8 Automatic isolation valves (AIVs) 44

7.10.9 Gas detectors 44

7.11 Identification and labelling 44

7.11.1 Additional emergency control valves (AECVs) 44

7.11.2 Manual section isolation valves 45

7.11.3 Ancillary equipment 45

7.11.4 Valves and equipment 45

7.11.5 Pipes and pipework 45
7.12 Hot tapping carbon steep pipe 47
●

7.12.1 General 47

7.13 Provision for connections 48
7.14 Plant pipework 48
2

8 Buried pipework 50

8.1 General 50

8.2 Route 50

8.3 Depth and position in the ground 51

8.4 Protection of buried pipework 53

8.4.1 General 53

8.4.2 Corrosion 54

8.5 Cover 55
8.6 Identification of buried pipework components 56

9 Entry into and exit from buildings 57

9.1 Sleeving and sealing 57

9.2 Materials 57

9.3 Types of entry and exit 57

9.3.1 Above ground entry 57

9.3.2 Below ground entry 58

9.4 Entry into high rise buildings 59

9.5 Delicate wall constructions 59

9.6 Insulating fittings 59
9.7 Thermal expansion 60

10 Pipework in ducts, and other spaces in buildings 61

10.1 General 61
10.2 Design considerations for service ducts and other spaces containing

other services 63

10.3 Ventilation of ducts etc. 63
10.4 Unventilated ducts and voids 65

11 Pipework in multi-storey and multiple-dwelling buildings 66

11.1 General 66

11.2 Buildings containing domestic type premises 66

11.3 Support 66

11.4 Materials and jointing 67
11.5 Laterals 67
12 Pipework support 68

13 Flexible connections 70

13.1 General 70

13.2 Pressure loss across hoses 70
 13.3.1
13.3 Conditions of use 70
 13.3.2
General 70
 13.3.3
Semi-rigid coupling and flange adaptor 71
 13.3.4
Bellows 71
 13.3.5
Swivel joint 71
 13.3.6
Quick release coupling 72

Flexible tube or hose 72
13.4 Suitability 73

14 Manual valves 74

14.1 Features 74

14.2 Selection 74
14.3 Position indication 74
3


14.4 Overtravel 74

14.5 Speed of operation 74

14.6 Fire resistance 75

14.7 Double seals 75

14.8 Pressure drop 75

14.9 Servicing 75
14.10 Valve types 75

15 Vents and breathers 79

15.1 General 79

15.2 Vents 79
15.3 Breathers from regulators and related safety devices 81

16 Compressors, boosters and pre-mix machines 83

16.1 General 83
 16.2.1
16.2 Installation 83
 16.2.2
Location 83
 16.2.3
Ventilation 84
 16.2.4
Mounting 84
 16.2.5
Pipe Connections 84

Electrical Connections 85
16.3 Protection Equipment 86
● 16.3.1
 16.3.2
Statutory Requirements 86

Further protection (pre-mix machines) 87
 16.4.1
16.4 Schematic installation diagrams 87
 16.4.2
Boosters 87
 16.4.3
Pre-mix machines 88

Wiring 89

16.5 Notices 90

16.6 Operating data 91
 16.7.1 Commissioning
16.7 Commissioning, operation, maintenance and servicing 91
 16.7.2 Operation, maintenance and servicing

91
92

17 Procedures on completion of installation 93

17.1 General 93
17.2 Inspection and Maintenance planning 94
APPENDIX
1 Glossary, acronyms, abbreviations, symbols and units 97
2 References 100
3 Gas flow through pipework 106
4 Calculating allowable pressure loss 110
5 Wall thickness of pipework 112
6 Installation pipework with MOP above 0.5 bar up to 60 bar

(Requirements of BS EN 15001) 115
7 Pressed fittings. Jointing procedure 125
4
8 Compliance with DSEAR 126
9 Selection of a gas supply protection system 131
10 Weep by-pass pressure proving systems 134
11 Gas detection systems 141
12 Types of flexible connections 143
13 Low pressure cut-off switches 146
14 Commissioning 149
15 Typical record of new installation 150
FIGURES
1 Operational pressure limits 2
2 Typical gas supply line diagram 21
3 Example of an AECV label 41
4 Lever-operated AECV with on/off labels fitted 45
5 Positioning gas marker tape 46
6 Yellow Natural Gas tape 46
7 Yellow LPG tape 46
8 Yellow gas tape 46
9 Typical section of pipe in footways 52
10 Typical buried pipework under a roadway 55
11 Marker plate for syphons, valves and purge points 56
12 Typical above-floor entry – steel and PE pipework 57
13 Typical above-ground PE to steel building entry fitting 58
14 Typical below-floor level entry - steel pipework 58
15 Typical pre-fabricated below-ground entry.

PE pipe in a steel sleeve 59
16 Using unrestrained laterals to accommodate thermal expansion and

contraction – external pipework 60
17 Gas pipe running through a ceiling void with joints, showing location of vents 63
18 Suggested in-floor duct ventilation system 64
19 Single booster installation 88
20 Parallel booster installation 88
21 Fan-type mixer 89
5
22 Compressor-type mixer 89
23 Schematic drawing of possible wiring circuit (boosters) 90
24 Warning notice near to the meter inlet valve and any gas compressor
or gas engine 90
25 Warning notice on installation pipework 91
26 Example of configuration of test points 122
27 An example of pipework layouts showing preferred pipe locations to

Achieve Zone 2 NE classification 127
28 Typical layout for a weep by-pass or pipework integrity proving system 136
29 Typical limiting orifice 137
30 Low pressure cut-off valve 138
31 Mechanically jointed semi-rigid coupling 143
32 Flange adaptor 143
33 Swivel joints 144
34 Typical schematic wiring diagram for 3 phase starter 146
TABLE
1 UK and EU pipework standards – purpose, pressure, position 5
2 Maximum allowable pressure drop 16
3 Maximum gas velocity related to filter size 16
4 Jointing of carbon and stainless steels 28
5 Screwed and welded carbon and stainless steel connections 28
6 Welding standards 30
7 Inspection and testing of steel welds 31
8 Inspection and testing of PE fusion welds 32
9 Inspection and testing of brazed and soldered joints 33
10 Standardised branches for carbon steel pipes 48
11 Minimum proximity of buried pipe parallel to buildings 50
12a Minimum depth of cover for Natural Gas pipework 51
12b Minimum depth of cover for LPG pipework 51
13 Recommended minimum distances between buried gas pipework and

other systems 53
14 Free area of ventilation openings 65
6
15 Supporting above-ground pipe 68
16 Suitability of flexible connections 73
17 Valve types and features for all services 77
17 Suitability of valves for IGEM/UP/2 applications 78
19 Zoning distance to be used with breathers for outdoors, freely ventilated

installations 82
20 Zoning distance to be used with breathers for outdoors, congested or confined

installations 82
pressure differential between extremes for gas = 0.6 (air = 1.0)

21 Approximate flow in straight horizontal pipes with 1.0 mbar
and with 2.5 mbar differential for gas = 1.5. MOP  75 mbar. Pipe
lengths 5 m to 250 m 107
22 Pressure loss in pipework fittings and components 108
23 Wall thickness of carbon steel pipe 112
24 Wall thickness of stainless steel pipe 113
25 Wall thickness of stainless steel tube 113
26 Minimum wall thickness of copper pipe 113
27 Wall thickness of PE pipe 114
28 Materials for compression fittings, bolts, nuts, etc. 116
29 Nuts and bolts for carbon steel and PE flanged joints 118
30 Minimum extent of non-destructive examination 119
31 Zone 2 NE minimum natural ventilation requirements for pipework 129
7
SECTION 1 : INTRODUCTION
1.1 This Standard supersedes IGEM/UP/2 Edition 2, Communication 1729, which is

obsolete.
1.2 This Standard has been drafted by an Institution of Gas Engineers and Managers
(IGEM) Panel, appointed by IGEM’s Gas Utilization Committee, and has been
approved by IGEM’s Technical Co-ordinating Committee on behalf of the Council
of IGEM.
1.3 This Standard covers the design, installation, operation and maintenance of gas
installation pipework which includes compressors, boosters and pre-mix
machines but now with an upper limit on discharge pressure of 0.5 bar, on
industrial and commercial premises.
1.4 This Standard applies to new installations as well as to replacement of, or

extension to, existing installation pipework. It is not retrospective but it is
recommended that existing installations be modified to meet this Standard,
when appropriate.
1.5 Under normal circumstances correctly jointed pipework should not leak
throughout its lifetime. However, the local environment, mechanical damage
and interference could cause leakage to occur. Therefore, it is necessary to
ensure that if leakage does occur, a dangerous condition will not result. New
advice is given in this standard on the location of pipework joints.
1.6 There is new advice given in this Standard relating to classification of hazardous
areas for Natural Gas (NG) installations. Further information is provided in
Appendix 8.
Not e: For ot her gases, such as LPG addit ional adv ice m ay be available from t he fuel supplier or by
referring t o Energy I nst it ut e guidance EI I P- MSCP- P15.
1.7 For new installations a full risk assessment of the design and work activities is
carried out to minimise the risk of danger to the installer, the client, third
parties and property. Existing installations are subjected to a completion of a
risk assessment with improvements made as are reasonably practicable without
excessive cost. In such installations, it is essential that installations are
maintained and inspected as determined by the risk assessment.
1.8 Terms such as “maximum operating pressure” (MOP), “maximum incidental

pressure” (MIP) and “operating pressure” (OP) were introduced in Edition 2 to
reflect gas pressure terminology used in European standards.
Other terms were introduced to assist in recognition of design information to be

transferred between interested parties.
Of particular note are “lowest operating pressure” (LOP) and “design minimum
pressure” (DmP).
Referring to Figure 1, attention is drawn to how OP oscillates about the set point
(SP). Note also that MOP can be declared at a higher value than OP. The
strength test pressure (STP) has to be at least MIP and, in many cases, will
exceed MIP. This means that, at least with respect to integrity, the installation
will withstand a fault pressure from the upstream system.
1.9 This Standard makes use of the terms “must”, “shall” and “should” when

prescribing particular requirements. Notwithstanding Sub-Section 1.12:
the term “must” identifies a requirement by law in Great Britain (GB) at the

time of publication
the term “shall” prescribes a requirement which, it is intended, will be
complied with in full and without deviation
1
 the term “should” prescribes a requirement which, it is intended, will be

complied with unless, after prior consideration, deviation is considered to be
acceptable.
Such terms may have different meanings when used in legislation, or Health and
Safety Executive (HSE) Approved Codes of Practice (ACoPs) or guidance, and
reference needs to be made to such statutory legislation or official guidance for
information on legal obligations.
STP
MIP
MOP
Pressure
SP
OP
time
STP = Strength test pressure

MIP = Maximum incidental pressure
OP = Operating pressure
MOP = Maximum operating pressure
SP = Maximum set point of, typically, the active regulator.
FIGURE 1 - OPERATIONAL PRESSURE LIMITS
1.10 The primary responsibility for compliance with legal duties rests with the
employer. The fact that certain employees, for example “responsible engineers”,
are allowed to exercise their professional judgement does not allow employers

to abrogate their primary responsibilities. Employers must:
have done everything to ensure, so far as it is reasonably practicable, that
“responsible engineers” have the skills, training, experience and personal

qualities necessary for the proper exercise of professional judgement
have systems and procedures in place to ensure that the exercise of
professional judgement by “responsible engineers” is subject to appropriate

monitoring and review
not require “responsible engineers” to undertake tasks which would
necessitate the exercise of professional judgement that is not within their
competence. There should be written procedures defining the extent to
which “responsible engineers” can exercise their professional judgement.
When “responsible engineers” are asked to undertake tasks which deviate
from this, they should refer the matter for higher review.
1.11 It is now widely accepted that the majority of accidents in industry generally are
in some measure attributable to human as well as technical factors in the sense
that actions by people initiated or contributed to the accidents, or people might
have acted in a more appropriate manner to avert them.
It is therefore necessary to give proper consideration to the management of

these human factors and the control of risk. To assist in this, it is recommended
that due regard be paid to HSG48 and HSG65.
2
1.12 Notwithstanding Sub-Section 1.9, this Standard does not attempt to make the
use of any method or specification obligatory against the judgement of the
responsible engineer. Where new and better techniques are developed and
proved, they should be adopted without waiting for modification to this
Standard. Amendments to this Standard will be issued when necessary, and
their publication will be announced in the Journal of the Institution and other
publications as appropriate.
1.13 Requests for interpretation of this Standard in relation to matters within its
scope, but not precisely covered by the current text, should be addressed in
writing to Technical Services, IGEM, IGEM House, High Street, Kegworth,
Derbyshire, DE74 2DA and will be submitted to the relevant Committee for
consideration and advice, but in the context that the final responsibility is that of
the engineer concerned. If any advice is given by or on behalf of IGEM, this
does not relieve the responsible engineer of any of his or her obligations.
1.14 This Standard was published in xx xxxxx 2012.
3
SECTION 2 : SCOPE
2.1 This Standard applies to installation pipework and pipework downstream of any
plant isolation valve that is not "appliance pipework", on industrial and
commercial premises.
Not e 1: For t he purposes of t his St andard, inst allat ion pipework also em br aces com pressors,
boost er s and pre- m ix m achines ( see Sub- Sect ion 2.5) .
2.2 This Standard covers installation pipework arrangements as described in

IGEM/G/1.
Not e 1: Pipework on dom est ic prem ises is cover ed by BS 6891 provided t he pipework diam et er
does not ex ceed 35 m m and carries a 2 nd fam ily gas and BS 5482 for pipework carrying a
3 rd fam ily gas wit h no pipework size lim it at ion.
Not e 2: Pipework upst ream of a m et er inst allat ion and, hence, upst ream of inst allat ion pipewor k, is
covered by t he Pipelines Safet y Regulat ions ( PSR) , I GE/ TD/ 4, I GE/ TD/ 3, and I GEM/ TD/ 1
respect ively.
Not e 3: Met er inst allat ions are covered by BS 6400, I GE/ GM/ 4, I GEM/ GM/ 6 and I GE/ GM/ 8,
respect ively.
2.3 This Standard applies to new installations as well as to replacement of, or

extension to, existing installation pipework (see Sub-Section 1.4).
2.4 This Standard deals with the design, installation, operation and maintenance of
pipework, including selection of materials and components.
2.5 This Standard applies to pipework designed to contain lighter than air methane
based gases (such as 2nd family gas, for example Natural Gas), and heavier than
air gases (such as 3rd family gas in the gaseous state, for example butane and
propane gas (LPG) and many bio-gases).
Not e 1: I t is likely t hat m any of t he r equir em ent s w ill be appropriat e for light er t han air gases such
as 1 st fam ily gases, for exam ple Towns Gas, and ot her bio- fuel gases w hich have a
significant concent rat ions of hydrogen up t o about 25% or carbon m onoxide, such as t hose
generat ed from pyroly sis bio- m ass processes. I n such cases it is vit al t hat account is t aken
of t heir different const it uent s, condensat es and acidic/ sulphur cont ent and t he consequent
effect on m at erials and operat ions. I t is essent ial t o consider t hat hydrogen has a far higher
flam e speed t han m any ot her gases and t hat carbon m onox ide is a very poisonous
flam m able gas.
Not e 2: Bio- gases w ill generally not be of consist ent qualit y or pressure and m ay not have t he
significant odour associat ed wit h nat ural gas.
Not e 3: Gases w it h a specific gravit y less t han 0.8 can be consider ed as light er t han air. Ot her gases
m ay exhibit bot h heavier and light er t han air propert ies for dispersion.
2.6 This Standard, excluding Appendix 6 applies for MOP not exceeding 0.5 bar for
commercial and industrial premises and domestic premises with pipework
exceeding 35 mm diameter.
2.7 This Standard applies for MOP exceeding 0.5 bar up to 60 bar provided full
compliance with the additional requirements of Appendix 6 for commercial and
industrial premises.
Not e: The scope of BS EN 15001 is lim it ed t o indust rial piping. Com pliance w it h BS EN 15001 is in
effect a legal r equir em ent for MOP exceeding 0.5 bar for indust r ial piping as it is a m eans of
legal com pliance wit h t he Pressur e Equipm ent Dir ect iv e ( PED) .
2.8 This Standard applies to pressure-raising machines having a discharge pressure

limited to a maximum of 0.5 bar.
Not e: For higher discharge pressur es, requir em ent s are given in I GEM/ UP/ 6.
4
Premises Operating pressure (not exceeding)

≤21 mbar ≤0.5 bar ≤5 bar ≤60 bar
type
Domestic BS 6891
(pipe <35 mm dia)
IGEM/UP/2 excluding Appendix 6
(pipe >35 mm dia)
BS EN 1775
Commercial IGEM/UP/2 excluding IGEM/UP/2 including
Appendix 6 Appendix 6
BS EN 1775
BS EN 15001
Industrial IGEM/UP/2 excluding IGEM/UP/2 including
Appendix 6 Appendix 6
BS EN 1775
BS EN 15001
BS 6891 – Domestic Pipework (UK National Standard)
IGEM/UP/2 – Installation Pipework on I&C premises (UK Industry Standard)
BS EN 1775 – Gas Pipework for Buildings (EU Functional Recommendations)
BS EN 15001 Pt1 & 2 – Gas Installation Pipework (EU Functional Requirements)
TABLE 1 - UK AND EU PIPEWORK STANDARDS – PURPOSE, PRESSURE,

POSITION
2.9 This Standard considers specifically pipework of steel, stainless steel (including
corrugated stainless steel tubing (CSST)), copper and polyethylene (PE). In
certain applications, the use of other materials may be specified, when such
materials are required to be used in accordance with appropriate standards
and/or the principles of this Standard for materials of similar properties.
When considering components of pipework, for example valves, this Standard

covers a large selection of materials. However, the information is subject to the
manufacturer's specification for the material in question.
2.10 The term "diameter" refers to nominal inside diameter for carbon and stainless
steels and to nominal outside diameter for copper and PE, unless otherwise
stated (for example when "nominal bore" is the relevant parameter).
2.11 Pressures quoted are gauge pressures unless otherwise stated.
2.12 Italicised text is informative and does not represent formal requirements.
2.13 Appendices are informative and do not represent formal requirements unless
specifically referenced in the main sections via the prescriptive terms “must”,
“shall” or “should”.
5
SECTION 3 : LEGISLATION AND STANDARDS
This Standard is set out against a background of legislation in force in GB at the time of
publication (see Appendix 2). The devolution of power to the Scottish, Welsh and Northern
Ireland Assemblies means that there may be variations to the legislation described below for
each of them and consideration of their particular requirements must be made. Similar
considerations are likely to apply in other countries and reference to appropriate national
legislation will be necessary.
Appendix 2 lists legislation, guidance notes, standards etc. which are identified within this
Standard as well as further items of legislation that may be applicable. Where standards are
quoted, equivalent national or international standards etc. equally may be appropriate. Unless
otherwise stated, the latest version of the referenced document should be used.
3.1 HEALTH AND SAFETY AT WORK ETC. ACT (HSWA)
HSWA applies to all persons involved with work activities, including employers,
the self-employed, employees, designers, manufacturers, suppliers etc. as well
as the owners of premises. It places general duties on such people to ensure, so
far as is reasonably practicable, the health, safety and welfare of employees and
the health and safety of other persons such as members of the public who may
be affected by the work activity.
All persons engaged in the design, construction, commissioning, operation,

maintenance and alteration of pipework must be competent to carry out such
work. Competency is achieved by an appropriate combination of education,
training and practical experience.
3.2 MANAGEMENT OF HEALTH AND SAFETY AT WORK REGULATIONS

(MHSWR)
Linked closely with specific duties under GS(I&U)R (see Sub-Section 3.3)
MHSWR impose a duty on employers and the self-employed to make
assessments of risks to the health and safety of employees, and non-employees
affected by their work. They also require effective planning and review of
protective measures.
3.3 GAS SAFETY (INSTALLATION AND USE) REGULATIONS (GS(I&U)R)
3.3.1 GS(I&U)R are relevant statutory provisions of HSWA setting out general and
detailed requirements dealing with the safe installation, maintenance and use of
gas systems, including gas fittings, appliances and flues.
Not e: GS( I &U) R do not apply t o cert ain prem ises ( see HSL56 Guidance Not es 28 and 29) .
However, where t hey do not apply, t he principles of GS( I &U) R need t o be applied,
not w it hst anding t hat t he requirem ent for Gas Safe Regist rat ion ( see clause 3.3.5) need not
be applied.
3.3.2 GS(I&U)R address both NG and LPG.
3.3.3 GS(I&U)R place responsibilities on those installing, servicing, maintaining or

repairing gas appliances, pipework etc. as well as suppliers and users of gas.
3.3.4 GS(I&U)R define the gas supplier for both NG and LPG. HSL56 provides
guidance on those definitions, in particular for the more complicated case of LPG
supplied from storage vessels and from cylinders.
3.3.5 GS(I&U)R define the type of work that requires persons carrying out such work,
or their employers, to be an "approved class of person", for example be on the
Gas Safe Register.
3.3.6 The installer must check the safety of any appliance or pipework they install or
work on and take appropriate action where they find faults. Where the premises
6
are let or hired out, the landlord or hirer has special responsibilities to ensure
that any installer they use for the gas fitting, service or maintenance or safety is
a member of an approved class of persons (see clause 3.3.5) and is competent
to carry out such work. If any serious fault is found, the installer must inform
both the landlord/hirer, as well as the user, so that such faults can be rectified
before further use.
3.3.7 GS(I&U)R place responsibilities on LPG suppliers to deal with escapes of LPG.
For NG, GS(M)R apply (see Sub-section 3.4).
Not e: Advice on dealing wit h gas escapes is cont ained in I GE/ SR/ 20.
3.4 GAS SAFETY (MANAGEMENT) REGULATIONS (GS(M)R)
3.4.1 GS(M)R place specific duties on gas transporters (GTs), or their emergency
service providers (ESPs), for dealing with gas escapes from pipes on their
networks. Their primary duty is to make the situation safe. They are responsible
not only for dealing with escapes from their own pipes, but also for dealing with
escapes from gas fittings supplied with gas from pipes on their network. In
GS(M)R, the term “gas escapes” includes escapes or emissions of carbon
monoxide (CO) from gas fittings.

3.4.2 The ESP has specific duties to:
provide a continuously staffed and free telephone service to enable persons

to report gas escapes and
pass such reports on to the person who has the responsibility for dealing
with the escape.
In addition, there are duties imposed on gas suppliers and gas transporters
(GTs) to notify the ESP should they, rather than the ESP, receive a report of an
escape from the consumer.
3.4.3 GS(M)R require GTs to investigate fire and explosion incidents upstream of the
emergency control valve (ECV) and to send a report of the investigation to HSE.
GTs are also required to investigate fire and explosion incidents downstream of
the ECV but this is limited to establishing whether the seat of the fire or
explosion was in an appliance and, if so, which one, or in the meter installation
or installation pipework.
3.4.4 Responsibility for investigating RIDDOR reportable incidents (see Sub-Section

3.10) as a result of an escape of CO from incomplete combustion of gas from a
gas fitting, is placed on gas suppliers. HSE must be notified before such
investigations commence.
Not e: Advice on dealing wit h gas escapes is cont ained in I GE/ SR/ 20.
3.5 ELECTRICITY AT WORK REGULATIONS
3.5.1 These Regulations apply to a wide range of electrical work, from overhead
power lines to the use of office computers and batteries and include work on gas
equipment using electrical energy.
3.5.2 They are concerned with the prevention of danger from electric shock, electric
burn, electrical explosion or arcing, or from fire or explosion initiated by
electrical energy.
3.5.3 They impose duties on every employer, employee and self-employed person and
require that persons engaged in electrical work be competent or be supervised
by competent persons.
Not e: HSR25 provides guidance on t he Regulat ions.
7
3.6 CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS

(COSHH)
3.6.1 These Regulations, which reinforce existing statutory obligations under HSWA,
impose a duty on employers to protect employees against risks to health,
whether immediate or delayed, arising from exposure to substances hazardous
to health, either used or encountered, as a result of a work activity. They also
impose certain duties on employees.
3.6.2 Under COSHH, work must not be carried out which is liable to expose employees
to hazardous substances unless the employer has made a suitable and sufficient
assessment of the risk created by the work and the steps that need to be taken
to comply with the Regulations. After assessing the risk, it is necessary to
inform employees of the risks and to carry out the appropriate training and
instruction to ensure the risks are minimised. In certain cases, control measures
such as ventilation or personal protective equipment may be necessary and,
where provided, they must be used.
3.7 CONTROL OF ASBESTOS AT WORK REGULATIONS
3.7.1 These Regulations set out standards for the identification, monitoring and
assessment of work that may expose workers to asbestos and the measures
needed to control the risk.
3.7.2 Employers cannot carry out any work that exposes, or is likely to expose,
employees to asbestos unless an assessment of that exposure has been made.
Employers have to set out steps to be taken to prevent, or reduce to the lowest
level reasonably practicable, that exposure. Employers have to carry out
medical surveillance of employees if they work over a certain time limit.
3.7.3 The Regulations impose a duty on those with responsibilities for the repair and
maintenance of non-domestic premises to find out if there are, or may be,
asbestos containing materials within them; to record the location and condition
of such materials and assess and manage any risk from them, including passing
of any information about their location and condition to anyone likely to disturb
them. There is an 18 month lead in period for this duty.
3.7.4 Further information is available in HSG227, HSL27, HSL28 and HSL127.
3.8 GAS APPLIANCES (SAFETY) REGULATIONS
Until 1992, the safety of consumers using gas appliances offered for sale in the
UK was covered, generally, by the Consumer Protection Act and, specifically, by
the Gas Cooking Appliances (Safety) Regulations and the Heating Appliances
(Fireguard) Regulations. The Gas Appliances (Safety) Regulations introduced
specific requirements, for all gas appliances, which must be met before the
product can be sold. All new appliances must carry CE marking and be endorsed
for use in the UK.
3.9 GAS COOKING APPLIANCES (SAFETY) REGULATIONS
These Regulations give specific advice on installing cookers which may be

second-hand or already belong to the customer.
8
3.10 REPORTING OF INJURIES, DISEASES AND DANGEROUS OCCURRENCES

REGULATIONS (RIDDOR)
3.10.1 RIDDOR require employers, self employed people or those in control of work
premises to report certain work related accidents, diseases and dangerous
occurrences.
3.10.2 Other people have duties to report certain gas incidents which may not appear

to be work related:
death or major injury arising out of the distribution, filling, import or supply
of NG or LPG should be reported by the conveyor for NG and the filler,

importer or supplier for LPG
dangerous gas fittings (as defined in RIDDOR) should be reported by a
"member of a class of persons".
3.10.3 Major injuries, death and dangerous occurrences must be notified immediately,
for example by telephone, to the enforcing authority by the “responsible person”

as defined by RIDDOR. Report can be made to the Incident Contact Centre:
for fatal and major injuries only, telephone on 0845 300 9923 (opening
hours Monday to Friday 8.30 am to 5 pm) and complete appropriate on-line

form
all other reports at HSE website www.hse.gov.uk
Complete the appropriate online report form listed below. The form will then
be submitted directly to the RIDDOR database. You will receive a copy for

your records.

report of an injury

report of a dangerous occurrence

report of an injury offshore

report of a dangerous occurrence offshore

report of a case of disease

report of flammable gas incident
report of a dangerous gas fitting.
On-line written report are to be submitted within the required timescale (10
days, or 14 days for dangerous gas fittings). Other reports should be made as
soon as practicable and within 10 days of the incident.
3.10.4 HSL73 contains detailed guidance on RIDDOR, including a full list of injuries etc.
that need reporting.
3.10.5 IGE/GL/8 provides guidance on the reporting and investigation of gas-related

incidents.
3.11 PROVISION AND USE OF WORK EQUIPMENT REGULATIONS (PUWER)
3.11.1 Work equipment has a wide meaning and includes tools such as hammers,
laboratory apparatus, for example Bunsen burners, ladders, lifting equipment
and machinery for use at work.
3.11.2 The Regulations place duties on employers in relation to selection, suitability,

maintenance, inspection, installation, instruction and training, prevention of
danger and control of equipment.
3.11.3 More information on the Regulations can be found in HSL22. Free leaflets
include INDG291 and INDG229.
9
3.12 CONFINED SPACES REGULATIONS
These Regulations apply to a large range of confined spaces. The supplier or

designer of an enclosure and equipment within it is required to perform a risk
assessment of the enclosure with respect to safe access and egress and to give
clear instructions to operators on access/egress as well as to what actions to
take in the event of a gas alarm occurring.
Employers and the self employed should prevent entry into confined spaces
unless avoidance is not reasonably practicable and unless there is a system of
work which renders the work safe. They are also required to have specific
emergency arrangements in place.
3.13 BUILDING REGULATIONS
a) England and Wales (as Amended)
Building Regulations are Statutory Instruments that must be followed

when engaged in any building work. They are written in a format of broad
Regulations, setting out simple requirements in a Separate Schedule. Suggested
ways of complying with these Regulations are contained in Approved Documents
(ADs).

The ADs that apply to gas work are:

A Structure

B Fire safety

F Ventilation

G3 Hot water storage

J Heat producing appliances

L Conservation of fuel and power

M Access to and use of buildings
P Electrical safety in dwellings.
b) Building Standards (Scotland) Regulations and Amendments
The Building Standards (Scotland) are written directly as Regulations within the

Statutory Instrument. The Regulations can be satisfied:

by compliance with Technical Standards published by the Scottish office
conforming with the provisions of “deemed to satisfy” documents, for

example British Standards
other equivalent means.
c) Equivalent Regulations and Standards, Northern Ireland and Isle

of Man
Equivalent Regulations and ADs are being developed in Northern Ireland and the
Isle of Man and an awareness of these is required.
3.14 CONSTRUCTION, (DESIGN AND MANAGEMENT) REGULATIONS (CDM)
3.14.1 These Regulations impose duties on designers, clients (and their agents),
developers, planning supervisors and principal contractors. Not all the
regulations apply to all construction projects. Further information is given in
HSL144. For a notifiable project (as defined in CDM) the planning supervisor
must notify HSE before construction work commences. Construction includes the
alterations, repair redecoration, maintenance, decommissioning or demolition of
a structure. It also covers installation, commissioning maintenance or removal
of gas services.
10
3.15 PRESSURE SYSTEMS SAFETY REGULATIONS (PSSR)
3.15.1 These Regulations impose duties on designers, importers, suppliers, installers

and user or owners to ensure that pressure systems do not give rise to danger.
This is done by the correct design installation and maintenance, provision of
information, operation within safe operating limits and, where applicable,
examination in accordance with a written scheme of examination drawn up or
approved by a competent person (as defined in PSSR).
3.15.2 Relevant fluids for the purposed of this document would be NG at a pressure
greater than 0.5 barg that is, above atmospheric pressure, or LPG (which is a
liquid with a vapour pressure greater than 0.5 barg at ambient temperature). A
pressure system would include bulk storage tanks, pipelines and protective
devices but not an LPG cylinder (transportable pressure receptacle). Once the
pressure in the pipework drops below 0.5 barg, and the user/owner can show
clear evidence that the system does not contain, and is not liable to contain, a
relevant fluid under foreseeable operating conditions, then that part of the
system is no longer covered by the Regulations. This is likely to be the case
after the pressure relief valve associated with a pressure reducing valve which
takes the pressure to below 0.5 barg, for example at the entry to a building but
note the special requirements placed on protective devices in such systems (see
para 110b of HSL122). The regulations also apply to pipelines and the protective
devices in which the pressure exceeds 2 barg (see Sch 1 part 1 item 5 of
HSL122).
3.15.3 More information is available in HSL122 and some information is presented in

the HSE free leaflets INDG261 and INDG178.
3.16 DANGEROUS SUBSTANCES AND EXPLOSIVE ATMOSPHERES

REGULATIONS (DSEAR)
These Regulations are concerned with protection against risks from fire,
explosion and similar events arising from dangerous substances used or present
in the workplace. The regulations require that risks from dangerous substances
are assessed, eliminated or reduced. They contain specific requirements to be
applied where an explosive atmosphere may be present and require the
provision of arrangements to deal with accidents, emergencies etc. and
provision of information, training and use of dangerous substances. The
regulations also require the identification of pipelines and containers containing
hazardous substances.
The following publications contain details of the regulations and their

application:

INDG370

HSL134

HSL135

HSL136

HSL137
HSL138.
All gas systems except those in domestic parts of buildings fall within the scope
of DSEAR. This requires that a risk assessment be completed for each premise
to determine if any hazardous area exists and its extent. Normally, systems of
MOP not exceeding 0.5 bar do not require the use of certified electrical
components or restrictions on sources of ignition if correctly installed, tested
and maintained.
11
3.17 PRESSURE EQUIPMENT DIRECTIVE (PED)
3.17.1 PED applies to the design of pipework of MOP exceeding 0.5 bar which is
designed and installed for a site user, for example a factory occupier. PED is
implemented in the UK by the Pressure Equipment Regulations (PER) and PSSR.
Compliance with PED can be demonstrated by the use of a harmonised
standard. BS EN 15001-1 and -2 have been specially prepared for the gas
industry and include a wide range of materials. Systems falling within the scope
of PED must display a CE mark and this must be affixed by an approved person
or body.
Systems in which the pressure (bar) times the volume (litres) is less than 250
are partially exempt from PED on the basis that they have a low contained
energy. Pipework of diameter not greater than 25 mm nominal size is also
partially exempt.
Not e: Ot her pipewor k syst em s “ designed and specified” by t he cust om er w hich are t hereaft er
inst alled and t est ed by a cont ract or w ill not nor m ally fall wit hin t he scope of PED and
sect ions of pipework designed and m anufact ur ed “ off- sit e” will, generally, always fall
out side t he scope of PED if designed and specified by t he cont ract or.
3.17.2 There is also a duty on the user of an installed system within the scope of PED
not to allow the system to be used until they have a written scheme of
examination covering protection devices, pressure vessels and parts, which if
they fail, give rise to danger.
The scheme of examination must be drawn up by a “competent person” and the

system must be examined in accordance with the written scheme of
examination by a “competent person”. The more complex a system is, the more
qualifications, experience and training are needed to ensure competence.
Guidance on the selection of competent persons is given in HSL122. Users (or

owners) of pressure systems are free to select any competent person they wish,
but they have to take all reasonable steps to ensure that the competent person
selected can actually demonstrate competence i.e. the necessary breadth of
knowledge, experience and independence. In judging levels of competence,
users or owners may wish to know that a national accreditation scheme has
been developed by the United Kingdom Accreditation Service (UKAS) for bodies
that provide services of this nature.
12
SECTION 4 : PLANNING AND DESIGN
4.1 PLANNING
4.1.1 Discussion shall take place with the GT, gas supplier and/or meter asset
manager (MAM) to confirm the availability of gas, its supply and operating
pressures, metering specification, any requirements for a non-return valve
(NRV) and any additional safety equipment.
Not e: Approval m ay be required, fr om t he gas supplier and t he GT, for t he specificat ion of NRVs
for gas pipework syst em s. This m ay apply for a syst em having an elevat ed gas pressure or
air/ gas- fired equipm ent inst alled downst ream of a m et er .
4.1.2 The designer must establish whether the pipework system will fall within PED
and if so ensure that it complies with BS EN 15001 (see Sub-Section 3.1.7 and
Appendix 6).
Not e: Com pliance w it h I GEM/ UP/ 2 including Appendix 6 w ill also ensure com pliance wit h
BS EN 15001.
4.1.3 As necessary, the designer should obtain the following information concerning
the meter installation and the pressures that it will provide under various

operating conditions:

meter installation outlet design minimum pressure (= DmPmi)

meter installation outlet lowest operating pressure (= LOPmi)
meter installation outlet peak level operating pressure (can be considered as

maximum outlet pressure) (= PLOPmi)
meter installation outlet temporary operating pressure (= TOPmi) (if

applicable)

meter installation maximum incidental pressure (= MIPmi)

meter installation outlet design pressure (= DPmi)

meter installation outlet strength test pressure (= STPmi)

capacity of the meter installation
any constraints that the MAM has imposed on the use of the meter
installation, or installation housing.
Not e 1: I n m any cases, som e or all of t he above inform at ion will be displayed on or near t he m et er
inst allat ion.
Not e 2: The load and pressure profile wit hin a pipework syst em is im port ant w it h respect t o t he
design and specificat ion of t he m et er inst allat ion ( see I GE/ GM/ 8, I GEM/ GM/ 6 or I GE/ GM/ 4,
as appropriat e) .
Not e 3: For a m et er inst allat ion wit h a st andard 21 m bar m et ering pressur e, t he follow ing pressures
will nor m ally apply:
STPm i = in ex cess of 82.5 m bar

MI Pm i = less t han 75 m bar
PLOPm i = 25 m bar
LOPm i = 18 m bar
Dm Pm i = 15 m bar.
Where extreme pressure and load factor fluctuations are expected (that is high
flow rate with on/off control), the gas supplier/MAM should be contacted at the
planning stage so that the correct meter installation can be specified.
Not e: The load and pressure profile wit hin a pipework syst em is im port ant w it h respect t o t he
design and specificat ion of t he m et er inst allat ion ( see I GE/ GM/ 8, I GEM/ GM/ 6 or I GE/ GM/ 4,
as appropriat e) .
13
4.1.4 Consideration shall be given to the position of pipework in relation to other

services (see also clause 8.3.2) and in relation to building structures (see Sub-
Section 7.2). Any requirements for other services and their relevant Codes of
Practice (CoPs) shall be taken into account.
4.1.5 The location and ventilation of the pipework and appliances shall take account of
results of risk assessments to ensure safety and adequate access for
maintenance (see Section 7).
4.1.6 Where the construction of pipework necessitates substantial building work, all
planning and relevant Building Regulations applications must be approved
before construction starts.
4.1.7 Where pipework is to be routed through an existing duct, shaft or void, fire
integrity shall not be adversely affected.
4.1.8 If it is planned to place pipework on existing supports, stanchions or a steel

framework, these shall be capable of supporting the existing load and added
weight of the new pipework (see Section 12).
4.1.9 The position of any existing underground services shall be identified prior to
installing any buried pipework (see Section 8 and IGE/SR/10).
4.1.10 A full risk assessment of the design and work activities must be carried out to
minimise the risk of danger to the installer, the client, third parties and
property. Where applicable, this should be incorporated into the full project
planning exercise and, if applicable, be undertaken as part of CDM. The risk
assessment shall be carried out in accordance with HSG65.
Any risk of danger (due to the position and environment in which the pipework
is installed) must be considered and steps taken as necessary to minimise the
risk of the pipework being affected in the future. Pipework must not be installed
in any area posing unacceptable risk, for example in an inadequately ventilated
void.
Where identified by risk assessment, or required contractually, a suitable permit

to work (including hot work) procedure shall be prepared and implemented.
Safe working practices must be employed to carry out all the activities

undertaken and should include:

design for gas free working during maintenance and repair

fire safety procedures and fire hazards identification during work
ensuring a safe environment during work.
Not e 1: The following guidance is available for reference t o assist safe working, HSG85 Elect r icit y at
work; I NDG402 Safe use of ladder s and st ep ladders; I NDG 229 Using work equipm ent
safely ; I NDG297 Safet y in gas welding, cut t ing and sim ilar processes; I NDG 258 Safe work
in confined spaces; HSG33 Healt h and safet y in roof work.
Not e 2: I nform at ion on risk assessm ent s is given in I GEM/ UP/ 16.
Not e 3: Met hod st at em ent s m ay also be required for cert ain work act ivit ies.
Not e 4: I GE/ SR/ 24 provides guidance on risk assessm ent t echniques.
14
4.2 DESIGN
4.2.1 General
4.2.1.1 The design should result in an installation that is fit for purpose, sufficient to
deliver the required capacity with the relevant pressure at the point of use.
4.2.1.2 The design should be calculated for full load and if possible making e allowance
for future load. Applying diversity factors is not recommended unless accurate
appliance operation information is available.
4.2.1.3 Pipework design should make allowance to cover unforeseen practical

installation problems that may require additional pipework and fittings – for
example to traverse structures within the premises. Consideration should also
be given to the addition of future components or equipment, for instance
individual metering devices.
4.2.1.4 The design shall be sufficient to permit safe and straightforward commissioning,
operation and maintenance of the pipework system. This should include
sufficient isolation valves to permit maintenance and extension whilst
minimising disruption to the supply.
4.2.1.5 The design calculations should take account of manufacturer’s data for pressure
drop through their pipe, fittings or equipment. The design should then include
the specification of the type of pipe, fittings and equipment to be installed in
order to avoid exceeding the pressure drop requirements for the installation.
4.2.2 Gas quality
During the design stage consideration shall be taken of the different

constituents of the gas and its dew point, that is condensates and acidic/sulphur
content and the possible consequent effect on materials and operations.
Condensate collection may also have to be considered. This may be more
relevant to biogases than to distributed NG.
4.2.3 Gas flow rate
Account shall be taken of the required maximum gas flow rate and an allowance
should be made for any possible future increase in the load.
Appendix 3 should be used for guidance and examples on calculating pipe sizes.
Not e: The m axim um gas flow rat e m ay be less t han t he t ot al connect ed load.
4.2.4 Gas pressure
4.2.4.1 The pressure drop through a pipework system should not exceed the values
given in Table 2.
However, in any event, the maximum pressure drop chosen/used must ensure
the effective operation of any connected appliance under all normal operating
conditions, and the safe operation of any connected appliance under all
foreseeable conditions.
Not e 1: I t is possible t o incur a higher pressur e drop and use sm aller diam et er pipework if t he
supply pressur e is raised, for exam ple by t he use of a boost er . However , t his pract ice is not
recom m ended as an alt er nat ive t o correct ly- sized pipewor k or as a solut ion for an exist ing
syst em and is a last resor t solut ion.
Not e 2: This will r equir e t he designer t o est ablish t he pressure available from t he m et er inst allat ion
under all operat ing condit ions, and t he pressure required by t he dow nst ream appliances for
safe and effect ive com bust ion.
Not e 3: For a m et ering pressure of 21 m bar, t he m et er inst allat ion will norm ally have been
designed t o provide t he following m et er inst allat ion out let pressures:
15
LOPm i = 18 m bar
Dm Pm i = 15 m bar.
Not e 4: On an inst allat ion w it h a m et ering pr essure of 21 m bar, t he designer has t o assum e t hat
“ st andard” appliances w ill be connect ed at som e st age, unless t he consum er specifically
advises ot her wise. I t has been est ablished t hat st andar d appliances have t he following
charact er ist ics ( see also Appendix 4) :
STP = 50 m bar
Pm ax = 25 m bar
OP = 20 m bar
Pm in = 17 m bar
Pign = 14 m bar ( 70% OP) .
GAS FAMILY AND TYPE OP MAXIMUM DESIGN PRESSURE

DROP AT DESIGN FLOW
2nd. NG  25 mbar 1.0 mbar

> 25 mbar 10% OP
3rd. LPG (propane)  42 mbar 2.5 mbar
> 42 mbar 10% OP
3rd. LPG (butane)  33 mbar 2.5 mbar
> 33 mbar 10% OP
Not e 1: For a 2 nd fam ily gas, t he pressur e drop is m easured from t he m et er inst allat ion out let t o
t he plant m anual isolat ion valve or t he boost er inlet ( if fit t ed) , as appropriat e.
Not e 2: For a 3 rd fam ily gas, t he pressure drop is m easur ed from t he out let of t he pressur e
regulat or on t he bulk st orage t ank/ cy linder t o t he plant m anual isolat ion valve. This is t he
vapour phase.
Not e 3: Where t he operat ing pressur e exceeds t hat norm ally encount ered, for exam ple 50 m bar
for LPG, or w here different sect ions of pipework are operat ing at differing pressur es,
considerat ion should be given t o ident ifying OP by m arking or labels.
TABLE 2 - MAXIMUM ALLOWABLE PRESSURE DROP
4.2.4.2 The pressure drop should be such that the limiting gas velocity is not exceeded
(see clause 4.2.5).
4.2.4.3 Materials, components, methods of jointing/supports etc. shall be capable of

withstanding the pressure applied when strength and tightness tested in
accordance with IGE/UP/1, IGE/UP/1A, IGE/UP/1B or BS 5482, as appropriate.
4.2.4.4 Any possibility of increasing MOP at a later date should be taken into account at
the design stage. This may avoid the need to up-rate the pipework at a later
date.
4.2.4.5 Where a section of installation pipework is to be supplied from a system having

a higher pressure regime, appropriate overpressure protection devices shall be
provided in addition to the pressure regulator if the downstream pipework,
appliance(s) or appliance controls would not withstand the higher pressure
(MIP) under fault conditions.
Not e: The inst allat ion of t he pr essure r egulat or and any, associat ed “ creep relief” and
overpressure prot ect ion device, w it hin or out side a building, m ay hav e vent ing im plicat ions.
See Sect ion 15.
4.2.4.6 The effect of altitude is relevant particularly in a high rise building where, for
LPG, the pressure reduction should be taken into account when sizing pipework
and determining the test pressure. For NG, the effect of altitude is an increase
in pressure (see Appendix 3).
4.2.4.7 Due allowance should be made for pressure loss within any fitting (elbow, tee,
valve, etc. see Appendix 3).
Not e 1: But t erfly valves and som e ot her t ypes of valve m ay display significant pr essure drop.
16
Not e 2: The int er nal qualit y of fit t ings, com ponent s, pipe welds and pipes m ay have a significant
effect on t he pressure drop of t he as inst alled inst allat ion.
4.2.4.8 Reference should be made to the appliance or equipment manufacturer’s

requirements to identify the minimum and maximum design pressure of any
particular components (see also sub-clause 13.2 for pressure losses across
flexible connections).
4.2.5 Gas velocity
The velocity of gas through pipework, at maximum flow, should be as defined in

Table 3. This velocity may be exceeded through valves and controls but should
not exceed the manufacturer’s limits.
Not e: The velocit y st at ed is based on t he avoidance of excessiv e erosion. I t m ay be exceeded on
t he basis of engineering j udgem ent and experience. How ever, t here is a possibilit y of noise
and erosion at high gas v elocit ies and w it h unfilt er ed supplies.
FILTER SIZE (IF FITTED) MAXIMUM GAS VELOCITY

(m) (m s-1)
> 0  200
> 200 75
Not exceeding 40
Unfiltered 20
TABLE 3 - MAXIMUM GAS VELOCITY RELATED TO FILTER SIZE
4.2.6 Calculation of flow, pressure drop and velocity
Flow, pressure drop and velocity shall be calculated to an appropriate accuracy,

using Appendix 3, an appropriate gas flow calculator, a computer programme or
manufacturer’s specifications.
Not e: Gas flow calculat ors and sim ple com put er pr ogram m es ar e available from various suppliers
and are convenient aids for t he calculat ion of gas flow, pressure drop and velocit y in
pipework.
4.2.7 Temperature variations
Installation pipework subject to temperature variations in excess of 60 K that

could lead to excessive stresses in that system shall incorporate components
such as bellows or other expansion joints to eliminate them (see Figure 17).
Not e: I nt er nal pipew ork in t he UK is unlikely t o exceed t his figure unless closely sit ed t o hot
services and equipm ent such as st eam pipework.
4.2.8 Pressure test and purge points
4.2.8.1 Pressure t est point s
A pressure test point should be installed downstream of any ECV, section

isolation valve and appliance (plant) isolation valve.
Additional pressure test points should be fitted in association with any secondary
meter, regulator, burner control or filter. For a filter, and if condition monitoring
is to be applied, a pressure test point should be fitted on its inlet and outlet.
Not e: 12 m m nom inal bore ( NB) screwed fit t ings, valves, plugs/ caps or t hose of t he brass t est
nipple t ype ar e sat isfact ory for t his purpose. All com ponent s need t o be suit able for t he
t est ing pressur e.
17
4.2.8.2 Purge point s
Sufficient valved purge points shall be installed and be sized at least 12 mm NB

and not less than 25% of the main pipe size and of sufficient size to enable the
purging procedures outlined in IGE/UP/1, IGE/UP/1A, IGEM/UP/1B or
IGEM/UP/1C as appropriate for the installation.
A purge point shall be installed on the inlet and outlet of any secondary meter of
size exceeding U25/G16, any section isolation valve, isolation components to be
removed for servicing and at the extremities of any spur.
Any purge point should comprise a connection fitting, a valve and a plug, cap or
blank.
Consideration should be given to the position of the purge points in relation to

safe areas where purge stacks/flares can be located.
4.2.9 Facilities for hydrostatic testing
4.2.9.1 Arrangements shall be provided for filling and emptying the test water, including
consideration of the gradient or slope of the pipework which may lead to the use
of multiple fill points.
Not e: Perm ission will need t o be sought from t he Environm ent al Agency if t he wat er is t o be
ext ract ed from a wat er cour se.
4.2.9.2 The pipe section shall be designed to incorporate valved air vents at high points
and provision of sufficient low level drainage points.
Not e: Hydrost at ic t est ing is required by I GE/ UP/ 1. I t can be a safer procedure t o apply t han
pneum at ic t est ing for higher pressures. For buried pipew ork inst allat ions, account should be
t aken of t he requir em ent s of I GEM/ TD/ 1. There are v arious m et hods for t est ing for
leakage; pressure drop, physical leakage and m easurem ent of wat er needed t o t op- up t he
syst em . The lat t er procedur e is m ore fully det ailed in I GEM/ TD/ 1. Experience has shown
t hat t est ing of pipework sect ions at ground lev el is preferable t o t est ing when bur ied or
support ed at high level.
4.2.10 Gas filters
4.2.10.1 Precautions shall be taken to prevent the ingress of debris, for example swarf
and welding scale, into pipework, during fabrication. Pipework that has been
installed newly, or disturbed, shall be cleared of debris prior to the
commencement of strength and tightness testing and purging.
Not e 1: Dust , scale and debris t ravelling at high v elocit y wit hin pipework m ay dam age severely
valves, filt ers, et c. I t is good engineer ing pract ice t o m inim ise t he risk of such dam age or
int erference wit h t he funct ioning of any valve, m et er, et c.
4.2.10.2 Filters should be installed such that contaminated filter elements can be
replaced and the filter housing is positioned such that no debris can fall back
into the pipework during element replacement.
4.2.10.3 Where permanent filters/strainers are not fitted, temporary commissioning

strainers shall be installed at each item of plant unless it can be assured that
the pipework is free of dust and debris.
Not e 2: Safet y shut off valves t o BS EN 161 should incorporat e a st rainer w hich m ay prot ect
equipm ent downst r eam of t he valve.
4.2.10.4 Particular care shall be taken with plant pipework downstream of any filter or
strainer.
Not e 3: I n som e inst ances, it m ay be desirable t o inst all a filt er t o lim it t he part icle size, so
prot ect ing any cont rol fit t ed in t he pipework.
the gas supply shall be filtered to a minimum level of 250 m. The filter should
4.2.10.5 Where dust could interfere with plant operation or cause equipment damage,
18
be fitted immediately upstream of any individual item of plant or groups of

plant.
Not e 1: Where plant is wit hin 20 m downst r eam of a m et er / regulat or filt er , an addit ional filt er m ay
not be necessary.
necessary t o include such filt r at ion t o a level as low as 50 m .

Not e 2: I n rare cases where a rot ar y displacem ent m et er wit hout scraper t ips is used, it m ay be
4.2.10.6 Due consideration should be given to the effect on gas velocity and pressure
drop when selecting the level of filtration.
4.2.10.7 Any quick-release filter cover shall remain closed or captive until the pressure is
released safely.
4.2.11 Equipment and pipework installation components
All new equipment and pipework components shall be CE marked or certified by

a notified body, if appropriate.
Not e: Appliances and equipm ent falling wit hin PED m ay need t o be CE m ar ked.
4.2.12 Valves and connections

4.2.12.1 Valves, as appropriate shall meet the requirements of:

BS EN 331

BS EN 1555-4

BS EN 12266-1

BS EN 13774 or,
BS EN 14141 as appropriate.
4.2.12.2 Pipework shall include valving necessary to provide section isolation, and as
required for strength and tightness testing and purging and for use in
emergency (see Sub-Section 7.10 and Section 14).
In certain situations, for example elevated pressures, location or where required

by work systems or identified by risk assessment greater levels of isolation
integrity and security shall be installed. This may include the use of multiple
valves, isolation proving, for example double block and bleed valves or locking
systems. Further information is given on HSG253.
4.2.12.3 Any additional isolation valve shall be installed as outlined in Sub-Section 7.10
and Section 14.
4.2.12.4 Consideration should be given to the inclusion of valved connections for possible
extensions.
Not e 1: Where a valved connect ion point has not been left t o enable an ext ension t o be m ade t o
exist ing pipew ork and it is desir ed t o avoid decom m issioning t hat pipew ork, considerat ion
can be given t o t he use of an appropriat e under pressure connect ion such as an under
pressure t ee or hot t ap.
Not e 2: Cognizance ought t o be t aken of t he pressur e drop t hrough t he fit t ing which is due
principally t o t he reduced bor e of t he dr illing.
4.2.12.5 For a ring main, an isolation valve shall be installed to enable maintenance fitted
with purge points on both sides.
Not e: Norm ally, t his valve is fit t ed at t he furt hest point from t he inlet t o t he ring.
Suitable provision should be made to enable the ring main to be isolated,

tested, purged and maintained.
Not e: Norm ally, t his requir es valv es at t he inlet t o t he r ing and at each branch fr om t he ring.
19
4.2.13 Gas supply line diagram
4.2.13.1 A gas supply line diagram must be provided for a gas supply to a premises

served by:

for a 2nd family gas, a service of 50 mm diameter or greater
for a 3rd family gas, service pipework of 30 mm diameter or greater.
The diagram must indicate the position of all installation pipework of internal
diameter 25 mm or greater.
A typical gas supply line diagram is shown in Figure 2. Its size should be at
least A4.
4.2.13.2 The diagram shall be updated following any modification to pipework.
4.2.13.3 The diagram shall be located such that it is available for reference by the
emergency services in the event of an incident, as well as in any meter house or
at the storage vessel as the case may be.
20
GAS PIPEWORK:
ADDRESS: NAME:
p p p
M
ECV P1
100 mm
METER HOUSE = 50 mm
to canteen
p p
AECV
p p p p
p p
= 25 mm P2 = 50 mm
A
p p p p to main
office
p p
= 80 mm
M A p
= 80 mm
WAREHOUSE
p
p p p p
= 80 mm
AECV
BOILER HOUSE
Regulator Regulator with

slam-shut valve
Electrical
Slam-shut valve bonding
Buried pipe
p
Pressure/purge Exposed pipe
point
Primary
Valve Meter
P1 , P2 Pressure
Check
regimes M Meter
For example
P1 = 150 mbar and Network
P 2 = 21 mbar
Meter installation
Installation pipework
FIGURE 2 - TYPICAL GAS SUPPLY LINE DIAGRAM
21
4.2.14 Hazardous areas classification considerations
4.2.14.1 Hazardous area classification must be established as required by DSEAR for all
pipework. The severity and thus the effects of the classification can be mitigated
by good design. Guidance can be found in IGEM/SR/25 Edition 2, IGEM/UP/16 or
EI IP-MCSP-P15.
4.2.14.2 During the design it is important to minimise the number of joints, ensure
adequate ventilation around joints and to provide access for inspection and
maintenance.
Not e 1: ‘Joint s’ refers t o all leakage sources such as t hr eads, union, flanges, pressed fit t ings,
com ponent casing or shaft seals but not t o soldered, brazed or welded connect ions.
Not e 2: The requirem ent s in I GEM/ SR/ 25 Edit ion 2 and I GEM/ UP/ 16 specifically apply t o m et hane
based gases, including landfill or bio- gas, wit h a com bined proport ion of m et hane- plus- iner t
gas of great er t han 89% by volum e; a gross calorific value not exceeding 45 MJ m - 3 ; a
m olecular weight not ex ceeding 19.1 kg km ol - 1 ; an LFL of not less t han 4.4% ; a
t em perat ure range of –20°C t o 50°C.
They do not include LPG and LPG/ air m ixt ures nor bio- gas wit h a specific grav it y great er
t han 0.8. I n t hese cases consult t he fuel supplier or see Energy I nst it ut e guidance EI I P-
MSCP- P15.
4.2.14.3 Gas pipework (with any potential leak sources) shall be located in ventilated
locations.
Not e: The infor m at ion on hazardous areas given in t his St andard is aligned w it h t hat in
I GEM/ UP/ 16 for syst em s wit h an MOP not exceeding 2 bar and where followed it should
achieve t he lowest level of hazardous area classificat ion, t hat is Zone 2NE. Where
I GEM/ UP/ 16 does not apply, refer t o I GEM/ SR/ 25 Edit ion 2.
22
SECTION 5 : MATERIALS
5.1 GENERAL
5.1.1 Any pipe, fitting or other component shall be designed and installed in
accordance with relevant recognised standards or specifications and the
manufacturer’s instructions (see also Section 3). Such components shall be of a
type and manufacture suitable for their intended use.
5.1.2 Materials shall have physical properties appropriate to the proposed duty,
consideration being given to the effect of gas composition, variation in operating
temperature and pressure, imposed forces and corrosion and other aspects of
the service environment and location (see also Sub-Section 2.6).
Not e: Biogases m ay have very different const it uent s see clause 13.1.1.
5.2 PROTECTION OF COMPONENTS PRIOR TO CONSTRUCTION
Any pipework component shall be protected adequately against corrosion or

damage that may occur prior to delivery to site and during storage and
handling.
Not e 1: Grease film s, prim er paint coat ing and plast ic end caps, as appropr iat e, m ay provide
suit able prot ect ion.
Not e 2: Furt her procedures are given in Sub- Sect ion 7.7.
5.3 SELECTION
5.3.1 General
5.3.1.1 Materials for pipework, including any fitting, valve, etc., shall be chosen taking
due account of Sub-Section 2.6, Sub-Section 5.1 and the following
requirements.
5.3.1.2 MOP of pipe is related to the specification and grade of material used and
Appendix 5 should be taken into account.
5.3.1.3 Pipe and fittings shall be protected against mechanical damage.
5.3.1.4 Pipe and fittings shall be compatible.
5.3.1.5 When selecting materials that are to be welded, soldered, brazed or screwed, it
shall be ensured that joining pipe and fittings are compatible for the joint and
for the joining process.
5.3.2 Carbon steel

5.3.2.1 Pipe shall be to, as appropriate:

BS EN 10208

BS EN 10216

BS EN 10217-1 (Grade P195 TR1 or TR2 or P235 TR1 or TR2)

BS EN 10220

BS EN 10255
API 5L Grade B,
and have a wall thickness suitable for the duty (see Appendix 5).

5.3.2.2 Fittings shall be to, as appropriate:

BS 1560-3
BS 1640
23


BS 1965-1

BS 3799

BS EN 1092-1

BS EN 1514-1

BS EN 1759-1

BS EN 10208

BS EN 10253
BS EN 10255.
and be appropriate for the pipe material and jointing method.
5.3.3 Stainless steel

5.3.3.1 Pipe shall be to, as appropriate:

BS EN 10216-5

BS EN 10217-7

ASTM A269 (304L, 316, 316L or 321)
ASTM A313 (TP 304, TP 316).

5.3.3.2 Tubes shall be to, as appropriate

ASTM 213 (316 or 316L)
ASTM 269 (316 or 316L)


BS 1640 (WP304 or 316)

BS 3799

BS 4882 (B8T or 8)

BS EN 10222 (304 or 316L)

BS EN 10253-2

BS EN 1092-1

ASTM A182 (F304 or F316)
ASTM A193 (B8T or 8).
and be appropriate for the pipe material and jointing method.
5.3.4 Polyethylene (PE)
5.3.4.1 Pipe shall be to BS EN 1555-1 and -2.

Not e: I n t he UK m anufact urers produce PE pipe t o GI S/ PL2- 2 and GI S/ PL2- 8 for t he GTs.
5.3.4.2 PE pipe shall be used only when buried or when fully protected in a purpose
provided external enclosure or a below-ground duct. Such a duct shall not be
used for any other purpose.
5.3.4.3 PE pipe must not be used within a building. For an entry or exit, it shall be
suitably sleeved (see clause 5.3.7) and the requirements outlined in Section 9
shall be applied.
5.3.4.4 PE pipe may be used for above ground external supplies within production plant
for biogases provided it is of a type resistance to UV degradation, or protected
24
from UV degradation or has a declared life which is less than the life due to UV
degradation.
5.3.4.5 PE pipe should not be located in a fire risk area or where mechanical damage
could occur.

BS EN 1555-3.
Not e: I n t he UK m anufact urers produce PE fit t ings t o GI S/ PL2- 4 and GI S/ PL2- 6 for t he GTs,
whilst self anchoring m echanical fit t ings are m anufact ured t o GI S/ PL3. Furt her det ails are
given in Appendix 2.
5.3.4.7 Valves and ancillaries shall be to BS EN 1555-4.

Not e: I n t he UK m anufact urer s produce PE valv es t o GI S/ V7- 2. Furt her det ails are given in
Appendix 2.
5.3.5 Copper
5.3.5.1 Pipe shall be to BS EN 1057.
5.3.5.2 When buried, pipe shall be factory sheathed.


BS 2051-1
BS EN 1254.
5.3.5.4 When buried, fittings shall not be attached to carbon steel pipe or fittings.
5.3.5.5 Fittings shall be protected against mechanical damage.
5.3.6 Corrugated stainless steel tube (CSST)
5.3.6.1 Pipe and fittings shall be to BS EN 15266 or BS 7838, as appropriate, which limit
the pipe diameter to a maximum of 50 mm.
Not e: Larger sizes m ay be accept able provided t he com ponent s com ply wit h t he essent ial
requir em ent s of BS EN 15266.
5.3.6.2 MOP shall be limited to 75 mbar, unless otherwise specified by the

manufacturer.
Not e: BS EN 15266 covers pipe and fit t ings up t o MOP of 500 m bar.
5.3.6.3 Pipe and fittings shall be as specified by the manufacturer and the pipework
system shall be pliable.
5.3.6.4 Compatibility of pipe and fittings shall be checked visually prior to assembly.
5.3.6.5 The synthetic cover shall be checked for damage prior to assembly and any
damaged section discarded or repaired in accordance with the manufacturer’s
instructions.
5.3.7 Sleeving
5.3.7.1 Sleeving for metallic and PE pipework shall be of suitable material, for example,
GRP, copper or steel, and must not impair the fire resistance of any structure.
5.3.7.2 Sleeving for PE used for an entry or exit into/from a building shall be metallic
and to a fire resistant standard and be sealed with an appropriate bulkhead
fitting.
25
5.3.8 Corrosion
The materials chosen shall be resistant to corrosion or protected against

corrosion, for instance by the use of wrapping tape or painting. See Section 8
for more information on the requirements for buried pipework.
26
SECTION 6 : JOINTING
It is inappropriate to cover every jointing system available. Where alternative methods to

those outlined below are available and provide an equivalent standard of safety and reliability,
their use is not precluded (see Sub-Section 1.12). The decision to use such an alternative will
be based on materials employed compared with similar items specified in this Standard and
the limitations on, for example, linear and angular movement and their effect on the integrity
of the pipework system as a whole.
Not e 1: The t ype of j oint ing used m ay be rest rict ed by t he grade of pipe. For ex am ple, som e grades of carbon st eel
pipe are not suit able for t he applicat ion of screwed t hreads t o BS EN 10226- 1 or I SO R7.
Not e 2: Addit ional requirem ent s for buildings cont aining m ult iple- dwellings are given in I GE/ G/ 5.
6.1 GENERAL
6.1.1 Any person carrying out welding, brazing, soldering or fusion jointing shall be
suitably trained and competent, and hold an appropriate certificate of
competence.
Welders performing work which is within the scope of GS(I&U)R must hold
appropriate certificates of competence, otherwise be supervised by a registered
person.
6.1.2 Formal procedures shall be in place identifying any need for testing of joints and
shall include the test criteria.
6.1.3 Any joint proven to be inadequate shall be repaired, re-made or replaced.
6.1.4 The effect of 3rd family gas on certain elastomeric seals shall be taken into
account.
6.1.5 Pipe and material internal finishes shall be checked for imperfections prior to
installation. Pipe ends shall be made square and shall be free of burrs.
Not e: The int ernal qualit y of fit t ings, com ponent s, pipe w elds and pipes m ay have a significant
effect on t he pressure drop of t he as inst alled inst allat ion.
6.1.6 When using stainless steel or copper pipe, pressed joints may be used but are

subject to the following limitations:

MOP shall not exceed 100 mbar
they shall comply with the fire test requirements of Annex A, Procedure A of

BS EN 1775
they shall comply with an appropriate standard such as DVGW VP614 for

high temperature tests
they shall comply with an appropriate manufacturing standard

Not e: At present , such st andards ar e only available in draft form , for exam ple pr EN 1254- 7.

they shall comply with Appendix 7 of this Standard
the pipe wall thickness shall be at least that specified by the joint

manufacturer
the pipework installation and its environment should be reviewed before a
decision to use pressfit type fittings is made, particularly in respect of
vibration and heat.
27
6.2 CARBON AND STAINLESS STEELS
6.2.1 General
6.2.1.1 Pipe and fittings shall be jointed as indicated in Table 4, using the minimum
practicable number of joints.
Not e: Sem i- r igid couplings, flange adapt ors or com pression fit t ings m ay be used as an alt ernat iv e
t o welded or screw ed j oint s for exposed above- ground pipework prov ided t hat t hey are
suit ably resist ant t o m echanical end loading. These t ypes of j oint m ay be used wit h
advant age where t here m ay be a risk of fire from t he welding operat ion or wher e t he
m aint enance of a clean envir onm ent is essent ial during t he inst alling work. Flange adapt er s
can only be used out side unless par t of a m et er inst allat ion.
NOMINAL
MOP (bar)
 0.5
BORE
(mm)
 25
> 0.5
> 25  50
Screw or weld Screw or weld
Screw or weld Weld
> 50 Weld Weld
Not e: The use of screwed j oint s bet ween exist ing and new pipework m ay be perm it t ed for t he
larger sizes and MOP exceeding 0.1 bar, if t he ex ist ing pipework t er m inat es in a screwed
connect ion.
TABLE 4 - JOINTING OF CARBON AND STAINLESS STEELS
6.2.1.2 Screwed and welded connections should be in accordance with the standards
indicated in Table 5 (but see clause 6.2.1.3).
Not e: Joint s achiev ing t ight ness by m et al t o m et al cont act and t he assist ance of sealant are
t er m ed “ screw ed” j oint s.
6.2.1.3 When connecting to plant pipework, valves, etc. which have connections to
other standards, for example NPT, API, ASA, DIN etc. and conformity to Table 5
is not possible as a result, connections shall be made using appropriate
matching thread forms or flanges. Such connections should then be type-
identified permanently.
COMPONENT SCREWED WELDED

Flange BS 10 BS 10
BS 1560 BS 1560
BS EN 1092 BS EN 1092
Thread ISO R7
BS EN 10226-1
Fitting BS 143 & 1256 BS EN 10253
BS EN 10241
BS EN 10242
TABLE 5 - SCREWED AND WELDED CARBON AND STAINLESS STEEL

CONNECTIONS
6.2.1.4 Male threads shall be tapered and shall be to BS EN 10226-1. Long screw
fittings shall not be used.

6.2.1.5 Jointing materials for flanged joints shall be to, as appropriate:
BS 3381 above 16 bar (Spiral wound 316L windings, synthetic filler and
stainless steel outer ring and appropriate for pipe material and jointing

method)

BS 6956

BS 7076
BS 7531 (Grade X or Y).
28
6.2.1.6 Jointing compounds or tapes for screwed joints shall be to BS EN 751-1

(compounds), BS EN 751-2 (anaerobic sealants) or BS EN 751-3 (tapes), as
appropriate and shall be applied in accordance with manufacturers’ instructions.
For new pipework, hemp shall not be used.

Not e: Where food and drink preparat ion or m anufact ure t akes place, it is im por t ant t o use
m at erials t hat m eet sit e healt h and safet y requir em ent s. Many sealant s cont ain m ineral oils
t hat m ay not be appropriat e for use in such areas. Before using any m at erial in such ar eas,
it is vit al t o check t he m at erial COSSH st at em ent s and t o verify t heir use is appropriat e
wit h t he responsible per son on sit e. I n ot her cases, t he use of poly t et rafluoroet hylene
( PTFE) t ape and st ring m ay not be appropriat e since any ingress of t he m at er ial int o t he
product ion pr ocess could dam age t he pr oduct . This is especially relevant t o t obacco,
breakfast cer eals and ot her baking processes.
All paint m at er ials for prim ing and finish coat s have t o be checked for suit abilit y in t he w ork
area and need t o be resist ant t o bact erial growt h.
6.2.1.7 For stainless steel pipes, compression couplings and joints shall be to BS 4368
with metal seals or metallic o-rings, but their use shall be restricted to joints of
diameter not exceeding 54 mm and then only so that the joints are accessible
for maintenance.
6.2.1.8 For stainless steel pipes, pressed joints shall not be used for MOP exceeding
100 mbar. The joint shall be made in accordance with Appendix 7.
6.2.1.9 Pressed fittings should not be used to connect directly to vibrating machinery
such as a forced draught burner or booster.
6.2.1.10 Flange gaskets shall not be re-used. All surfaces should be clean and dry before
assembly of flange joints.
6.2.2 Welding

6.2.2.1 Where pipe is welded:
the number of flanged joints shall be minimised and the flanges shall be
welded to the pipe
Not e: Flanged j oint s m ay be required t o per m it replacem ent of com ponent s, inser t ion of

spades, et c.
 integral flanges or
valves shall have:
 be designed for insertion between flanges or

 have ends that are prepared for welding.
6.2.2.2 Pipe and fittings shall be capable of being welded reliably.

Not e 1: Manufact urers’ dat a will provide infor m at ion and requirem ent s.

Not e 2: Fact ors t o consider in t his respect include t he lim it at ion of:

carbon equivalent t o 0.45

carbon cont ent t o 0.21

cont ent of ot her elem ent s, for exam ple phosphorous and sulphur
SMYS t o 360 N m m - 2
St eels out side t hese lim it s will require w eldabilit y t est ing.
6.2.2.3 Welding consumables should conform to the relevant standards.
29
6.2.2.4 Welding procedures and welding shall be in accordance with the standards listed
in Table 6.
STANDARD GAS WELDING ARC WELDING

BS 2971 carbon
BS 4677 stainless
BS 4872 carbon
BS EN 287-1 carbon
stainless
BS EN 1011-3 all steels
BS EN ISO 15614-1 carbon carbon
stainless stainless
BS EN 12732 carbon
ASTM A269 stainless
ASME B31.3 process
pipework
TABLE 6 - WELDING STANDARDS
6.2.2.5 Welders should be qualified in accordance with BS EN 287-1.
Not e 1: Welder qualificat ions m ay be t o ot her equiv alent s st andar ds such as ASME VI I I .
Not e 2: I f t he com pet ence of a welder is found t o be unsat isfact or y during t he course of work, a
decision shall be m ade on t he ext ent t o which his com pet ence and t he accept abilit y of t he
welding work r equir es m ore det ailed invest igat ion.
6.2.2.6 The welding faces shall be mechanically cleaned and shall be free of materials
which might impair the quality of the weld and the requirements of the welding
procedure shall be met. Precautions shall be taken to prevent stray arcs.
6.2.2.7 The pipe ends shall be aligned as accurately as possible with one another and
with pipe fittings, allowing for the tolerances on the diameter, the wall thickness
and the out-of-roundness of the pipes. The elements shall be aligned to give the
most advantageous distribution of tolerances for the application of the root
bead. No change in this position shall occur during the welding.
Welds on longitudinally and spirally welded pipes shall be staggered by not less
than 10 times the pipe wall thickness, subject to a 50 mm minimum, with the
welds in a "9 o'clock to 3 o'clock" position.
6.2.2.8 If there is a risk of the quality of the weld being impaired due to the prevailing
weather conditions, such as frost, fog, rain or blown sand, no welding work shall
be carried out unless effective preventative measures are taken.
The welding faces shall be preheated before welding, if required by the welding
procedure, to drive off any moisture present.
6.2.2.9 The electrodes, as prescribed by the welding procedure specification, shall be

kept dry and protected from damage during storage and use.
30
6.2.2.10 Inspection and testing of welds shall be in accordance with Table 7.
MOP INSPECTION/ CRITERIA

TEST
 0.1 bar Visual No cracks, notches or porosity.
No electrode run points or other burnt
areas.
Smooth surface.
No sharp transitions between weld beads.
> 0.1 bar Visual and/or Visual – as above.
NDT/NDE NDT/NDE – appropriate standards, for
and/or DT example BS EN ISO 5817.
TABLE 7 - INSPECTION AND TESTING OF STEEL WELDS
6.3 POLYETHYLENE (PE)
Polyethylene pipe, fittings, equipment and tooling used in the UK by Licensed

Gas Transporters conform to the GIS/PL2 suite of specifications.
Not e: Furt her guidance is given in I GE/ TD/ 3.
6.3.1 General
Solvent welding shall not be used for PE pipe.
6.3.2 Fusion jointing
6.3.2.1 Pipe and fittings shall be capable of being fused reliably.

Not e 1: Manufact urers’ dat a provides inform at ion and requir em ent s.

Not e 2: Fact ors t o consider in t his respect include:

pipe, fit t ings, v alves and ancillaries t o a suit able st andard
suit able equipm ent , for exam ple t o I SO 12176- 1, I SO 12176- 2, GI S/ PL2- 3 and
GI S/ PL2- 5.

6.3.2.2 For butt fusion welding, the following information should be available:

limits of ambient temperature

hotplate temperature

fusion cycle

cycle step application pressures

cycle step duration
average head width.
Not e: GI S/ PL2- 3 applies t o equipm ent for but t j oint ing polyet hy lene ( PE) pipes, 90 m m t o
630 m m inclusive nom inal diam et er .
6.3.2.3 For electrofusion welding, relevant information should be obtained from the
manufacturer of the PE pipe/fittings.
Not e: GI S/ PL2- 5 applies t o polyet hylene ( PE) elect rofusion j oint ing equipm ent and ancillary
t ooling.
6.3.2.4 Inspection of fusion joints shall be in accordance with Table 8.
31
METHOD INSPECTION CRITERIA
Butt fusion Visual. Bead shape: Bead depression not below

All joints. pipe surface.
Surface smooth and
symmetrical around whole
circumference of pipe.
Alignment: Closely aligned components.
Bead width: Check correct.
Visual. Remove Check for contamination or

external beads: lack of fusion.
Electro- Visual. Alignment: Use BS EN 1555-5 criteria.

fusion All joints.
Always use an alignment
sockets
clamp.
Socket shall be capable of
being spun 360° when in the
clamp.
Ensure pipe has been cut
square.
Mark pipes prior to fusion.
Scraping: Check that it is adequate.
Penetration: Correct coupling of spigot to
socket.
Cleanliness: No grease or dirt near fusion
interface.
Ensure the fittings were kept
in their bags until the last
possible moment.
Melt: No melt exudation outside
fitting.
No abnormal displacement of electric wire.
Check fusion indicators have risen evenly.

Electro- Visual. As above, as appropriate, and:

fusion All joints. no collapse of fitting onto pipe
saddles
no damage to pipe by ancillary tooling.
TABLE 8 - INSPECTION AND TESTING OF PE FUSION WELDS
32
6.4 COPPER
6.4.1 General
6.4.1.1 Where copper capillary fittings are to be used for MOP exceeding 75 mbar, the
joint shall be brazed (it shall not be soft soldered) and made using a filler metal
having a melting point of not less than 600oC.
Not e: This equally applies t o brass fit t ings.
6.4.1.2 Demountable press fit joints shall not be used.
6.4.1.3 Compression couplings and joints shall be to BS EN 1254-2 with metal seals or
metallic o-rings, but their use shall be restricted to joints of diameter not
exceeding 54 mm and then only so that the joints are accessible for
maintenance.
6.4.1.4 Pressed joints shall not be used for MOP exceeding 100 mbar nor for diameter
exceeding 108 mm. The joint shall be made in accordance with Appendix 7.
6.4.1.5 A factory-applied integral sheathing/cover shall not be considered to fulfil other

requirements for purpose-provided sleeving (see Sub-Section 5.3.7).
Not e: Where pipewor k is required t o be enclosed in a sleeve, for exam ple when passing t hrough
an unvent ilat ed void, t he coat ing on t he copper pipe does not fulfil such a purpose and a
purpose- designed sleeve has t o be applied t o t he pipe.
6.4.2 Brazing and soldering
6.4.2.1 Pipes and fittings shall be capable of being brazed/soldered reliably.

Not e: Manufact urers’ dat a will provide infor m at ion and requirem ent s.
6.4.2.2 Brazing should be carried out in accordance with BS EN 1775.
6.4.2.3 Brazing procedure approval, if required shall be carried out in accordance with
BS EN 13134.
6.4.2.4 Fillers shall be to BS EN 1044 and fluxes shall be to BS EN 1045.
6.4.2.5 Inspection of brazed and soldered joints shall be in accordance with Table 9.
MOP INSPECTION CRITERIA
Any Visual Check adequacy of joint, that heat has not

adversely affected the material, that filler
metal is visible and is free of porosity
defect around whole joint circumference.
TABLE 9 - INSPECTION AND TESTING OF BRAZED AND SOLDERED

JOINTS
6.5 CORRUGATED STAINLESS STEEL TUBE (CSST)
6.5.1 The jointing fittings and procedure shall be as specified by the system

manufacturer and, as a minimum, include:
verification that the components of the system fit together correctly and in

accordance with the manufacturer’s specifications

a list and description of specific tools needed to perform jointing

instructions for construction

a recommended maintenance programme
limitations on bend radii
33
 provision to prevent torsion being applied to the pipe during jointing and
construction.
6.5.2 Fittings shall not be disassembled and subsequently re-assembled, unless

permitted by the manufacturer’s instructions.
6.5.3 Joints shall not be made by hot methods, for example welding or brazing.
6.5.4 The appropriate torque values used to perform joints shall be checked using an
appropriate procedure.
6.5.5 The factory-applied integral sheathing/cover shall not be considered to fulfil

other requirements for purpose-provided sleeving (see Sub-Section 5.3.7).
Not e: Where pipewor k is required t o be enclosed in a sleeve, for exam ple when passing t hrough
an unvent ilat ed void, t he nor m al coat ing on t he CSST does not fulfil such a purpose and a
purpose- designed sleeve has t o be applied t o t he pipe. I t is accept ed t hat a specially coat ed
sect ion m ay be accept able for t his dut y.
6.5.6 Semi-rigid corrugated stainless steel tube (CSST) shall not be used as the final
gas appliance connection when it would subject to vibration and heat.
34
SECTION 7 : GENERAL PRINCIPLES FOR INSTALLING PIPEWORK
7.1 GENERAL
7.1.1 Under normal circumstances correctly jointed pipework should not leak
throughout its lifetime. However, the local environment, mechanical damage
and interference could cause leakage to occur from pipework joints. Therefore, it
shall be ensured that if leakage does occur, a dangerous condition will not
result.
Not e: Pipework j oint s are m echanical j oint s w it h a pot ent ial for leakage in t heir service life and do
not include t hose which are w elded, solder ed or brazed.
7.1.2 Pipework joints shall be located in positions where air movement can dilute any
leakage and prevent explosive concentrations occurring. Therefore, it is
important to locate pipework joints in ‘open positions’ where air movement is
not restricted in order to avoid hazardous area implications. Dead areas where
air movement is restricted by appliances, equipment or structures, such as at
the back of boilers, should be avoided unless local ventilation can be added to
promote dilution.
Not e: I n except ional cases, wher e pipewor k j oint s cannot be locat ed in ‘open posit ions’,
vent ilat ion m ay be added or a regular inspect ion r egim e applied t o reduce t he hazar dous
area classificat ion. Furt her guidance on t he hazardous area im plicat ions is giv en in
I GEM/ UP/ 16.
7.1.3 Sections 8 to 12 outline specific guidance and requirements depending upon the
location of pipework, whereas the guidance provided in this section shall be
used for all pipework locations.
Not e: Addit ional guidance m ay be r equir ed for pipework sit ed where special const raint s apply.
7.2 LOCATION OF PIPEWORK
7.2.1 Pipework must be installed only in a position in which it can be used safely,
having regard to the position of any other nearby service and to such parts of
the structure of any building in which it is laid that might affect its safe use, for
example electrical intake chambers, transformer rooms and lift shafts.
7.2.2 Pipework joints (other than welded, brazed or soldered) unless buried shall be
located in ventilated positions.
7.2.3 Any requirements for other services shall be taken into account along with any
requirements of the relevant CoPs.
Not e: While m ore det ailed guidance is provided for buried pipew ork and in Sect ion 8, for exposed
pipework, it is not possible t o prescribe precise clearances from ot her services et c. as,
inev it ably, t hese vary dependent upon t he part icular cir cum st ances prevailing at t he sit e of
t he inst allat ion.
7.2.4 Pipework must not be installed in an unventilated duct or void (see Sub-Section
10.4).
Not e 1: Pipework m ay be cont inuously sleeved t o allow it t o pass t hrough such a duct or void ( see
clause 7.8.
Not e 2: Research has proved t hat w here sm all diam et er low pressur e gas inst allat ion pipework ( of
diam et er not exceeding 35 m m , at OP not exceeding 25 m bar) is inst alled at int er m ediat e
j oist ed floor s in dw ellings, t here is sufficient advent it ious v ent ilat ion of t he floor
const ruct ion t o safely disper se any m inor leakage of gas. This conclusion can reasonably be
ext ended t o com m ercial and indust rial propert ies for sim ilar ly const ruct ed floors, and for
pipework of sim ilar diam et er and pressure. Ther efore, t here is no requirem ent t o inst all
purpose provided vent ilat ion t o floors of t his const ruct ion in convent ional m asonry, t im ber
fram e or light st eel fram e buildings. The r esult s and conclusions of t his Repor t apply t o
Nat ural Gas inst allat ions only and, t herefore, cannot be applied t o inst allat ions supplied
wit h 3 rd fam ily gases.
35
7.2.5 Pipework must not be installed in a cavity wall, neither shall it pass through a
cavity wall except by the shortest possible route.
7.2.6 Pipework must not pass through or along a protected shaft containing a stair or

lift (see The Building Regulations), unless all the following conditions apply:

OP does not exceed 75 mbar and

pipework, including fittings, is of carbon or stainless steel

any joint is either threaded (screwed) or welded
CSST pipe is of continuous length without joints.
7.2.7 Pipework in an exposed, high, location, for example on the roof of a building,
shall be protected by suitably-positioned lightning conductors.
Not e: BS 6651 provides appropriat e guidance.
7.2.8 Where hygiene is of importance such as in catering installations, the pipework

shall be installed with at least 25 mm clearance between the pipework and an
adjacent surface (such as a wall) to enable the pipework and the surface behind
it to be cleaned.
7.3 HAZARDOUS AREA CONSIDERATIONS
During the design it is important to minimise the number of joints, ensure

adequate ventilation and to provide access for inspection and maintenance. If
this cannot be achieved it may be necessary to apply a hazardous area
classification to that part of the installation. IGEM/UP/16 provides guidance on
the classification and means to avoid or reduce it. See also Section 4 and
Appendix 8.
7.4 CONNECTION TO THE METER INSTALLATION
7.4.1 Pipework connected to the primary meter installation shall be a solid section of
rigidly supported pipe that is installed so as not to impose any mechanical stress
on the meter installation.
7.4.2 CSST shall not be directly connected to any primary meter outlet unless the
meter is rigidly secured to a fixed meter bracket/bar. In such cases, a solid
section of rigidly supported pipe shall be connected to the meter connection
before the connection to the CSST.
7.5 CONSTRUCTION AND SLEEVING
7.5.1 Pipework must not be installed in such a way as to impair the structure of any
building or as to impair the fire resistance of any part of its structure.

7.5.2 Pipe laid in concrete floors or otherwise buried shall:

be protected against failure caused by movement

have as few joints as practicable

not include compression fittings nor CSST joints or pressed fittings
be protected from mechanical damage by a suitable depth of cover and/or
by a protective material cover.
7.5.2 For pipework installed so as to pass through any wall or is installed so as to pass

through any floor of solid construction:

the pipework shall be enclosed in a sleeve and
the pipework and sleeve shall be so constructed and installed as to prevent
gas passing along the space between the pipe and the sleeve (for example
by sealing one end) and between the sleeve and the wall or floor and so as
to allow normal movement of the pipework
36
 sleeves shall terminate and be sealed at least 25 mm beyond the finished

wall or floor surface where cleaning, condensation or surface coating could
lead to local corrosion.
7.6 PROVISION FOR EXPANSION AND FLEXIBILITY
7.6.1 The use of flexible hoses and bellows shall be kept to a minimum.
Not e: This equipm ent is vulnerable and t herefore is at great er risk of leaking.

Provision for expansion shall be considered:

in buried pipework if there is a risk of settlement or subsidence
in buildings and external pipework if the pipework is not sufficiently flexible
to accommodate thermal movement.
7.6.2 Where there is a risk of mechanical loading exceeding the manufacturer’s

specifications, expansion joints of the bellows type shall be fitted with anchor
points to limit expansion in the intended direction. If necessary, rubber and
plastic elements shall be protected from local thermal radiation and/or
mechanical damage by a metal shield.
Not e: Furt her guidance m ay be sought from I GEM/ G/ 5.
7.7 PROTECTION OF PIPEWORK
7.7.1 General
Pipework components shall be suitably protected against corrosion at all times

during transportation, storage and installation.
Not e: Furt her guidance on t he handling, t ransport and st orage of st eel pipe, bends and fit t ings is
provided in I GEM/ TD/ 1 Edit ion 5 Supplem ent 1 and, for PE pipe and fit t ings, I GEM/ G/ 8.
7.7.2 Stored pipework
7.7.2.1 There is not a fully satisfactory method of weather-protecting steel components

stored in the open. Measures such as sheeting and lime-washing shall be
regarded only as temporary protection.
7.7.2.2 Long-term outdoor storage of steel pipe shall be avoided, wherever possible.
Where unavoidable, the bore shall be kept clean either by fitting end caps or by
applying a suitable protective compound to pipe ends. If end caps are used,
they should be sufficiently close-fitting to prevent ingress of moisture. Before
caps are applied, the bore shall be dry and the pipe ends shall be protected
against corrosion by application of suitable protective compound or tape.
7.7.2.3 Although resistant to a wide range of inorganic substances, PE can be attacked

by certain aromatic and aliphatic hydrocarbon compounds. PE pipe and fittings
should be stored away from these materials and any that are damaged in this
way shall not be used.
Not e: Most lubr icat ing and hydraulic oils, chem ical solv ent s and cert ain gas condit ioning fluids fall
int o t his cat egory. The m echanism of at t ack is one of absorpt ion of t he chem ical leading t o
soft ening of t he PE and a subsequent adverse effect on propert ies such as st r engt h and
st iffness.
7.7.2.4 PE fittings shall be stored in their protective packaging until immediately before
use.
Not e: Furt her inform at ion on t he handling, t ransport and st orage of PE pipe and fit t ings can be
found in I GEM/ G/ 8.
7.7.2.5 PE pipework and fittings shall not be subject to prolonged exposure to sunlight
or other ultra-violet sources, unless permitted by the manufacturer.
37
7.7.3 Installed pipework
7.7.3.1 PE pipework shall not be subjected to prolonged exposure to sunlight or other

ultra-violet (UV) sources. Where PE pipe is installed above ground, provision
shall be made to protect the pipe from such sources, for example by enclosing
the pipe in a glass-reinforced plastic or steel sleeve.
7.7.3.2 Pipework installed above ground shall be supported properly and so placed or
protected as to ensure that there is no undue risk of mechanical damage to the
pipework.
Not e: Such prot ect ion m ay include enclosing t he pipework in a st eel duct ( see also Sect ion 10) .
7.7.3.3 Precautions shall be taken to prevent corrosion of materials in locations where

corrosion of the pipework system may occur. This may be by the use of
corrosion resistant materials such as stainless steel rigid pipes or by factory
coating, hand wrapping or painting. Stainless steel rigid pipework should not
normally require wrapping.
Not e: The proxim it y and posit ion of pipework cont aining corrosiv e subst ances or on which vapour
could condense need t o be t aken int o account .
Vulnerable areas of pipework systems include flanges, couplings, suspension

points, pipe supports and entry and exits to buildings. Special consideration
shall be made for providing corrosion protection for such areas.
Site applied wrapping shall have at least a 55% overlap together with any
recommended protective wrapping (see BS EN 12068).
Paint coatings in areas subject to corrosion shall be of a type having corrosion

resistant properties.
7.7.3.4 Buried pipework shall be protected in accordance with Sub-Section 8.4.
7.7.3.5 Copper, thin walled stainless steel and pliable stainless steel (CSST) pipework
that is exposed or surface mounted shall not be used in areas where itis
particularly vulnerable to damage and unauthorised interference for example in
educational establishments. Where copper pipe is located in concealed locations
in such areas, it shall be jointed using soft solder or brazed fittings.
In educational establishments, flexible stainless steel appliance connections,

rubber Bunsen burner connections and CSST pipework systems are prone to
damage and the design shall consider the associated operational and safety
issues.

Flexible stainless steel appliance connections (not CSST) shall:

be as short as reasonably practicable and not exceed 1.4 m long

not be located within a rising duct

be connected to the fixed gas installation pipework with self sealing and

swivel plug/socket end connections
be protected by stainless steel restraint cables, securely fixed to a secure
surface such as a wall, floor, or fixed bollard, of such length as will prevent
the flexible connection from being over-stretched or excessively bent at its
end connections.
A self sealing plug shall be connected to every self sealing fitting to seal the
connection when not in use, unless there is a manual isolation valve fitted
immediately before the fitting.
Not e: Special considerat ions for educat ional est ablishm ent s are fully described in I GEM/ UP/ 11.
38
7.8 CLEARANCES
7.8.1 Adjacent surfaces, structures and equipment shall not impair the ventilation
around pipework joints.
7.8.2 Unless pipes are separated by electrical insulating material, they shall be
suitably spaced from other services. For MOP not exceeding 100 mbar,
electricity supply and distribution cables and other metallic services shall be
spaced at least 25 mm from any pipework. For MOP exceeding 100 mbar, the
need for greater clearance shall be considered.
7.8.3 A minimum clearance of 150 mm shall be provided to electricity meters and

consumer units.
Not e 1: A Consum er unit can be defined as an assem bly of one or m ore fuses, cir cuit - breakers or
residual curr ent operat ed dev ices nor m ally inst alled bet w een t he m et er and t he elect rical
inst allat ion in prem ises. I t is norm ally inst alled adj acent t o t he elect ricit y m et er .
Not e 2: Pipework in dam p locat ions m ay require gr eat er clearance ( see clause 7.7.2) .
Not e 3: Spacing will, probably, need t o be increased in order t hat m aint enance and inspect ion can
be carr ied out easily, wit hout dam aging ser vices or t heir prot ect iv e wrappings/ coat ings and
wit hout hazard t o per sonnel. For som e larger and higher pr essure pipework, a spacing of as
m uch as 250 m m m ay be r equired.
Not e 4: I nform at ion on spacing is provided in BS 8313 and BS EN 15001.
Reference shall also be made to Section 10 for pipework in ducts, etc. and to
Section 8 for buried pipework.
7.9 ELECTRICAL SAFETY
7.9.1 General
7.9.1.1 Due account shall be taken of the requirements of DSEAR to perform risk
assessments on any gas installation, to ascertain if any additional safety and
operational requirements may be necessary to prevent danger (see
Appendix 8).
Not e: I n m ost cases, t his w ill det erm ine w het her or not t he gas pipework generat es a zoned
hazardous area at j oint s and if t her e is a need for t he use of cer t ified safet y elect rical
com ponent s and/ or addit ional safet y vent ilat ion. I n all cases, a pr ocedur e for pipe
m aint enance w ill be appropr iat e.
7.9.1.2 Pipework shall have main equipotential bonding applied in accordance with
BS 7671.
7.9.1.3 Bonding or cathodic protection (CP) connection shall not be made to gas
pipework if it would produce an electrical hazard to any occupier of the premises
or any person working on the pipework.
7.9.1.4 Main equipotential bonding of any other services to gas pipework shall be
connected to the pipework on the outlet side, within 600 mm where practicable,
of any primary meter or at the point of entry of the pipework into the building
where a meter is not fitted, or as determined by an electrically competent
person in accordance with BS 7671.
Not e: Furt her guidance, for exam ple as provided in BS 6891, m ay be adopt ed.
7.9.1.5 Main equipotential bonding shall not produce electrical continuity across any
insulating joint deliberately incorporated in pipework, for example protective
multiple earth (PME) or CP insulators.
7.9.1.6 Consideration shall be given to providing permanent continuity bonding around

any part of pipework likely to be removed for repair or maintenance. For semi-
39
rigid couplings and flange adaptors, reference should also be made to

clause 13.3.2.
7.9.1.7 All work must be carried out in accordance with the Electricity at Work
Regulations.
7.9.2 Electrical isolation
7.9.2.1 Electrical isolation should be as specified in BS EN 60079 and BS 7671, as

appropriate.
7.9.2.2 Means of isolation should be provided to disconnect incoming power supplies

from certain sections of plant, as required for maintenance for normal and
emergency purposes.
7.9.2.3 The position and duty of any isolating switch should be clearly identifiable on
site.
7.9.2.4 Any circuit isolator supplying apparatus located in a hazardous area should
disconnect the neutral as well as the phases (double pole isolation).
7.9.2.5 Any automatic or remotely-controlled equipment should be provided with

immediately-adjacent stay-put-stop buttons or equivalent safeguards, including
arrangements for padlocking in order to prevent accidental starting during
maintenance inspection. Either an isolator should interrupt all control and
monitoring circuits, main phase and neutral connections, or suitable provision
should be made for multiple isolations.
7.9.3 Earthing
7.9.3.1 The whole of the electrical installation must be earthed adequately and
effectively and in accordance with appropriate standards.
Not e: I n t he UK, t he supply aut hor it y has no m andat ory obligat ion t o supply t he user w it h an
eart hing t er m inal ( wit h t he except ion of PME syst em s) .
7.9.3.2 Any metallic part of the installation, including any stairway and its supports,
should be earthed.
The following should be taken into account when designing earthing
● where the supply is taken directly from the local distribution system by
arrangements:
means of an underground cable, the electricity supply authority will usually

permit connection of the user’s earthing conductor to the sheath of that
● where the supply is taken directly from the local distribution system by
cable
means of an overhead line, it may be necessary for the user to provide an
● where the supply is taken from a local transformer, the user’s earth
earth
connection usually will be made at the same electrode as that to which the
transformer secondary neutral is connected.
7.9.3.3 Care should be taken to avoid interactions between the electrical earthing,
instrumentation earthing and CP systems.
7.9.3.4 The design and siting of electrical earthing electrodes should be given specialist
attention. Such electrodes should be manufactured from stainless steel,
austenitic steel or other CP-compatible materials.
Not e: Copper or any ot her incom pat ible elect rodes are not suit able as t he buried st eel pipework
m ay corrode preferent ially wit h respect t o t he elect rode.
40
Coke or other carbonaceous materials should not be used as part of the

electrode system.
7.9.3.5 Sites supplied from protective multiple earth (PME) or combined neutral earth
(CNE) systems present certain problems on which specialist advice should be
sought.
Not e: I n part icular, t his is im por t ant wher e int rinsically safe circuit s are em ployed and t he
im pedance of eart h r et ur n pat hs from safet y barriers are t o be kept below 1 ohm .
7.10 ASSOCIATED COMPONENTS
Guidance on the selection of valves is provided in Section 14.
Clauses 7.10.1.1, 7.10.1.2 and 7.10.1.3 may be applicable, depending on the

type of premises, under GS(I&U)R.
It is a legal requirement that an ECV be fitted at the end of the Network. This is
the responsibility of the GT. The ECV terminates the Network (see IGEM/G/1).
7.10.1 Additional emergency control valves (AECVs)
7.10.1.1 An additional emergency control valve (AECV) shall be fitted at the point of
entry into individual buildings.
7.10.1.2 Any AECV shall be fitted with a label bearing the words “Gas Emergency
Control” or similar, and shall indicate the action to be taken in the event of a
gas escape (see Figure 3).
FRONT
FIGURE 3 - EXAMPLE OF AN AECV LABEL
7.10.1.3 Any key, lever or hand wheel of the AECV shall be attached securely to the
operating spindle of the control.
Any such key or lever shall be parallel to the axis of the pipe in which the AECV
is installed when the control is in the open position.
41
7.10.1.4 Where any key or lever is not attached so as to move only horizontally, gas shall
not be able to pass beyond the AECV when the key or lever has been moved as
far as possible downwards.
7.10.2 Additional manual isolation valves

7.10.2.1 An additional manual isolation valve shall be fitted in the following situations:

in every lateral, downstream of the connection to any riser

for NG, at any offtake of 50 mm internal diameter or greater

for LPG, at any offtake of 30 mm internal diameter or greater

for buried pipework (inlet)
in pipework to each self-contained area into which gas is supplied for use.
For example catering installations, boiler rooms, etc.
This valve shall be located outside the area or near an exit, and be in a
readily accessible position. Where the manual valve is not in a readily
accessible position and there is no acceptable and accessible upstream
valve, an Automatic Isolation Valve system shall be fitted. Where such an
AIV is fitted, an emergency stop button or control shall be located to enable
operation in an emergency. Where necessary, the emergency stop button or
control shall be shielded to prevent inadvertent operation.
At locations where either the manual gas isolation valve is fitted or where an
automatic electric valve system can be reset, a notice shall be affixed
stating:
“IN THE EVENT OF AN EMERGENCY, THE GAS ISOLATION VALVE MUST BE

CLOSED. ALL DOWNSTREAM BURNERS AND PILOT VALVES ON APPLIANCES
MUST BE TURNED OFF PRIOR TO ATTEMPTING TO RESTORE THE SUPPLY”
7.10.2.2 A manual isolation valve should be installed at any offtake to assist tightness
testing and purging (see clause 4.2.8) and to permit section isolation without
interruption of supply to other parts of the premises. Any such valve shall be
clearly identifiable and should be readily accessible and easy to operate,
preferably at a convenient height from floor or platform level. Either the means
of operating the valve shall be marked clearly and permanently or a notice in
permanent form shall be displayed prominently near such means so as to
indicate when the valve is open and when it is shut.
7.10.2.3 A manual isolation valve or equivalent device (if not fitted by the appliance/plant
manufacturer/supplier), shall be fitted on the inlet to any appliance or plant gas
control system to enable each individual appliance or plant to be isolated for
servicing or cleaning. Such a valve shall be readily accessible and easy to
operate. As far as is practicable, the valve shall be of the single quarter-turn
type.
Not e 1: This is applicable t o individual appliances, appliances suit ed ( an assem bly of appliances
j oined t o give t he appearance of one lar ge const ruct ion including plint h- m ount ed) and
com m er cial cat er ing suit es ( a num ber of appliances pre- inst alled int o one com plet e
assem bly as supplied) . The self- sealing coupling used for t he flexible connect ion cannot be
regarded as t he single m anual m eans of isolat ion, unless a quar t er - t ur n m anual m eans of
isolat ion is incorporat ed as part of t he self- sealing coupling assem bly
Not e 2: This m eans t hat t he valve will be sit uat ed upst ream of t he final connect ion, but
downst r eam of any branch in t he pipewor k t o any ot her appliances.
Not e 3: The self- sealing socket in a flexible connect ion does not conform t o t his r equir em ent unless
t he flex ible connect ion has an int egral quart er t urn valve.
7.10.2.4 Any manual isolation valve used in a gas installation, as well as on equipment
and appliances, should incorporate visual indication of the ‘open’ and ‘closed’
positions. Where an operating lever is used for this indication, the normal means
42
of fixing the lever should ensure that, when the valve is open, the lever is
parallel to the axis of the pipe.
The “off” position should be approximately one downward quarter turn through
90o of the lever to the right or left.
7.10.3 Non-return valves (NRVs) etc.
7.10.3.1 Any NRV shall be installed and maintained in accordance with the
manufacturer's instructions, care being taken with regard to orientation,
levelling and pressure loss across the device (see clause 4.2.4).
7.10.3.2 For a piped gas supply to burners provided with air, oxygen or other extraneous
gases under pressure, a suitable device must be installed upstream of the first
control in the gas supply to each burner, group of burners or the plant. The
device may be a NRV, an automatic flame safety system, a slam-shut valve
system, etc.
Not e: Burner s t hat com ply w it h BS EN 676 or BS 5885 provide such prot ect ion by design.
7.10.3.3 Where a positive displacement booster or compressor (screw, reciprocating or

slide vane types) is installed, a NRV or equivalent device of a type acceptable to
the GT must be fitted upstream of the booster or compressor (see also
IGEM/UP/6).
7.10.3.4 Means shall be provided to allow regular testing and maintenance of any NRV or
equivalent device.
7.10.4 Traps
Where wet gas is supplied or where condensate drop out could occur, and in the
exceptional case where in-situ hydrostatic pressure testing is to be carried out,
a container shall be fitted at low points in the installation to collect any
condensate or fluid. Such a container shall be in a readily accessible position
and a valve(s), suitably plugged or capped, shall be fitted to each drain
connection to permit safe removal of liquid.
Not e: Norm ally, where dry gas is supplied, a condensat e t rap is not necessary .
7.10.5 Purge points
Purge points shall be installed in accordance with clause 4.2.8.2.
7.10.6 Pressure test points
Pressure test points shall be installed in accordance with clause 4.2.8.1.
7.10.7 Secondary and check meters
7.10.7.1 Secondary and check meters to be installed in new and existing installations
shall be selected to ensure that the resultant pressure drop at design load
across the system complies with clause 4.2.4. Meters should be selected to
match the design flow rate range and the desired accuracy.
Not e 1: I GE/ GM/ 4 defines secondary and check m et ers.
Not e 2: Furt her guidance for specificat ion and inst allat ion is given in I GEM/ GM/ 6 and I GE/ GM/ 8 as
appropriat e.
7.10.7.2 The installation of any secondary meter or check meter shall be in accordance
with any additional requirements in the manufacturer’s instructions.
43
7.10.8 Automatic isolation valves (AIVs)
7.10.8.1 Normally, the use of an AIV operated from a gas, fire or smoke detection
system is not required for a gas installation (but see Appendix 9). However,
where specified, for example as a result of a risk assessment, it shall be fitted
The selection of the AIV and its operating system shall be considered carefully
(particularly with respect to supply in those cases where appliances do not
incorporate automatic flame safeguards).
7.10.8.2 Where automatic flame safeguards are not fitted on all appliances, any AIV
system shall be designed to prevent, in the event of closure of the valve,
restoration of the gas supply before downstream pipework is checked for
integrity.
It is acceptable to install an AIV in a pipework system that supplies only

appliances fitted with full flame safeguard and SSOV protection, which
automatically opens following closure due to a transient loss of power. On
closing, the AIV shall not then be allowed to be manually reset until the
downstream pipework is checked, for example by checking all appliance gas
valves are closed or by applying a low pressure cut-off system (see Appendix
10).
7.10.8.3 Any electrically-operated AIV should comply with the essential requirements of
BS EN 161.
Where an AIV is fitted, provision for its remote operation in an emergency shall
be made.
Not e 1: Ext ernal operat ion m ay also be considered.
Not e 2: Such a valve m ay also be operat ed by ot her building/ sit e safet y sy st em s in an em ergency.
Not e 3: AI Vs are not norm ally required for MOP not exceeding 0.5 bar.
The valve shall close as soon as possible after being de-energised, preferably
within 1 second for valves up to and including 100 mm NB and within 3 seconds
for larger sizes. The valve should comply with BS EN 161 but it is permitted to
have a drop handle meeting the essential requirements of BS EN 161.
Not e: Norm ally, dropweight valv es are not r ecom m ended, as t hey m ay be prone t o st icking in t he
open posit ion aft er per iods of non- operat ion.
7.10.9 Gas detectors
Any building or room containing a gas installation has to be ventilated to

prevent the accumulation of gas such as could occur from minor gas escapes
(see Section 10).
The fitting of a gas detector shall not be regarded as a substitute for good
ventilation although, when fitted, it should comply with BS EN 61779 and be
installed in accordance with BS EN 50073.
Not e: Furt her guidance is provided in Appendix 11. Gases wit h an SG sim ilar t o air ( 1) m ay require
det ect or s t o be locat ed at high and at low levels.
7.11 IDENTIFICATION AND LABELLING
7.11.1 Additional emergency control valves (AECVs)
Where the directions to open and close are not obvious or as indicated, an
ON/OFF yellow label for example from a continuous roll of self-adhesive
material, must be fixed to any AECV (see Figure 4).
Not e: I t will be necessary t o ensure t hat t he valve can be t urned off in t he dir ect ion indicat ed.
44
on on on
off
on
On/off tape
on
off off
FIGURE 4 - LEVER-OPERATED AECV WITH ON/OFF LABELS FITTED
7.11.2 Manual section isolation valves
Any manual section isolation valve should be readily identifiable, for example
painted yellow, or be labelled “Gas Isolation Valve” if the valve is visible and
accessible. Such a label should be mounted as close as possible to the valve or
be attached to the adjacent pipe and be coloured yellow (primrose yellow ref.
BS 4800 10 E 53) background with black writing.
7.11.3 Ancillary equipment
Consideration should be given to the labelling and numbering of ancillary

equipment such as NRVs, regulators, pre-mix machines and boosters.
Not e: This is par t icularly pert inent on large sit es where equipm ent ident ificat ion m ay be difficult
due t o t he num ber of gas equipm ent it em s on sit e.
7.11.4 Valves and equipment
A marker plate shall be installed above ground to identify the position of any
underground valve, syphon or purge point (see Sub-Section 8.6).
7.11.5 Pipes and pipework
7.11.5.1 Any pipe and pipework shall be readily identified to indicate it carries a fuel gas.
This shall be achieved by fully painting with yellow ochre (to BS 4800 08 C 35)
or primrose yellow (to BS 4800 10 E 53) paint or by banding the pipe (which
does not have to be so painted) with GAS marker tape (see Figures 6, 7 and 8)
or in accordance with BS 1710.
7.11.5.2 Where gas marker tape is used, the positioning of banding should be as shown
in Figure 5. Additional banding shall be provided as necessary to enable every
section of pipework within the installation to be visibly identifiable.
Not e: For paint ing, it is com m on pract ice t o use y ellow ochre for MOP not ex ceeding 75 m bar and
prim rose yellow for MOP exceeding 75 m bar.
45
after any connection

to the main line
150 mm
150 mm after any valve

before termination
flange or valve
150 mm
Not e: Minim um widt h 25 m m .
FIGURE 5 - POSITIONING GAS MARKER TAPE
FIGURE 6 - YELLOW NATURAL GAS TAPE
Not e: Minim um widt h 25 m m
FIGURE 7 - YELLOW LPG TAPE
FIGURE 8 - YELLOW GAS TAPE
7.11.5.3 For MOP exceeding 75 mbar, pipework shall be marked with the OP at the outlet
from the meter installation. Where installations have systems operating at
differing pressures, each systems pipework shall be marked with the contained
pressure. The inlet and outlet pressures to any pressure reducing equipment
shall also be marked.
46
7.12 HOT TAPPING CARBON STEEL PIPE
7.12.1 General
Hot tapping is a process used for performing new extensions to existing

pipework under pressure. It shall be performed in accordance with BS
EN 12732.
7.12.2 Hot tapping is a process requiring specialist skills, experience and equipment to
ensure the safety of the operation and used on pipe diameters from NB 50 up to
and including NB 500 within the scope of BS EN 12732.
It shall be limited to existing pipe minimum wall thickness of 3.6 mm.
It shall not be used on ancillaries of cast iron or nodular cast iron.
The welder(s) shall be suitably qualified.
7.12.3 The following precautions shall be taken so that the tapping operation can be

performed correctly:
the minimum distance between the hot tapping location and any other

welded joint shall be 75 mm, or 1.5 x Do, where Do is the outside diameter
the minimum distance between the hot tapping location and any other

threaded or flanged joint shall be 150 mm

the pipe wall shall be free of inclusions and/or material defects
if a welding stub is used, the ratio between the diameter of the gas-carrying

pipe and that of the branch at the welding stub shall not exceed 2:1
if a split tee is used, the ratio between the diameter of the gas-carrying pipe

and that of the branch at the tee shall be 1:1

the gas flow shall be reduced to a minimum, but not less than 0.4 m s-1
the temperature of the flowing gas shall not exceed 40°C.

7.12.4 The design shall be submitted in advance and shall at least include:

a construction drawing of the pipework indicating the location of the tapping

details of the materials to be used
the Welding Procedure Specification (WPS) and the Welding Procedure.

Approval Record (WPAR) for the welds:

non-destructive testing record(s)

wall thickness measurements

examination for faults due to rolling
dye penetrant examination of the pipe material to detect cracks.

The evaluation procedure is as follows:
the WPS and the WPAR for the welds are first evaluated by the welding

expert
the design is then evaluated.
47
MAIN BRANCH PIPE DIAMETER

PIPE (mm)
DIAMETER 15 20 25 40 50 80 100 150 200 250 300 350 400
DN (mm)
400 c c c c d d d d b b b b a
350 c c c c d d d d b b b a
300 c c c c d d d b b b a
250 c c c c d d d b b a
200 c c c c d d b b a
150 c c c c d b b a
100 c c c c b b a
80 c c c c b a
50 c c c c a
40 b b b a
25 b b a
20 b a
15 a
a= tee
b= reducing tee
c= nipolet, threadolet, sockolet, elbowlet
d= weldolet, sweepolet
TABLE 10 – STANDARDISED BRANCHES FOR CARBON STEEL PIPES
7.13 PROVISION FOR CONNECTIONS
Where wet gas is being supplied or where condensate could occur, any
connection should be taken from the top or side of pipework.
7.14 PLANT PIPEWORK
7.14.1 A manual valve or other acceptable means of isolation (see Section 14) shall be
fitted at the inlet to all plant, in accordance with Sub-Section 7.10.
7.14.2 Means shall be provided to purge, commission and de-commission plant

pipework and burner controls, for example using a valved and plugged/capped
small bore offtake, with provision for temporary venting to a safe place (see
Sub-Section 4.2.8). Reference should be made to IGEM/UP/4.
7.14.3 On the outlet of any plant isolation valve, there should be incorporated a means
of disconnecting the pipework, for example a union or flange.
7.14.4 Where appropriate, a NRV shall be fitted in accordance with clause 7.10.3 and
IGE/UP/12.
7.14.5 Auxiliary pipes, impulse pipes, relief and vent pipes, and fittings associated with
control and safety devices shall be suitably sized and adequately supported.
They shall be constructed of suitable materials and fittings (see Sections 5 and
6). Where copper pipe is used, it shall not be vulnerable to damage that might
lead to a potentially dangerous condition.
Not e: Any copper pipework fit t ed t o a flexible connect ion shall be support ed t o prevent dam age t o
t he pipewor k when t he flex ible connect ion is discont ent ed or t he appliance is m ov ed.
7.14.6 Where plant movement could affect the integrity of any burner control valve
system, consideration shall be given to installing a stainless steel flexible pipe
complying with BS EN ISO 10380, fitted with a protective cover or braiding as
48
necessary, to the downstream side of the safety shut-off valves (SSOVs) or

control train.
Not e: Alt ernat ively, an addit ional SSOV, in a non- v ulnerable posit ion, m ay be considered.
7.14.7 Control trains on burners shall be adequately supported and located in

accessible, well-ventilated environments and where commissioning and
maintenance work can be performed safely.
7.14.8 Relief and vent pipes shall terminate in a safe and well-ventilated location, away
from ignition sources or building inlet vents. Where necessary, the vent location
shall be considered for hazardous area classification (see IGEM/SR/25).
7.14.9 Plant pipework shall be subjected to hazardous area classification (see Sub
Section 7.3).
Not e: I n general nat ural gas pipework and cont rol syst em s should not require hazardous area
classificat ion r equir ing addit ional safet y equipm ent or cont rols providing t he requir em ent s
of I GEM/ UP/ 16 and Sub Sect ion 7.3 are com plied wit h.
49
SECTION 8 : BURIED PIPEWORK
8.1 GENERAL
The general principles outlined in Section 7 shall be applied.

Not e: This sect ion gives general guidance on t he burying of pipes. For long or large diam et er or
higher pressur e pipes, I GE/ TD/ 4 or I GE/ TD/ 3 as appropriat e m ay also be of assist ance.
8.2 ROUTE
8.2.1 Pipework shall neither pass under the load bearing foundations of a building, nor
under a load bearing wall or footing, unless suitably protected by a load-bearing
structure or sleeve which is certified by a structural engineer. Where such a
sleeve is used, the pipe should be supported or centred within the sleeve and,
unless the pipe is PE, should be protected against corrosion.
Not e: I deally, t he sleeve will ex t end at least 500 m m beyond t he building and m ay be left open
ended.

8.2.2 The route for buried pipework shall be chosen so as to avoid:

areas already congested with underground plant
close proximity to unstable structures or walls which retain materials above

the level of the ground in which the pipe is to be laid
areas over which heavy site traffic will pass, especially where a properly

constructed carriageway does not exist
areas where there may have been recent infill. Where this is not possible,

welded steel pipe or PE pipe should be used

ground liable to subsidence or side-slip

areas of known or suspected aggressive soil conditions

proximity to any structure known to have unventilated voids
close proximity to high voltage cables.
8.2.3 Buried pipework shall be sited at least the minimum distances from buildings as
shown in Table 11 until attaining the direction to enter the respective building.
Not e 1: For larger diam et er PE pipes ( for exam ple great er t han 315 m m ) a risk assessm ent will be
needed t o ensure great er dist ance is not requir ed. Furt her infor m at ion can be found in
I GE/ TD/ 4 Table 13.
Not e 2: For LPG, for st ruct ures support ed above ground level, for exam ple caravans, it m ay be
perm issible, subj ect t o a risk assessm ent , t o reduce t he pr escr ibed dist ances.
MATERIAL MINIMUM PROXIMITY (m)
MOP ≤ 0.5 bar MOP > 0.5 bar

Steel 0.25 m 1m
PE 0.25 m 1m
Copper* 0.25 m* N/A
*limited to 75 mbar.
TABLE 11 - MINIMUM PROXIMITY OF BURIED PIPE PARALLEL TO

BUILDINGS
8.2.4 Consideration should be given to installing an insulating fitting when the route of
the gas pipe is in close proximity to electrical cabling.
8.2.5 If gas pipework needs to be isolated from other buried systems, the isolation
plate should be placed half way between the two systems and the insulation
50
plate should be wider than the largest pipe/cable by at least 2 m and placed
centrally. The material should be a minimum of 10 mm thick and be a non-
absorbent plastic.
8.2.6 Provision should be made for movement and expansion, particularly inside
buildings.
8.3 DEPTH AND POSITION IN THE GROUND
8.3.1 Pipework shall be laid at the minimum depth as given in Table 12a and 12b.
Not e: I t is accept able t o reduce t he dept hs provided addit ional prot ect ion, for exam ple concret e
slabs, st eel plat es, reinforced backfill et c. gives an equivalent level of prot ect ion t o t hat
achieved by t he dept hs given.
LOCATION OF PIPE UNDER MINIMUM DEPTH OF COVER (m)

MOP ≤ 75 mbar
and  ≤ 63 mm  > 63 mm
MOP > 75 mbar or
Carriageways 0.45 0.75

Path footways 0.6 0.6
Verges 0.6 0.75
Other fields and agricultural land 1.1 1.1
Other private ground 0.6 0.6
TABLE 12a - MINIMUM DEPTH OF COVER FOR NATURAL GAS PIPEWORK
LOCATION OF PIPE UNDER MINIMUM DEPTH OF COVER (m)

GAS AND LIQUID SERVICE
PIPEWORK PIPEWORK
Carriageways 0.75 0.6

Path footways 0.75 0.6
Verges 0.75 0.6
Other fields and agricultural land 0.75 0.6
Other private ground 0.6 0.375
TABLE 12b - MINIMUM DEPTH OF COVER FOR LPG PIPEWORK
8.3.2 Pipework shall be installed at sufficient clearance from any other service to be
considered safe in operation (see also Sub-Section 7.9). Figure 9 and Table 13
provides a guide for external buried pipework.
Pipework should be installed at clearances sufficient to allow subsequent

maintenance of any of the buried plant and at common depths below ground
level to assist detection of the service.
51
Not e 1: I t is preferable t hat , subj ect t o any local agr eem ent and t he pract icalit ies of finding a rout e
for pipework under foot way s, roadways et c., owners of services such as gas pipew ork,
elect r icit y cables et c. agree appropriat e volunt ary codes for t he posit ioning of plant below
ground. This m ay not alway s be achievable for exist ing indust r ial and com m ercial prem ises.
Not e 2: This is a t ypical arrangem ent .
Not e 3: The arrangem ent m ay be suit able for, say, a 90 m m nom inal diam et er PE pipe in a 2 m
wide pavem ent .
FIGURE 9 - TYPICAL SECTION OF PIPE IN FOOTWAYS
8.3.3 Where the gas pipe crosses non-gas tight systems (such as sewers) refer to
Table 13.
Not e: I f an adequat e spacing cannot be obt ained, a prot ect ive sleeve m ay be em ployed or t he
pipe carried in a pipe br idge.
8.3.4 The distance between a PE gas pipe and hot pipework shall be sufficient to
ensure that the surface of the gas pipe cannot exceed 20°C.
52
CROSSING OR RUNNING PREFERRED MINIMUM DISTANCE

IN PARALLEL WITH CROSSING (m)
CONFIGURATION
Low-voltage electric cables No preference 0.25
Sewers, pipework or tanks Gas pipe above Crossing: 0.25

containing corrosive Parallel: 1.5
materials PE pipe may be 0.3
where solvents
are not present
Metal pipes Gas pipe above Crossing: 0.25

Parallel: 0.5
Plastic pipes (other than Gas pipe above Crossing: 0.25

sewers or pipes Parallel: 0.3
carrying corrosive materials)
Ditches and other open No preference Crossing: 0.25
systems Parallel: 0.5
Underwater crossing:
minimum cover 0.6
Other buried structures No preference 0.5

except buildings
High-voltage power No preference Crossing 0.5
transmission cables Parallel 0.5
(Consideration should
be given to induced
currents for
buried and overhead
power cables)
Insulated high temperature Gas pipe above Gas pipe above

steam/water pipes Crossing 0.3
Parallel 0.3
Table 18 from BS EN 15001 published by kind permission of BSI.
TABLE 13 - RECOMMENDED MINIMUM DISTANCES BETWEEN BURIED

GAS PIPEWORK AND OTHER SYSTEMS
8.3.5 The depth of buried pipework and any known clearances from other plant shall
be recorded for future reference.
8.4 PROTECTION OF BURIED PIPEWORK
8.4.1 General

Pipework shall be buried in such a manner that:

mechanical damage to the pipe, fittings or wrappings is unlikely
it is guarded against physical damage, for example from rocks, sharp

materials and the effects of traffic loading
it is protected against chemical action caused by, for example, corrosive soils
and high tension power cables.
53
8.4.2 Corrosion
8.4.2.1 Pipework which is otherwise liable to corrode shall be protected appropriately.
8.4.2.2 Pipe wrapping and shrinkable materials shall be in accordance with

BS EN 12068.
8.4.2.3 Where a tape wrapping is employed, the manufactures instructions shall be

complied with and a minimum overlap of 55% shall be provided.
Not e: Appropriat e m et hods include t he applicat ion of self - adhesive plast ic t apes, pet roleum
im pr egnat ed woven clot h t apes, et c. The lat t er m ay need t o be over wrapped wit h a
wat erproof cov ering of PVC t ape.
8.4.2.4 Other coatings are available, epoxy and polyurethane-based coating shall
comply with BS EN 10289 and BS EN 10290 as appropriate.
8.2.4.5 Where steel pipework is laid in a corrosive soil, the excavation shall be backfilled
around the pipework with a passive material, for example dry washed sand or
crushed limestone. In addition, such pipework shall be protected by tape
wrapping or loose polyethylene sleeving.
8.4.2.6 For carbon steel pipework, the use of CP should be considered, information
being provided in IGEM/TD/1 and BS 7361. Reference should also be made to
BS EN 12954.
Operators of other buried metallic structures may need to be consulted, before

CP is applied.

8.4.2.7 Stainless steel pipes and fittings may only be used buried if:
the pipes and fittings are provided with an external PE coating and wrapping

or shrinkable material in accordance with BS EN 12068
the soil conditions are such that cathodic protection is not required and no
such system has been installed.
8.4.2.8 The use of buried copper pipework systems is not recommended. If Copper
pipework is used the pipework and fittings shall be protected against corrosion
and mechanical damage by the application of a suitable coating.
8.4.2.9 Pipe fittings and components should be pre-coated by the manufacturer with
suitable materials. Where this is not possible, a wrapping material such as one
of those detailed in BS EN 12068 shall be applied.
Special attention shall be given, for example, to items such as valve spindles,
greasing lines and vent/pressure pipes where an adhesive insulating coating can
be applied. The use of a protective sleeve over the valve spindle shall be
considered.
8.4.2.10 PE pipework shall not be laid in chemically corrosive soil, such as those
containing tars, oil, plating, dry cleaning fluids, etc., nor should it be exposed to
extremes of temperature, for example, its proximity to steam pipework.
8.4.2.11 Where the contained gas is wet or otherwise corrosive, the pipe material shall
be resistant to internal corrosion unless other precautions are taken to ensure
safety.
54
8.5 COVER
8.5.1 Prior to trench backfill, any coating and or wrapping should be completed.
Finefill surround to the buried pipework shall then be applied. Care shall be
taken not to damage any coating or wrapping during this stage.
Not e 1: A suit able m et hod involves t he riddling of suit able subsoil t hrough an 18 m m m esh r iddle,
over t he ex cavat ion and t he soil being packed fir m ly ar ound t he pipework t o 100 m m of
cover.
Not e 2: Buried pipework wit hin buildings m ay require differ ent procedur es from ext er nal buried
pipework. I n part icular, allow ance m ay be needed for m ovem ent and expansion.
Not e 3: Buried pipework wit hin buildings needs t o be bur ied at a m inim um of 40 m m below t he
surface of t he floor and up t o 50 m m deep dependent upon t he design requirem ent s for
point loading.
8.5.2 No structures, such as slabs and beams, shall be laid under the pipe without
taking suitable precautions to prevent damage. These precautions can include
the use of plastic pads, special coatings of polyethylene or reinforced coatings.
8.5.3 After application of the pipe finefill surround material, the trench should be
backfilled with selected material. This backfill material should, typically, be of a
“cohesive granular” or “grade granular” composition that will minimise any
potential for settlement and achieve load bearing properties when compacted.
Excavated material may be suitable. Backfill and compaction should be in layers
not exceeding 150 mm depth.
8.5.4 On completion of trench “backfill”, where appropriate, footway or carriageway

base courses and wearing courses or other finishing materials should be applied.
Not e: Det ails of such road st ruct ur es, t heir specificat ion dept h and com pact ion procedur es can be
det er m ined by reference t o t he HAUC Specificat ion for t he Reinst at em ent of Openings in
Highways.
8.5.5 In any situation where subsequent detection of the buried pipework may prove
difficult, for example when using PE pipe or when other services are in close
proximity to the pipework, a marker tape (incorporating a tracer wire for PE
pipe) should be placed directly above the pipework as shown in Figure 10 which
shows a typical reinstatement arrangement.
R unning surface
W earing course
B asecourse
R oadbase
S ub - base
B ackfill
M arker tape
S urround to
apparatus apparatus
( finefill )
FIGURE 10 - TYPICAL BURIED PIPEWORK UNDER A ROADWAY
55
8.6 IDENTIFICATION OF BURIED PIPEWORK COMPONENTS
A marker plate shall be installed above ground to identify the position of any
siphon, valve or purge point, typically as shown in Figure 11.
V3
Minim um dim ensions 150 m m x 150 m m overall.
V
denot es valve ( S would denot e siphon, PP a purge point )
3
denot es dist ance of m arker plat e from V, S, or PP ( m ) .
FIGURE 11 - MARKER PLATE FOR SYPHONS, VALVES AND PURGE

POINTS
56
SECTION 9 : ENTRY INTO AND EXIT FROM BUILDINGS
9.1 SLEEVING AND SEALING
Attention shall be paid to Sub-Sections 7.5 and 7.7.
9.2 MATERIALS
It is preferable to use above ground entries. If PE is to be used for above ground

entries, that part of the pipe entering the building must be placed inside a
metallic or GRP sheath. The sheath must be constructed and installed so as to
prevent escape of gas into the building if a leak should occur. Transition to
metallic pipe shall take place within 1 m of entering any building.
9.3 TYPES OF ENTRY AND EXIT
9.3.1 Above ground entry
9.3.1.1 An entry or exit made above floor level shall be in accordance with the principles
shown in Figure 12 (see examples in Figure 13).
Building entry fitting

may include an integral
valve.
AECV
Insulation Joint may be
required when the
incoming pipe/sleeve is
metallic and in contact SEAL
SUPPORT (FOR HIGH RISE)
with the ground. SUPPORT (FOR HIGH RISE)
FIGURE 12 - TYPICAL ABOVE-FLOOR LEVEL ENTRY – STEEL & PE

PIPEWORK
57
PE TO STEEL FACTORY ENTRY FITTING PE TO STEEL FACTORY ENTRY FITTING

WITHOUT INTEGRAL VALVE WITH INTEGRAL VALVE
FIGURE 13 - TYPICAL ABOVE GROUND PE TO STEEL BUILDING ENTRY

FITTING
9.3.2 Below ground entry
Pipework shall enter or leave a building through a continuous gas-tight sleeve,

as shown in Figure 14. The horizontal sleeve shall terminate in a square recess,
having a minimum dimension of 300 mm, in the floor of the building. Where the
pipe diameter exceeds 100 mm, the dimension of the square recess shall be at
least three times the diameter of the pipe being installed. The riser and bend
shall be jointed to the incoming or outgoing pipework and wrapped.
The insulation joint shall be

to a suitable standard
incorporating fire resistance
such as DIN 3389.
AECV
SEAL
SEAL
FIGURE 14 - TYPICAL BELOW-FLOOR LEVEL ENTRY - STEEL PIPEWORK
9.3.3 PE entries shall be made using the principles shown in Figures 14 and 15. The
requirements of Sub-Section 9.2 shall be applied.
58
FIGURE 15 - TYPICAL PRE-FABRICATED BELOW-GROUND ENTRY. PE

PIPE IN A STEEL SLEEVE
9.4 ENTRY INTO HIGH RISE BUILDINGS
Any entry into high rise building shall be constructed according to IGEM/G/5.
The principles shown in Figures 12, 14 & 15 will apply.
9.5 DELICATE WALL CONSTRUCTIONS
Where a pipe entry or exit is to be made through a delicate wall construction, a

suitable support, for example a duct foot support, should be fitted at the inside
face of the decorative cladding.
9.6 INSULATING FITTINGS
9.6.1 Consideration should be given to installing an insulating fitting when the route of
the gas pipe is in close proximity to electrical cabling.
9.6.2 All metal pipe, whether gas carrying or containing a PE liner, capable of
providing electrical continuity between earth and the above ground pipework
shall include an insulating fitting.
Not e 1: Eart h in t his cont ex t includes t he ground and cont iguous m asonry such as t he building wall
or paving.
Not e 2: An insulat ing fit t ing is not r equir ed w here an alt ernat iv e, r eliable m eans of pr event ing
elect r ical cont inuit y bet w een t he m et al pipe and eart h has been provided, for exam ple a
sleeved above ground ent ry connect ed t o a PE net work pipe.
9.6.3 Insulation fittings shall be installed upstream of any AECV. The uninsulated
section of exposed pipe shall be as short as possible.
Not e 1: I nsulat ing fit t ings com plying wit h DI N 3398- 1 are suit able for use inside buildings, fit t ings
com plying wit h GI S/ E17- 2: 2006 are not suit able for use inside buildings.
Not e 2: I n all circum st ances, par t icularly when t he insulat ing fit t ing is inst alled out side a building, it
m ust be prot ect ed from t he accum ulat ion of debris and m oist ure which m ay com pr ise it s
insulat ing propert ies.
9.6.4 All exposed pipe between the ground and the insulating fitting (including, where
necessary, the metal body of the fitting itself) shall be encapsulated in an
approved insulating sleeve or otherwise protected to prevent physical contact
with the surface of the pipe. The wrapping or other protection shall be marked
“Electric shock hazard, do not remove this sleeve/guard”.
59
9.7 THERMAL EXPANSION
9.7.1 Gas pipework which is subject to temperature variations that could lead to
excessive stress shall incorporate means such as bellows or other expansion
joints to remove those stresses. This is not normally needed where the
temperature variation is less than 60 K.
9.7.2 Bellows shall be in accordance with ISO 15348; metallic hose assemblies shall
comply with BS EN ISO 10380 (flexibility type 1 or 2).
9.7.3 Pliable hose assemblies designed as meter connections that conform to BS EN

ISO 10380 (flexibility type 3) or PRS/3 shall not be used.
9.7.4 In the UK it is usual to design external pipework systems longer than 3 m with a
temperature variation of 80 K. Thermal expansion of an external riser may be
accommodated by the use of unrestrained laterals (see Figure 16).
FIGURE 16 – USING UNRESTRAINED LATERALS TO ACCOMMODATE

THERMAL EXPANSION & CONTRACTION – EXTERNAL
PIPEWORK
60
SECTION 10 : PIPEWORK IN DUCTS, AND OTHER SPACES IN

BUILDINGS
This section deals with pipework in building service ducts, enclosures such as false ceilings,
suspended floors and other voids through which pipework may be routed.
10.1 GENERAL
10.1.1 The general principles outlined in Section 7 shall be applied.
10.1.2 Where a manual or automatic valve is to be located in a duct or ceiling void,

access panels and space for operation and maintenance shall be provided and
the position of the valve shall be shown on any line diagram (see Section 4) and
should be indicated on the access panel.
10.1.3 Where pipework is located above a false or suspended ceiling or below a

suspended floor, the space above the ceiling or below the floor shall be treated
as a duct. When assessing ventilation requirements, the notional duct size may
be taken as being not less than 300 mm larger than the pipe diameters.
10.1.4 Ducts (above ground level) and small spaces/enclosures may not require
additional ventilation provided they have an internal volume not less than 10 m3
and adventitious ventilation above 0.5 air change per hour. For internal volumes
not exceeding 10 m3, additional ventilation shall be provided.
10.1.5 Horizontal ceiling-level ducts and spaces containing gas pipework with an OP not
exceeding 100 mbar shall be ventilated, preferably externally, with grilles of not
less than 100 cm2 total free area. Where this is not practicable, grilles
ventilating into the habitable space, each of not less than 100 cm2 free area
shall be installed near to each joint location and either at each end of the duct
or on each of the perimeter walls if it is a ceiling space.
10.1.6 Where pipework with an OP not exceeding 100 mbar is located in below ground
spaces such as basements or rooms that are visited less than monthly,
ventilation shall be such as to ensure the air change rate is above 0.5 air
changes per hour. Where this is not practicable, consideration shall be given to
the provision of artificial ventilation with flow interlocks and automatic shut-off
valves (AIVs), or the provision of gas detection alarm systems, or monthly
checks of the environment for lack of gas leakage with a combustible gas tester.
Where the OP exceeds 100 mbar, apply other options or see IGEM/SR/25
Edition 2.
10.1.7 Any void within a cavity in a partition wall shall not be considered or used as a
duct, unless designed specifically and purpose-built as a ventilated duct.
10.1.8 Any duct shall be checked for the presence of combustible gas before and after
carrying out any work within it, for example by using a portable gas detector.
10.2 DESIGN CONSIDERATIONS FOR SERVICE DUCTS AND OTHER SPACES

CONTAINING OTHER SERVICES
10.2.1 Pipework shall not be installed in any duct that does not comply with the
structural requirements of the Building Regulations.
In particular, the requirements for fire separation are important and the gas
installation and duct ventilation system must not jeopardise compliance with
such requirements.
Not e 1: A building serv ice duct m ay need addit ional vent ilat ion for purposes ot her t han gas safet y,
for exam ple t o m inim ise condensat ion or for respirat ion when per sons need t o work inside
t he duct ( BS 8313 provides guidance on vent ilat ion for ot her purposes) .
61
Not e 2: The Confined Space Regulat ions and ACoP HSL101 provides guidance on design t o m inim ise
risks t o persons working in t hese spaces and CDM provides guidance on m inim um access
sizes.
Not e 3: Large com bined service walkways or subways cont aining low pressure NG pipes which are
regular ly visit ed by com pet ent per sons need not be t r eat ed in t he sam e m anner as duct s
wit h regard t o t he sizing of v ent ilat ion openings, provided it can be assur ed t hat t here is at
least 0.5 air changes per hour .
10.2.2 Structural requirements for those ducts which must be constructed to restrict
the spread of fire are beyond the scope of this Standard. Reference shall be
made to the Building Regulations and to the more comprehensive design
guidance in BS 8313 and BS 5588.
Not e: Advice includes considerat ions for access openings, fir e rat ing of enclosures for different
circum st ances and different cat egories of building, fir e st opping and t he sealing of openings
where pipes penet rat e t hrough enclosures.
10.2.3 All matters concerning the application of fire safety requirements of Building
Regulations should be discussed with the appropriate local authority building
control officer or fire officer.
10.2.4 Pipework may run in the same duct as most other services, including hot and
cold water services, heating pipes, electrical conduits and cables and pipes
containing other fuels. However, there are some restrictions and, where gas
pipework is to be routed in combination with other services, reference shall be
made to BS 8313 and UKLPG CoP 22 in which detailed guidance is given on
spacing, provision for maintenance and restrictions on combinations of services
etc.
10.2.5 Services containing oxidising or corrosive fluids shall not be installed in the
same duct as installation pipework.
10.2.6 Where it is intended to install installation pipework in the same duct as

ventilation distribution ducts or vacuum pipes that operate at sub-atmospheric

pressure:
the installation pipework shall be continuous with no joints or shall be of all
welded construction or
10.2.7 Pipework shall not be routed within or through air-handling ductwork that is
used to distribute air around buildings.
In addition, pipework shall not be routed in or through a ceiling void used as a

plenum for an air distribution system, unless the pipework is enclosed in a fire
resistant and gas-tight sleeve. The sleeve shall be through ventilated to a safe
place.
Not e 1: This does not apply t o indiv idual plenum s wit hin a ceiling space of a room .
Not e 2: I t is accept able t o inst all gas pipework t o run in or t hrough a ceiling void used as a plenum
for a single room or space w it hin a building, i.e. w her e t he air is not dist ribut ed around t he
building.
Not e 3: Com m on fanned ext ract s fr om ceiling voids cont aining gas pipes, where t he ext ract is
direct ly t o t he out side, are not const rued as “ dist ribut ing air” . However , t he fan would need
t o be int er locked t o an aut om at ic gas isolat ion valve t o prevent any pot ent ial gas leakage
being circulat ed t o ot her room s when t he fan is not running. Where appliances w it hout
flam e prot ect ion are inst alled downst r eam of an AI V, a pressure proving st art up syst em
m ay be requir ed ( see I GE/ UP/ 12) .

10.2.8 For service ducts accessible by personnel:
ventilation shall be provided such that a continuous flow of air exists

throughout the space
where mechanical fans are employed, on loss of proven fanned air supply
the gas supply shall be isolated automatically
62
Not e: A delay per iod of approxim at ely 5 m inut es m ay be perm it t ed t o allow st andby syst em s

t o com e int o operat ion .
to prevent nuisance shut down of the automatic gas valve on short duration
power trips, consideration shall be given to the application of local power
back-up or other system that delays closure for a short period, for example

up to 3 seconds
Access requirements are provided by BS 8313.
Not e 4: Below - ground service duct s m ay require nat ural draught vent ilat ion st acks t o creat e an air
flow. A difference in height bet ween t he t w o st acks of at least 3 m should be adequat e for
m ost low - pressure inst allat ions. I n ot her cases, see I GEM/ SR/ 25 Edit ion 2.
Not e 5: Long, below- ground com bined service walkways or subways where nat ural vent ilat ion is
im pract icable, for exam ple on a hospit al sit e, m ay be vent ilat ed by m echanical air fans but
a risk assessm ent has t o be undert aken t o consider t he effect s of fan failure and any
dist ribut ion of a pot ent ial gas leak.
10.3 VENTILATION OF DUCTS ETC.
10.3.1 Any duct containing pipework must be ventilated in order to comply with
GS(I&U)R.
Not e: Service duct s are covered in Sub- Sect ion 10.2
10.3.2 A duct or ceiling void containing gas pipework shall be ventilated to ensure that
a minor gas escape does not cause the atmosphere within the duct or void to
become unsafe (see Figures 17 and 18).
Not e 1: The level of v ent ilat ion is not int ended t o clear a m aj or gas escape ar ising from dam age or
failur e of pipework.
FIGURE 17 – GAS PIPE RUNNING THROUGH A CEILING VOID WITH

JOINTS, SHOWING LOCATION OF VENTS
63
FIGURE 18 – SUGGESTED IN-FLOOR DUCT VENTILATION SYSTEM
10.3.3 Any duct ventilation system should be designed on the principle of requiring
natural ventilation only.
10.3.4 Any ventilation opening shall lead to a safe place, preferably to outside air.
Not e: A duct , or an isolat ed sect ion of duct cont ained solely wit hin a room or space, m ay be
vent ilat ed wit hin t hat room , provided t he room is v ent ilat ed t o norm al occupat ional
st andards and t hat t he duct does not cont ain ot her services which requir e a fir e separat ion
barrier t o be m aint ained ( refer t o t he Building Regulat ions) .
10.3.5 Where a false ceiling has been constructed to form a fire separation barrier
between the ceiling space and the room below, ventilation openings shall not
bridge the separation barrier and vent into the room unless those openings are
protected by automatic closing fire dampers.
Not e: Where t he false ceiling is not a fire separat ion barrier , and where v ent ilat ion direct t o
out side air is not pract ical, vent ilat ion m ay be provided t o t he r oom below ( see
clause 10.1.3) . For a com m on false ceiling, for exam ple for several part it ioned room s, any
int ernal vent ilat ion has t o prevent any gas leakage being dist ribut ed.
10.3.6 Any ventilation opening shall be located such that air movement can occur
within the duct, that is, at the top and bottom of vertical ducts or at each end of
horizontal ducts. In addition, openings shall be provided at intervals along the
length of long horizontal ducts typically at not less than 15 m intervals. High
ceiling voids shall be ventilated at high points to prevent the collection of
flammable gases unless the pipe is all welded/brazed, but reference also should
be made to clause 10.3.4.
If a 3rd family gas is to be used, its heavier-than-air nature shall be taken into
account for tall spaces below floors.
10.3.7 Gas detectors shall not be used as an alternative to correct ventilation of ducts.
However, a risk assessment may indicate their use as an additional protection
(see Appendix 11).
10.3.8 The rate of ventilation for gas safety shall be adequate to dilute a minor gas
escape to below 10% of lower flammable limit (LFL) (see clause 10.3.1). To
ventilate ducts the vent opening shall be at least those sizes in accordance with
Table 14 and as taken from BS 8313.
Not e: For pipework not ex ceeding 35 m m diam et er , in dom est ic- t ype prem ises, m or e det ailed
vent ilat ion requirem ent s for t he sm aller sizes of duct s are given in BS 6891.
64
CROSS SECTIONAL MINIMUM FREE AREA

AREA OF DUCT (m2) OF EACH OPENING (m2)
not exceeding 0.05 Cross sectional area of
duct
0.05 and not 0.05
exceeding 7.5
exceeding 7.5 1/150th of the cross
sectional area of duct
TABLE 14 - FREE AREA OF VENTILATION OPENINGS
In the exceptional case for lighter than air gases when the full requirements for
low level ventilation in vertical ducts cannot be provided, the risk assessment
shall consider the measures for mitigating the occurrence of a gas escape such
as all welded construction, regular maintenance and regular verification that
leaks do not exist. Gas detection may also be considered.
10.4 UNVENTILATED DUCTS AND VOIDS
Pipework shall not be installed in an unventilated duct or void. However, if

creating a ventilated enclosure or filling the void:
the pipework shall be sleeved continuously through the unventilated duct or

void, with the sleeve ventilated at one or both ends into a safe place, or
the unventilated duct or void shall be filled with a crushed inert infill to
reduce to a minimum the volume of any gas which may accumulate. The
infill material should be of a dry, chemically neutral and fire resistant nature,
for example crushed slate chippings or dry washed sand.
65
SECTION 11 : PIPEWORK IN MULTI-STOREY AND MULTIPLE-

DWELLING BUILDINGS
11.1 GENERAL
11.1.1 For pipework in blocks of flats and other multiple-dwelling buildings, any
additional requirements of IGE/G/5 shall be applied.
Not e: A dwelling is int ended t o signify dom est ic- t y pe occupancy.
Where a multi storey building does not contain multiple-dwellings, it is

recommended that the principles of IGE/G/5 are applied. However, it is
recognised that certain circumstances of a commercial or industrial building, for
example where there are established maintenance regimes, may mean that
some requirements of IGE/G/5 may be relaxed. In any event, the following
requirements shall be applied.
11.1.2 The general principles outlined in Section 7 shall be applied.
11.1.3 It shall not be possible for gas that has escaped from the riser to accumulate
within the building and ventilation shall be provided in all areas where escaping
gas could accumulate.
Not e: Reference m ay be m ade t o I GE/ G/ 5, if applicable. Due t o densit y, a NG escape will
accum ulat e at high level, w hereas a LPG escape will accum ulat e at low level.
11.1.4 Any pipework passing through a floor shall be sleeved (see Section 10) and be
by the most direct route practicable.
11.1.5 There shall be a minimum distance of 500 mm between any external riser and
any lightning conductor.
11.1.6 Where a flexible connection for a riser or lateral is enclosed in a duct, the whole
section of flexible shall be contained in the duct.
11.1.7 Pipework shall be fire-stopped as it passes from one floor to another, unless it is
in a ventilated protected shaft which is ventilated at top and bottom directly to
outside air. When pipework from a continuous duct enters an individual floor, it
shall be fire-stopped at the point of entry.
11.1.8 Where a building is of timber or light steel frame construction, reference shall be
made to IGE/UP/7.
Not e: Appendix 4 of I GE/ G/ 5 provides guidance specifically for m ult iple- dwelling buildings.
11.2 BUILDINGS CONTAINING DOMESTIC TYPE PREMISES
Where a building containing a domestic type premises is leased by a landlord to

a tenant, the landlord must ensure that:
any gas installation is maintained in a safe condition
Not e: Furt her guidance is cont ained in HSL56, specifically t he guidance t o Regulat ion 36.
11.3 SUPPORT
11.3.1 Any riser shall be supported in accordance with Sub-Sections 12.6 and 12.7
11.3.2 Risers shall be supported along their length, at the base and at intermediate
levels, unless permitted to be suspended from the top alone as outlined in Sub-
Section 12.6 and such supports shall be fire resistant.
66
11.4 MATERIALS AND JOINTING
11.4.1 Jointing of any riser shall be in accordance with Section 6 and Table 5.
11.4.2 For any riser exceeding 20 m high or exceeding 50 mm diameter, pipework shall
be of welded steel construction or CSST of continuous length without a joint.
11.4.3 In addition to the jointing procedures of Section 6, joints shall be tested as

follows:
where pipework is in a potentially inaccessible position (which would be only
acceptable when routine maintenance would not be necessary), for example
in a ventilated and closed duct, 100% of the welds shall be subjected to

NDT/NDE
for any riser exceeding 20 m high, consideration shall be given to carrying
out NDT/NDE on at least 10% of the welds.
11.5 LATERALS
11.5.1 Any lateral shall be protected against damage by thermal or structural

movement of the riser, for example by fitting a metallic flexible connection at an
intermediate position (see Section 13).
11.5.2 Where a riser serves more than one lateral, a means of isolation shall be fitted
at the start of each lateral. This should be outside any premises fed by the riser
(see Sub-Sections 9.6 and 9.7).
67
SECTION 12 : PIPEWORK SUPPORT
12.1 Pipework shall be adequately supported, using materials of sufficient strength,

quality, fire resistance and size to ensure safety.
Not e: I n som e inst ances, shor t vert ical lengt hs in ot herw ise horizont al pipe r uns m ay be j udged
t o be self support ing. Horizont al runs of som e m at er ials m aybe secured by plast ic clips.
12.2 Support spacing should not exceed the distances shown in Table 15.
NB FOR MAXIMUM UNSUPPORTED LENGTH (m)

CARBON
STEEL AND Screwed Screwed Welded Welded External* Copper/
CCST (OD FOR steel steel steel steel PE corrugated
PE AND horizontal vertical horizontal vertical vertical stainless
COPPER) steel
(mm)
15 (15) 2.0 2.5 2.5 3.1 2.0 1.2
20 (22) 2.5 3.1 2.5 3.1 2.0 1.8
25 (28) 2.5 3.1 3.0 3.7 2.0 1.8
32 (35) 2.7 3.3 3.0 3.7 2.0 2.5
40 (42) 3.0 3.7 3.5 4.3 2.0 2.5
50 3.0 3.7 4.0 5.0 2.0 2.5
65 4.5 5.6 2.0 2.5
80 5.5 6.8 2.0 2.5
100 6.0 7.5 2.0 2.5
150 7.0 8.7 2.0
200 8.5 10.6 2.0
250 9.0 11.2 2.0
*Not e: Use t his dim ension or as given in t he m anufact ur er’s inst ruct ions for propriet ary syst em s.
TABLE 15 - SUPPORTING ABOVE-GROUND PIPE
12.3 Pipework should be routed along those parts of buildings and structures where
supports can be attached without imposing unacceptable stresses.
Not e: Support spacing m ay need t o be reduced in order t o spread t he load on st r uct ures which
relat ively are weak.
12.4 Where necessary, additional supports shall be installed near to components such
as flanged joints, union fittings, boosters, meters, branch off takes and valves
or where additional loadings are anticipated.
12.5 Additional supports shall be installed on plant pipework incorporating

compression fittings, especially near to changes of direction, to ensure the
pipework is secure and in order to minimise the risk of catastrophic failure of a
fitting.
12.6 If required, special support should be provided for flexible and semi-rigid
connections (see Section 13).
12.7 For a long pipework run and any riser, support shall be provided throughout the
length of the pipework and shall not cause damage to any corrosion protection
on the pipework.
Not e 1: For a r iser , axial suppor t m ay be provided by one or a com binat ion of t he following

m et hods, as appropriat e:

from t he base by, for exam ple, a duck foot bend or sim ilar
at various point s along t he riser.

Not e 2: A riser m ay be suspended from t he t op alone, if all t he following cr it eria are m et :

t he pipewor k is of welded st eel const ruct ion and

t he building is capable of support ing t he t ot al weight of t he riser and

t he pipewor k and it s j oint s are st rong enough t o support t he weight of t he riser and

t her e are no ot her com ponent s, apart from flanges, in t he riser and
t he r iser is r est rained adequat ely t o lim it hor izont al m ovem ent .
68
12.8 The provision of pipework support shall not be such as to prevent thermal
movement.
Anchor points and expansion devices shall be considered where expansion is

likely to be excessive.
12.9 The method of restraining pipes within their supports shall not encourage
corrosion or lead to failure of any pipework corrosion protection, pipes or
supports.
Not e: This can r equire t he addit ion of a flex ible layer of non- absorbent m at erial bet w een t he
support and t he surface of t he pipe or of it s corrosion prot ect ion.
12.10 Where supports and anchor points are welded to pipework the following shall

apply:

the material shall be suitable for welding to the pipework;
the stresses occurring shall be investigated and found to be within

acceptable limits

tubular supports shall have an open connection to atmosphere
welds shall be inspected and meet quality requirements at least equal to
those for branches/fillet welds in accordance with Table 7.
69
SECTION 13 : FLEXIBLE CONNECTIONS
This section does not apply to pliable stainless steel pipework (CSST).
Types of flexible connections and their applications are described in Appendix 12.
13.1 GENERAL
13.1.1 The use of a flexible connection shall be considered in situations where it is

known, or anticipated, that pipework will be subject to vibration, movement,
expansion or strain.
Not e: Addit ional, specialist , advice m ay be needed on t he select ion and applicat ion of m at er ial.
This is especially im port ant wit h biogases cont aining corrosive const it uent s.
In other situations, flexible connections shall not be used where there is a

practical alternative.
13.1.2 For buried pipework, when a flexible connection is to be used, it shall be either a
semi-rigid coupling or flange adaptor.
13.1.3 For a semi-rigid coupling or flange adaptor where pipework is not supported
firmly or is expected to be subject to movement, the angular deflection shall be
restricted to 3o and 1.5o respectively.
13.1.4 A semi-rigid coupling shall not be used as an expansion joint unless all the pipes
concerned are joined by couplings.
13.1.5 Flexible connections other than semi-rigid couplings shall not be used for PE
pipe. Mechanical compression joints (semi-rigid couplings) where applied to PE
pipe shall be of a type suitable for the pipe diameter and grade and the
contained gas and conform to GIS/PL3.
13.2 PRESSURE LOSS ACROSS HOSES
When using flexible connections which consist of metal corrugated hose

assemblies or bellows expansion joints, the manufacturers of the flexible
connections shall be consulted to check that the hose or bellows will supply the
correct volume of gas at an acceptable pressure drop for the application.
Not e: These pr essur e drops will also need t o be included in any pipework calculat ions ( see Sub-
Sect ion 4.2) .
13.3 CONDITIONS OF USE
13.3.1 General

13.3.1.1 Where a flexible connection is used, fittings shall:

be of a minimum length practicable
be protected against mechanical damage and the effects of the local

environment

not pass through a wall or similar rigid structure
be located in an accessible position and not be buried except that a semi-

rigid coupling may be installed in buried pipework (see clause 13.3.2)
be inspected and, where necessary, replaced at a frequency not less than

that specified by the manufacturer
have bonding straps fitted across any coupling or tube that does not provide

continuity otherwise, if electrical continuity of the pipework is required
be suitable for the operating pressure over the full ambient and operating
temperature ranges of the application.
70
13.3.1.2 If any doubt exists regarding the suitability of a flexible connection for a given
application, the manufacturer shall be consulted.
13.3.2 Semi-rigid coupling and flange adaptor
The following conditions apply when using semi-rigid couplings and flange

adaptors:
mechanically jointed couplings and flange adaptors shall not be used within

buildings unless they form part of the primary meter installation
couplings and adaptors shall be resistant to tension or, alternatively, be
fitted with the same form of restraint to prevent separation of the pipes, for
example by the use of the tie rods or chains
Not e: This is not necessary for a single coupling inser t ed in fir m ly support ed pipework having

rigid t ypes of j oint ing or when t he coupling is designed t o be end- load r esist ant .
above-ground couplings and adaptors shall be supported by anchoring
individual pipes or, alternatively, by welding brackets to the centre sleeves

of couplings
where a flange adaptor is used, usually it is impracticable to fit restraining
tie rods and, therefore, the pipework shall be jointed rigidly and supported

firmly either side of the adaptor
where a tie rod is attached to prevent pipe separation, it should be noted
that the tie rod restricts the angular deflection in the plane of the ties.
Where electrical continuity of the pipework is required, for example for CP or a

PME electrical insulation, separate bonding straps shall be fitted across the
couplings and flange adaptors in accordance with the manufacturer's
recommendations, unless the fittings incorporate integral continuity devices, for
example pinned elastomeric 'O' rings.
When installed below ground, in order to provide for structural movement, the
flexible section shall be able to move and, hence, special consideration should
be given to the backfill.
13.3.3 Bellows
13.3.3.1 Where a bellows-type flexible tube is used as a thermal expansion joint (in order
to prevent mechanical loading) the joint shall be fitted with restraining and
alignment ties.
13.3.3.2 Pipework either side of a bellows joint shall be supported separately, such that
the bellows itself does not support any of the weight of the attached pipework.
13.3.4 Swivel joint

The following conditions apply when using a swivel joint:

it shall only be installed in exposed pipework
where applicable, the main body of the joint should be connected to the

fixed pipework and the moving pipework should be connected to the rotor
the axis of rotation of the swivel shall be aligned accurately on both sides of

the joint
the joint should have lateral freedom and should be free from side bending

moments to ensure trouble free performance
the joint shall be periodically checked for gas tightness.
71
13.3.5 Quick-release coupling

The following conditions apply when using a quick-release coupling on a flexible:

it shall be of the self-sealing type

it shall be installed only in an exposed and readily accessible position
both parts of the coupling shall be compatible and should be made by the

same manufacturer
it should be of the type having self-sealing valves in both the plug and the
body and, in any event, it is essential that a self-sealing valve is
incorporated in the body. Where the volume of the pipework downstream of
the coupling is large, such a valve should also be incorporated in the plug, to
prevent dangerous quantities of gas escaping after the plug has been

removed
the flexible tube shall be fitted to the downstream connection of the quick-

release coupling
the female self sealing body section of the coupling shall be attached to the
rigid pipework and the male plug section shall be attached to the free end of

the flexible tube
where the coupling is of the twist-locking type, for example bayonet
connection, a swivel joint shall be included with the downstream flexible

tube except where the coupling incorporates an integral swivel
 a dust plug should be fitted in the upstream coupling body and/or

when the coupling is disconnected and not in use, and where appropriate;
 a dust cap should be fitted to the male plug on the end of the trailing
flexible tube.
13.3.6 Flexible tube or hose
13.3.6.1 For a 2nd family gas, a flexible tube or hose of non-metallic or stripwound

construction shall not be used except for either:
a connection not exceeding 15 mm nominal bore on domestic type

appliances (see BS 669-1) or
an application where it is subject to manual supervision and is only for
intermittent use, for example flexible connections to lighting torches, Bunsen
burners, brazing torches and flexible vents for purging operations.
Not e: Met al hoses com ply ing wit h BS 669- 2 are fit t ed w it h quick release couplings and
int egral sw ivel j oint s. Such t ubes ar e designed for use wit h cat er ing appliances but
m ay be suit able for ot her applicat ions.
In all other cases, any flexible tube or hose shall be constructed using
corrugated stainless steel to BS 6501-1, BS 669-2 or BS EN 14800, as
appropriate.
13.3.6.2 For a 3rd family gas, any flexible tube or hose shall comply with BS 669-2,
BS EN 14800, BS 3212, BS 4089 or BS 6501-1, as appropriate.

13.3.6.3 The following conditions apply when using a flexible tube or hose:
a manual valve shall be fitted on the inlet (upstream) side of and close to
the tube or hose, unless the flexible is equipped with a self sealing quick

release coupling
the tube or hose shall be rated for not less than three times OP or 350 mbar,

whichever is greater, at the temperature extremes for the application
the pipework either side of the tube or hose shall be supported separately
such that the tube itself is not supporting the weight of any of the attached

pipework
the tube or hose shall be installed such that there are no sharp bends,
particularly near the end fittings. Under no circumstances should the bending
72
radius be less than that specified by the manufacturer. If necessary,

additional pipe fittings should be used on the rigid pipework.
The tube or hose shall be installed such that movement takes place in one
plane only.
The minimum bend radius shall be as specified by the manufacturer.

Adjacent connections shall not touch each other

for vertical travel, the tube or hose shall be installed in a vertical loop
for horizontal travel, the tube or hose may be installed in a vertical loop for
short travel or in a horizontal loop when maximum travel is required. In the
latter case, the flex shall be supported to prevent sagging and subsequent

failure near the end fittings
torsional strain shall be prevented, for example by the use of slip flanged
joints, integral unions, or swivel joints, as appropriate.
13.4 SUITABILITY
The type of flexible connection used shall take into account the information
contained in Table 16 (except quick release couplings when clause 13.3.5
applies).
Not e: Quick release couplings are suit ed prim arily for use as connect ions t o appliances w hich
need t o be m oved regular ly and t o light ing t orches. I n eit her case, t hey supplem ent t he
convenience of t he flexible t ube connect ion.
PURPOSE SUITABILITY
SEMI-RIGID BELLOWS SWIVEL FLEXIBLE
COUPLING AND JOINT TUBE OR HOSE
FLANGE
ADAPTOR
Thermal No Yes3 No Not normally
expansion
Misalignment Yes Limited4 No Yes
1 5 6
Structural Yes Yes Yes Limited8
movement
Vibration No Limited3 No Yes9
Rotation No No Yes No
Torsion Limited1,2 No Yes No
Mobility No No Yes7 Yes10
Portability No No No Yes11
Not es:
1. See Appendix 12.
2. A sem i- rigid coupling m ay be accept able. A flange adapt or is unlikely t o be accept able.
3. See clause 13.3.3.
4. Bellows need t o be designed specially for prevent ion of m isalignm ent and vibrat ion.
5. Purpose- designed bellow s ar e preferred for use in duct s and for branch connect ions from
riser s in m ult i- st orey buildings
7. May provide t he necessary m obilit y of pipew ork by using suit able com binat ions of j oint s.
8. Short lengt hs m ay be used but braided hose t o BS 6501 or purpose designed bellow s are
preferred.
9. Manufact urers need t o be consult ed for advice on m inim um lengt h for t he am plit ude and
frequency of vibrat ion expect ed.
11. Tube hose needs t o be sheat hed.
Not e: For each applicat ion, t he suit abilit y of t he connect ion is show n t oget her w it h brief
explanat ory rem arks w hen necessary.
TABLE 16 - SUITABILITY OF FLEXIBLE CONNECTIONS
73
SECTION 14 : MANUAL VALVES
14.1 FEATURES
14.1.1 This section describes features that should be considered when selecting a
valve. Manufacturers' recommendations shall be consulted as they will provide
information and data, for example concerning the maximum pressure rating of
the valve together with pressure drop information.
14.1.2 Any valve shall have clear indication of direction of operation to open or close.
14.1.3 The installed valve shall not be susceptible to debris preventing its closure.
14.1.4 Any maintenance should be capable of being carried out with the valve in-situ.
14.1.5 Any valve should preferably be capable of rapid closure and have incorporated
position indication.
14.1.6 Any valve with rotary action such as wedge gate valve or a geared ball valve
should close in a clockwise direction and have clear indication of valve position.
14.1.7 Any AECV shall be sited to allow convenient access (see also clause 7.10.1)
14.2 SELECTION
A valve shall be selected for MOP of the pipework, speed of operation,

application (including type of gas), environmental conditions, corrosion
resistance, etc. (see Tables 17 and 18) and as appropriate shall meet the
requirements of BS EN 331, BS EN 1555-4, BS EN 12266-1, BS EN 13774
and/or BS EN 14141.
Not e: I f t he local t em perat ure is likely t o be high, t his will need t o be t aken int o account in
respect of lubr icat ion, sealing grease, sy nt het ic seals et c. Dirt y or dust y gases m ay require
local filt rat ion.
14.3 POSITION INDICATION
Any valve should have a position indication to identify the full open and closed
positions on visual inspection. Reference should be made to Sub-section 14.1.
14.4 OVERTRAVEL
Some types of valve incorporate sliding sealing surfaces such that further
movement of the closing part is provided after gas shut-off. For example, plug,
ball and parallel slide gate valves include this feature, usually termed
"overtravel", but, in general, “disk on seat” type valves do not. This design
feature assists in proving valve closure and gives added assurance of valve
closure on visual inspection. It also enables limit switches to be fitted to the
valve to monitor the closed position reliably.
14.5 SPEED OF OPERATION
Valves operated by a quarter turn, for example plug or ball valves, are the
quickest to operate whereas, with valves fitted with geared actuators, the speed
of operation will vary according to the gear ratio. Some applications will not
require fast opening of valves, for example where high pressure differentials
exist.
74
14.6 FIRE RESISTANCE
In the case of fire, generally, it is more important that a valve does not leak
externally rather than not leak through. Many valves would remain open in the
event of a fire and through-leakage would be of little consequence, whereas a
high external leak rate may contribute to the severity of the fire. A valve should
not include aluminium or zinc alloys or similar low melting materials in its
construction (handles, wheels, indicators, etc., need not comply with this). For
applications where a fire resistant valve is required, the manufacturer should be
consulted.
14.7 DOUBLE SEALS
Valves such as plug and ball valves, etc., have double sealing surfaces
compared with butterfly valves, etc., which rely on a single sealing surface. In
general, a double sealing design is preferred although individual designs need to
be considered in relation to overtravel and other engineering features. Valves
with double sealing surfaces may be provided with a tapped and plugged
connection for venting the space between the sealing faces for use when valve
closure proving is required.
14.8 PRESSURE DROP
The pressure drop across a valve will vary with the flow characteristics of the
valve design. For the pressure drop characteristics of each valve type the
manufacturer should be contacted. Full bore valves will provide a relatively
lower pressure drop. Butterfly valves tend to develop high pressure drops.
14.9 SERVICING
Valves and valve actuating gears/gearboxes shall be serviced as necessary,

taking account of the manufacturer’s instructions.
Valves which remains in one position over an extended period should be

operated regularly (or at least eased off from the set position) at such intervals
as will ensure that it may be operated readily when required.
Lubricated plug valves may require more attention than other types of valve.
14.10 VALVE TYPES
The types of valves in general use or which may be considered for use, are
listed below. Reference should be made to Tables 17 and 18 which contain the
features of specific types of valve.
Not e 1: Non- lubricat ed plug
A plug is t urned t hrough 90 o bet w een t he fully open and fully closed posit ions. The plug and
it s valve body eit her m ay bot h be t apered or bot h be parallel.
Not e 2: Lubricat ed plug
A plug is t urned t hrough 90 o bet w een t he fully open and fully closed posit ions. Such a v alve
incorporat es design feat ur es t hat enable lubricant t o be inj ect ed under pressure bet ween
t he plug and body while t he valve is in ser vice. The plug and it s body eit her m ay bot h be
t apered or bot h be parallel. Regular lubr icat ion and t est m ovem ent is essent ial.
Not e 3: Ball
A ball is t ur ned t hrough 90 o bet ween t he fully open and fully closed posit ions. The ball t urns
across soft seals on t he inlet and out let faces.
A plug boss m ay be fit t ed in t he space bet ween t he t wo seals for block and bleed purposes.
75
Not e 4: Wedge and par allel slide gat e
A gat e slides bet w een t he v alve seat s t o close t he valve, being wit hdrawn from t he seat s
when t he valve is open.
The gat e in t he wedge t ype valve is wedge shaped and t he valv e is fir m ly closed by m eans
of t he wedge act ion bet ween t he gat e and seat s.
I n t he parallel slide t ype valv e, t he gat e slides bet ween parallel seat s.
A plug boss m ay be fit t ed in t he space bet ween t he t wo faces for block and bleed purposes.
Not e 5: But t erfly
A disk wit h a pipe- sect ion body is pivot ed across t he pipe and rot at es up t o 90 o bet ween t he
fully open and fully closed posit ions. The lugged version, incorporat ing bolt s or st uds w hich
can be screwed from bot h sides, is t he only accept able t y pe.
Not e 6: Diaphragm
A flexible diaphragm is lift ed from and low ered ont o a st ream lined body seat , by a screw
t ype m echanism .
76
th
IGEM/UP/2 Edition 3 – 10 Working Draft

ISOLATION VALVE TYPE
VALVE NON-LUBRICATED PLUG LUBRICATED PLUG BALL
FEATURE
Servicing May need to be re-greased occasionally (when it is Lubrication is possible with the valve in service using grease sticks or Little servicing normally required. Some require removal for
necessary to remove the plug from the body). guns. Regular lubrication may be required to avoid sticking and maintenance.
leakage.
Position Yes, by means of an engraved or embossed Yes, by means of an engraved or embossed indicator line on the top Yes, often by means of an indicator suffixed to, or incorporated,
TABLE 17 - VALVE TYPES AND FEATURES FOR ALL SERVICES
indication indicator line on the top of the plug head. Ensure of the plug head. Ensure that the lever is fitted such that is in line in the stem head or ball shank head. When valves are lever
that the lever is fitted such that it is in line with the with the ports through the plug. operated the lever also acts as an indicator.
ports through the plug.
Overtravel Yes, but the degree is dependent upon the shape Yes, but the degree is dependent upon the shape of the ports in the Yes, but the degree is dependent upon whether the valve has
of the ports in the plug and body. Rectangular plug and body. Rectangular ports generally afford more overtravel full bore or reduced bore ports, but normally adequate.
ports generally afford more overtravel than circular than circular full -bore ports.
full-bore ports.
Valve seats Metal to metal sliding. Metal to metal sliding. Usually soft seats, but types with primary or secondary metal to
metal seats are available.
Speed of Fast with 90 movement from open to closed. Fast with 90 movement from open to closed. Fast with 90 movement for those fitted with lever actuation.
operation For geared activation, the speed is reduced.
Double seals Yes. Yes. Yes, and often double secondary seals.
Strength Normally adequate. Normally adequate. Normally adequate.
Pressure drop Usually low, but some valves have reduced bore Usually low, but some valves have reduced bore circular of Usually low.
circular or rectangular ports. rectangular ports.
Size range Not normally suitable above 50 mm due to high Available in all sizes, but wrench operation Is not normally suitable Available in all sizes.
operating torque and liability to stick. above 100 mm due to the higher operating torques required.
Double block and No. No. Not as standard, but available.
bleed facility
Lockable Not as standard. Not as standard. Not as standard, but available.
VALVE WEDGE, DOUBLE DISK AND BUTTERFLY DIAPHRAGM

62
FEATURE PARALLEL SLIDE GATE

Servicing Little servicing. Gland servicing is often difficult. Little servicing. Removal from the pipeline required for
Debris and corrosion in the body can prevent tight maintenance.
shut-off.
Position indication Not standard, but available. Yes, for valves with lever actuators and may be available on valves
with geared actuators.
Overtravel No, for wedge valves. Yes, for parallel slide gate No.
valves.
Valve seats Usually soft seated. May be metal to metal. The majority of valves have soft body seals and/or soft edged valve
discs. Valves with metal to metal seats are unsuitable.
Speed Slow. Fast for lever actuator types. For geared activation, the speed is
of operation reduced.
Double seals Normally yes. No.
Strength Normally adequate. Normally adequate.
Pressure drop Low. Can be significant in some valves due to the disc thickness, subject
to flow rate.
Size range Available in all sizes. Available in all sizes; lever operation restricted to 150 mm.
Double block and Available in some designs. No.
bleed facility
Lockable Not as standard. Not as standard.
Notes The wafer/sandwich type of valve (intended for insertion and These valves are not normally used by the Gas Industry for
clamping between pipe flanges using through bolting. Only lugged utilization application.
versions to be used.
77
th
IGEM/UP/2 Edition 3 – 10 Working Draft
IGEM/UP/2 Edition 3 –Draft for Comment

VALVE TYPE
VALVE
Non-lubricated Lubricated plug Ball Wedge Parallel Butterfly Diaphragm
APPLICATION
plug gate slide gate
Pipe section/plant 1a 1aj 1j 1g 1g 1fgh 2h
isolation
Buried/below 2 2 1ej 1eg 1eg 2 2

ground/burner
By-pass 1ai 1abij 1ij 1gi 1gi 1fgh 2
AECV 1ac 1abcj 1cj 1cg 1cg 2fghi 2

KEY TO CHART CATEGORY KEY TO CHART RESTRICTION
a Do not exceed 50 mm NB.
1 Acceptable, with
restriction. b Except if upstream of SSOV.
63
c Fire resistance of valve to be checked (BS EN 1775 compliant) if required.

2 Not normally e Steel or iron only.
recommended. Often
used for very large f Lugged.
valves sizes at low g Dust/debris to be checked.
pressure. h Normally, MOP less than or equal to 100 mbar, above this pressure it may be
appropriate to apply two valves in series with a valve test vent between them (double
block and bleed) if gas tight isolation is important for downstream operations.
i Valve to have the facility to be sealed or locked in the closed position.
j Mechanical assistance (gearing) required above certain pressure and size.
TABLE 18 - SUITABILITY OF VALVES FOR IGEM/UP/2 APPLICATIONS
Not e: The fir e resist ance t est s should refer t o Annex A Test procedure B of BS EN 1775. This annex descr ibes procedures A and B.
A pipework com ponent is considered t o be resist ant t o high t em perat ur es when it ret ains it s leak- t ight ness up t o a t em perat ur e at which t her e is no
longer any danger of a gas explosion.
For first , second and t hird fam ily gases ( see BS EN 437) t he per m issible t em perat ure is 650 °C ( t his is t he self ign it ion t em perat ur e of a nat ural gas/ air
m ix t ure) .
I t is accept ed t hat for cert ain pipework com ponent s, such as m et ers and insulat ing j oint s, t his leak- t ight ness relat es t o t he at m osphere ( ext er nal leak-
t ight ness) . For ot her pipewor k com ponent s, such as m eans of isolat ion, leak- t ight ness also includes leak- t ight ness at t he out let in relat ion t o t he inlet
( int er nal leak- t ight ness) .
A pipework com ponent m ay be considered t o be resist ant t o high t em perat ur es if it has passed a t est follow ing eit her procedur e A or procedure B.
Procedure A is generally applied for building product s, and Procedure B for pipework com ponent s.
78
SECTION 15 : VENTS AND BREATHERS
15.1 GENERAL
Vent pipework shall be designed for the same pressure as the associated
pipework section and be sized to pass the design flow. Permanent vents and
breathers shall be metallic.
15.2 VENTS
15.2.1 For safety and environmental reasons, venting of gas should be minimised.

15.2.2 There are four main categories of vent:

vents from relief valves etc

vents for venting in an emergency

vents for maintenance purposes
vents from SSOV systems (normally found on burners, process plant, gas
engines, gas turbines, etc).
Pressure relief valve vents are designed to discharge a limited quantity of gas
under fault conditions and shall be piped individually to the discharge location.
15.2.3 Emergency or maintenance vents are designed to discharge gas under fault or
planned maintenance conditions. These vents, when working at the same
pressure, may be combined but gas flow through one or more vent shall not
affect the correct operation of any equipment.
15.2.4 Any vent from a burner SSOV system shall be fitted with a vent pipe. Such pipes
may be manifolded together, in which case the cross sectional area of the
manifold pipe shall be equal to or greater than the sum of the cross sectional
area of the two largest vents involved.
Not e: I f specified by t he equipm ent m anufact ur er, som e burner SSOV vent s can be vent ed int o
t he com bust ion cham ber .
Any vent from auxiliary equipment and similar small relief valves may be
connected to a common vent provided that it is designed to avoid any
interaction between the components.
15.2.5 Types of vent pipe terminations
Various vent pipe terminations are in use in the gas industry. This clause
considers two basic conceptual types: “ideal” and “non-ideal”. However, there is
a range of alternative designs that although classified as “non-ideal” may have a
performance that approaches the “ideal” concept. The terminations considered

in IGEM/SR/25 Edition 2 are:

ideal
 impeded
non-ideal
 upward pointing and angled

 downward pointing
 other vent pipe terminations.
A further influence on the zoning of vent pipe terminations is the probability of

gas being present; this in turn will depend on the component that is the source

of the gas release. IGEM/SR/25 Edition 2 considers two sources of gas release:
those associated with process machinery and continuous flowing
instrumentation, which tend to give rise to Zones 1 and 0
79
 those associated with relief valves, which tend to give rise to Zone 2 (relief
valves usually operate infrequently, but may be subject to small valve seat
leakage).
Not e 1: The t er m “ ideal” is used t o descr ibe a not ional sim ple vent t er m inat ion design. I t is not
int ended t o m ean t hat it is t he best or preferred design for vent t er m inat ions in all
sit uat ions, but it w ill generally give rise t o t he short est zoning dist ance. A t rue” ideal” vent
is an open ended pipe, but in pract ice t his will not occur as t he vent design has t o prevent
t he ingress of wat er , snow and debris.
Not e 2: The non- ideal, im peded and downward point ing vent s would nor m ally generat e t he lar gest
hazardous ar eas as det ailed in I GEM/ SR/ 25 Edit ion 2 Appendix 9.
15.2.6 The materials, fittings and joining methods used for the installation of vent pipes
shall comply with Sections 5 and 6 respectively. The general principles outlined
in Section 7 should be applied. Vent pipes shall be strength and tightness tested
to same standards as the main pipework system.
15.2.7 Vents shall be terminated in a safe place in open air and for NG, when close to
buildings, they shall be terminated above roof level and shall not lead to a
hazardous area impinging on other buildings (see IGEM/SR/25 Edition 2 for NG
dispersion distances).
15.2.8 Due regard shall be taken of vent discharge hazardous area in proximity to
ignition sources, lighting, switch gear, windows, air intakes, electrical
equipment, etc.
15.2.9 For LPG or where it is not feasible or practical to terminate a NG vent above roof
level, venting shall be into a safe place, in the open. Termination shall be at
least 3 m above the ground or platform level and a minimum of 5 m from any
potential ignition source. It shall be located where there is no risk of vented
gases accumulating to cause a hazard or entering into buildings or other plant
through windows, air intakes, etc.
15.2.10 Consideration shall be given to the topography of the surrounding area, for
example the effects of downdraught from large buildings and, for heavier than
air gases, the prevention of accumulation of vented gas in depressions and low
spots. The quantity of released gas at low level shall be minimised by design by
use of small valves or by detection and alarm.
15.2.11 A vent pipe shall not be fitted in any position prejudicial to its safety, nor should
it be laid through any electrical intake chamber, transformer or lift shaft.
15.2.12 A vent/breather pipe shall be designed to prevent the ingress of water, snow
and debris.
15.2.13 Any permanently installed vent pipe shall be constructed and installed as
straight as practicable with the minimum number of bends.
Care should be taken, that long lengths of pipe or numerous bends do not
create a flow restriction through pressure drop.
15.2.14 Any vent from a burner double block and vent safety shut-off system, with
position proving but without pressure proving, shall be 25% of the nominal
diameter of the upstream main SSOV, or 15 mm nominal bore, whichever is the
greater.
15.2.15 A vent pipe shall be fitted to any regulator having an integral pressure relief
valve and to any pressure relief valve.
15.2.16 Vent points shall be provided to purge and commission pipework regulators and
burner controls. Such vents shall be valved and, where not permanently
80
connected to a vent pipe, shall be plugged or blanked off prior to normal

operation of the plant.
15.2.17 In order to avoid the possibility of ignition of gas from static discharge, care
should be taken to ensure that vents pipes are electrically continuous with the
main pipework. This is especially important with high flame speed gases such as
those containing hydrogen and for vent sizes exceeding 100 mm.
15.2.18 Where a vent is to be fitted within the protected zone of a lightning conductor,
reference should be made to BS 6651.
15.2.19 Any vent termination for relief valves or emergency vents shall be classified as a
hazardous area at the point of discharge. IGEM/SR/25 Edition 2 provides
appropriate guidance.
15.2.20 Manual isolating values should not be fitted in vent or breather pipes unless
procedures require them, in which case they shall to be locked in their correct
operating position.
15.2.21 Flame arrestors shall not be fitted to either a vent or breather pipe.
15.3 BREATHERS FROM REGULATORS AND RELATED SAFETY DEVICES
Breathers are not designed to discharge gas, only to facilitate the atmospheric
pressure on one side of a diaphragm to “breath”, allowing the diaphragm to
reposition according to prevailing conditions.
15.3.1 Vents and pressure relief valve vents should never be connected to breather
lines as vent or pressure relief gas could pressure load and alter the effect of the
diaphragm chamber function resulting in changes to gas control equipment.
15.3.2 Breathers for pressure control and safety devices need not normally be piped to
an outside atmosphere. However, consideration shall be given to piping the
breather to a safe external location if the pressure control or safety devices are
installed in a confined or poorly ventilated space, for example in a basement.
Such installations should be subjected to a risk assessment. Where this occurs
breather pipes shall be installed in accordance with the guidance given for
vents. The fitting of a vent pipe should not impair regulator performance.
15.3.3 Where it is necessary to pipe away a breather to a point outside the installation,
the pipe shall be independent of all other breather/vent pipework unless the
components feeding into the common pipework are designed specifically to
avoid any unacceptable interaction.
15.3.4 Where breathers are piped remote from the installation care should be taken in
the design of breathers to prevent blockage, ingress of debris, insects or water
at the breather termination points, but this should not impair operational
performance.
15.3.5 The zoning distances for breathers are shown in Table 19 and 20. These figures
have been extracted from IGEM/SR/25 Edition 2.
81
OP ZONING DISTANCE (X) UNDER ZONING DISTANCE (X) UNDER

(bar) NORMAL CONDITIONS (m) ADVERSE CONDITIONS (m)
2 ≤ 5 NE 1.5
≤
>
0.1 2 NE NE
≤
>
0.1 NE NE
Not e 1: For a descript ion of adverse condit ions see Appendix 8.
Not e 2: NE – negligible ext ent is only applicable in a freely vent ilat ed locat ion ( see Appendix 8) .
Not e 3: NE classificat ion is based upon a m ax im um NG release rat e of 1 g s- 1 ( see Appendix 8) .
TABLE 19 - ZONING DISTANCE TO BE USED WITH BREATHERS FOR

OUTDOORS, FREELY VENTILATED INSTALLATIONS
OP ZONING DISTANCE (X) UNDER ZONING DISTANCE (X) UNDER

(bar) NORMAL CONDITIONS (m) ADVERSE CONDITIONS (m)
> 2 ≤ 5 0.5 1.5

> 0.1 ≤ 2 0.5 1.5
≤ 0.1 0.5 1.5
Not e 1: For a descript ion of adverse condit ions see Appendix 8.
TABLE 20 - ZONING DISTANCE TO BE USED WITH BREATHERS FOR

OUTDOORS, CONGESTED OR CONFINED INSTALLATIONS
82
SECTION 16 : COMPRESSORS, BOOSTERS AND PRE-MIX MACHINES
16.1 GENERAL
This section provides guidance on the installation of pressure raising machines

delivering an outlet pressure not exceeding 0.5 bar. Where a machine
contributes greater than 25% of the maximum gas flow rate through a primary
meter, additional measures may have to be taken to minimise connected effects
of pressure transients on meters and main gas supply.
Not e: Furt her adv ice on t his and t he use of high pressure m achines, part icularly t hose for use
wit h gas t urbines or gas engines form ing part of a com bined heat and power sy st em , is
available in I GE/ UP/ 9 or I GEM/ UP/ 6, as appropriat e.
16.1.1 Any compressor, booster or pre-mix machine shall be suitable for its purpose
and comply with appropriate standards, such as BS 8487. Pre-mix machines
should not be applied to systems containing more than 5% hydrogen by
volume.
16.1.2 This section includes specifying the protection required by the gas suppliers in
order to comply with the relevant requirements of the Gas Act. The GT’s form
shall be completed and forwarded at least 14 days prior to the intention to
install.
Not e: The GT can be cont act ed t hrough t heir w eb sit e and by using t heir GT1 or GT2 docum ent s.
16.1.3 Any pressure transient generated during start-up, operation or shut down of a
machine shall not produce a greater pressure than the MOP of the installation
pipework.
16.1.4 Consideration shall be given in the selection of a booster such that its start up
characteristics do not cause the flow rate or rate of change of gas pressure in
the any upstream meter to exceed the manufacturer’s stated limits.
16.2 INSTALLATION
16.2.1 Location
16.2.1.1 Any machine shall be installed only in a well ventilated location and satisfy the
requirements of DSEAR.
16.2.1.2 The location should be clean, dry and accessible for maintenance.
Not e: I t is recom m ended t hat t he locat ion is near t o t he equipm ent being served, t hus m inim ising
t he lengt h of pipework at higher operat ing pressures.
16.2.1.3 A compressor, booster or pre-mix machine shall not be installed in a regulator

or meter house.
16.2.1.4 Due consideration should be given to the likely ambient temperatures to ensure
that any machine is not operating outside its temperature limits. If necessary, a
supply of cooling air should be provided, for example by means of additional
natural ventilation. Ambient temperatures shall be limited to a maximum of
45o C.
16.2.1.5 A booster or pre-mix machine shall not be located in a room specifically

intended to house an air compressor, unless the air inlet of each compressor is
ducted from outside the room to prevent, for example, gas which may leak
being drawn into the inlet of the air compressor and being distributed around
the compressed air system.
83
16.2.2 Ventilation
16.2.2.1 Where a machine is installed in a special room or housing, ventilation openings

shall be provided at high and low level to the atmosphere.
16.2.2.2 All high level ventilation shall be located as near to roof level as practical.
16.2.2.3 The design and location of the ventilation openings shall ensure good air
movement within the space. They should be disposed equally about the room or
housing with all openings at least 0.5 m from any external source of ignition
hazard.
16.2.2.4 Where electrical parts of a machine are in the same spaces as the machine and
that space is below 10 m3 net volume, the space shall be hazardous area
classified as Zone 2 under DSEAR unless the ventilation rate is such as to satisfy
the Risk Assessment required by DSEAR determines otherwise. See clause
16.2.1.1 and Appendix 8.
16.2.2.5 Where there is no excessive vibration, such as normally with a centrifugal

machine, the ventilation of the space shall also be sufficient to safely dilute a
leak from a hole size of 0.25 mm2 at the MOP to below 10% LFL.
Not e: See Appendix 8 for det ails on leak hole sizes.
16.2.2.6 Where a machine has significant vibration, such as may occur with some
reciprocating machines, the location may need to be classed as ‘adverse
conditions’. The ventilation of the space shall be sufficient to safely dilute a leak
from a hole size of 2.5 mm2 at the MOP to below 10% LFL. However, if special
attention is given to inspection intervals and to the selection of flexibles and
shaft seals that minimise leakage and the potential for failure, the leakage
criteria may remain at 0.25 mm2.
16.2.2.7 The design grille velocity of natural ventilation shall not exceed 2 m s-1.
16.2.2.8 Mechanical ventilation systems shall be fully interlocked with machine operation,
for example by air flow and motor starter interlocks. In smaller enclosures, gas
detection may be required to be interlocked, to prevent machine start-up if
flammable gas is present.
16.2.2.9 Where noise transfer levels necessitate attenuation of the ventilators, any
application of attenuation shall not reduce the effectiveness of the ventilation.
16.2.3 Mounting
16.2.3.1 Any machine shall be installed on a firm, flat horizontal bed or platform, unless
specified otherwise by the manufacturer/supplier of the machine.
16.2.3.2 Where the machine or its platform is not fixed securely to a concrete bed, the
use of anti-vibration mountings shall be considered to reduce noise or vibration.
16.2.3.3 Any pre-mix machine for lighter than air gas shall be sited lower than the outlet
pipework and burner system to guard against diffusion of the gas/air mixture
back through the air inlet when the pre-mix machine is shut-down. For heavier-
than-air gases, the opposite principles should be applied.
16.2.4 Pipe connections
16.2.4.1 Flexible metal hoses (see BS EN 14800) shall be fitted to the inlet and outlet
connections of any machine, unless specifically not required by the
manufacturer. The use of metal hoses or bellows is particularly relevant where
anti-vibration mountings are used, where the machine is made of cast
84
aluminium or where the gas temperature can cause pipework to expand and
impose stresses on the casing of the machine.
16.2.4.2 Connecting pipework shall be supported adequately and aligned correctly and
independently of the machine.
16.2.4.3 Where the pipework supply discharge diameter differs from that of the
connections to the machine, properly designed taper pieces or concentric
reducers shall be inserted as close to the machine as is practical and as
recommended by the manufacturer.
16.2.4.4 For a fan-type mixing machine operating within or close to the limits of
flammability at any time during normal operation, the length of the pipework to
the furthest burner shall not exceed thirty times the diameter of the pipe on the
machine outlet connection and the pipe volume should not exceed 0.06 m3.
16.2.4.5 In certain circumstances, a fan booster may show some degree of pressure
instability or surging at low gas flows. In these instances, a small controlled by-
pass, for example one incorporating a 25 mm lock-shield valve, should be fitted
around the booster and adjusted under no-flow conditions to eliminate the
instability. In such cases, the manufacturer should be consulted.
16.2.4.6 Where a machine may operate at low flows for long durations, it may be
necessary to incorporate a cooling loop around the machine. Advice shall be
sought from the manufacturer.

16.2.4.7 A check valve or NRV shall be fitted to a booster outlet when:
the outlet pipework volume is large and it is considered necessary to
minimise reverse pressure surges through the booster when it is turned off

or
boosters are connected in parallel and it is necessary to minimise gas re-

circulation or
machine reverse rotation needs to be prevented.
16.2.4.8 Where the manufacturer specifies that the system is to be commissioned using
air (see clause 16.7.1), the necessary connections for pipework to re-circulate,
return or vent the air to atmosphere shall be provided.
16.2.4.9 Provision shall be made in accordance with the manufacturer's instructions, in

the pipework, for any oil carry-over that may occur.
16.2.4.10 Any vent from a relief valve shall be in accordance with Section 15.
16.2.5 Electrical connections
16.2.5.1 The electrical installation shall conform to BS 7671, the Electricity at Work
Regulations and relevant parts of national Building Regulations and Standards,
as appropriate.
16.2.5.2 It is recommended that any machine is connected to run continuously as long as

the equipment served is on demand. It should not start and stop in conjunction
with thermostatic burner control as this increases wear and tear on motors and
drives and can cause frequent pressure fluctuations in the gas supply.
Modulating burner controls should be used where possible.
16.2.5.3 Any machine located in a purpose-designed compartment may require the use
of electrical components of a similar standard to that described in clause
16.2.5.4. The use of such equipment and the extent of any zoned area will
depend upon its location and the ventilation of the compartment. Advice on the
classification of hazardous areas is given in relevant parts of IGEM/SR/25.
85
16.2.5.4 Generally, electrical connections and equipment associated with gas boosters
and compressors on appliances at OP not exceeding 0.5 bar do not need to be
certified for use in hazardous areas. However, where a booster or pre-mix
machine is located in a meter/regulator house or room, the associated electrical
equipment should at least be suitable for use in a Zone 2 area with group II A
gases, for example type EE x "d" or equivalent (see BS EN 60079-15). A risk
assessment must be performed to ensure compliance with DSEAR.
16.2.5.5 Where a pre-mix machine produces a mixture within the limits of flammability,
(which will be within 50% LFL – 200% HFL containing 2.5 to 30% NG or 1.1 to
20% Propane) all electrical equipment including that on the mixture supply to
the burners, for example valves and pressure switches, shall be suitable for use
in a Zone 1 area with group II A gases for example, Type EE x "d" or equivalent.
16.2.5.6 The use of "star-delta" starters, which give a slower rate of start, will assist in
preventing the negative pressure surge which may occur when starting.
16.3 PROTECTION EQUIPMENT
16.3.1 Statutory requirements
A GT may require a consumer using a gas booster, compressor or similar

apparatus to fit and maintain a device to prevent pressure fluctuations in the
supply mains and any other inconvenience or danger to other customers.
16.3.1.1 Low gas pressure cut - off
Any machine shall have a low pressure cut-off switch fitted between the inlet
gas isolation valve and the machine which should be impulsed from the machine
gas supply inlet and suitably wired to prevent the machine causing a reduced or
negative pressure at the meter and in the gas supply system. On loss of gas
pressure, the switch shall cause the unit to shut down. Automatic restart on
restoration of gas pressure shall be prevented (see Appendix 13).
The maximum operating and fault pressures that may occur shall be considered
and consideration given to a switch having a suitable range or to provide some
other means of protection against high reverse pressures shall be selected. To
prevent the gas pressure falling below the settings of the pressure switch on
start up, it may be necessary to incorporate a suitably sized reservoir or to
damp the action of the pressure switch, ensuring that the response time does
not exceed 3 seconds (see also Appendix 13).
No other shut-off valve shall be fitted in the pipework between the unit and its
isolation valve.
16.3.1.2 Non- ret urn valve ( NRV)
A NRV, of a type acceptable to the GT shall be fitted to any machine having an

outlet pressure lift in excess of the upstream MIP.
Not e 1: This NRV would replace t he check valve specified in clause 16.2.4.7 and m ay be fit t ed t o
t he inlet or out let of t he m achine.
Selection of a NRV shall take account of the gas temperature and of pressure
and gas velocity pulsations produced by the machine.
Not e 2: Som e t ypes of NRV m ay fail rapidly w hen used in conj unct ion w it h a reciprocat ing
com pr essor .
Not e 3: An overpressure shut off valve m ay be inst alled as an opt ion t o an NRV, in w hich case it
m ay need t o be inst alled in t he rever se direct ion t o nor m al flow.
86
16.3.2 Further protection (pre-mix machines)
16.3.2.1 Low gas pressure
In the event of low pressure causing the machine to shut down (see clause
16.2.1.1), the gas supply shall also be shut off, requiring manual resetting. The
operation of the SSOV should be such as to minimise the distribution of
mixtures within the limits of flammability during the machine shut-down
sequence, for example by delaying actuation of valve closure until the machine
is almost at rest.
16.3.2.2 Flashback safeguards
Means shall be provided to protect the pre-mix from flashback, for example by
the installation of a flame arrestor in the mixture pipework at the inlet to the
burner zones and/or on the machine outlet. Flame traps shall not be inserted in
the mixture pipework from fan-type mixers as they may affect adversely the
operation of such machines. The manufacturer shall be consulted.
16.3.2.3 Air failure device
The machine shall be equipped with a suitable device that should stop the mixer
and automatically shut off the gas supply in the event of a reduction in the air
supply or a blockage of the air inlet, for example by means of a differential
pressure switch. Manual re-setting shall be required to re-start the machine
after such a shut-down.
16.3.2.4 Minim um m ixt ure pressure
A pressure switch shall be fitted on the mixture outlet for the machine and shall
be set to shut down automatically with the machine and the gas supply in the
event of the mixture pressure falling below the pre-set minimum.
16.3.2.5 Flam m able range
It is normal for the air/gas to be outside the limits of flammability, in which case
means shall be provided, for example using mechanical stops, to prevent the
machine from producing a flammable air/gas mixture. It shall not be possible to
override any such means without the use of tools.
16.3.2.6 High m ixt ure pressure
In some cases, it may be desirable to install a pressure switch in the mixture

line to shut down the machine in the event of excess discharge pressure. When
a machine is so shut down, the gas supply shall be shut off automatically.
16.3.2.7 Safet y shut - off valve
The automatic shut-off valve recommended in clauses 16.2.2.1 to 16.2.2.6 shall

close as soon as possible after being de-energised, preferably within 1 second
and before the machine has come to rest. Valves complying with BS EN 161
should be used, whenever practicable.
87
16.4 SCHEMATIC INSTALLATION DIAGRAMS
16.4.1 Boosters
Typical installation layouts showing the location of components relative to the

booster and one another are depicted in Figures 19 and 20.
LPCO control by-pass
PS NRV
flexible
gas
manual flexible
valve
booster
FIGURE 19 - SINGLE BOOSTER INSTALLATION
control by-pass
LPCO Check valve

or NRV
PS
flexible
manual
manual flexible
valve
valve
booster
gas
LPCO
PS
flexible
Check valve
or NRV
flexible
booster
FIGURE 20 - PARALLEL BOOSTER INSTALLATION
16.4.2 Pre-mix machines
16.4.2.1 Typical installation layouts showing the location of components relative to the
machine and one another are depicted in Figures 21 and 22.
88
air
minimum high
mixture mixture
filter air failure pressure pressure
Gas PS PS PS
LPCO
SSOV
PS
burners
flexible
manual NRV flexible ratio

isolating device
valve
booster
typical machine
FIGURE 21 - FAN-TYPE MIXER
air
compressor
air failure relief
minimum high
filter mixture mixture
PS pressure pressure
PS
PS
burners
flexible zero ratio flexible flame
regulator device trap
booster
Gas
LPCO
PS
manual plant SSOV NRV

isolating regulator
valve
FIGURE 22 - COMPRESSOR-TYPE MIXER
16.4.3 Wiring
A possible wiring circuit incorporating all the protection equipment is shown in

Figure 23. It is intended to depict a typical installation and should not be
considered to be the only method available.
89
start
stop • • high mixture

air failure gas
(filter P) LPCO pressure
R1
• • • • • • • • • 2
R1/1
•minimum
•
mixture
pressure
R1/2
• to start coil of mixer motor
to gas SSOV
FIGURE 23 - SCHEMATIC DRAWING OF POSSIBLE WIRING CIRCUIT

(BOOSTERS)
16.5 NOTICES

16.5.1 The following notices shall be displayed permanently adjacent to the plant:
operating instructions
Not e: I n som e cases, it m ay not be feasible or pract ical t o display com prehensive
inst ruct ions. I n such inst ances, full operat ing inst ruct ions shall be readily available t o

t he operat ors at all t im es.

emergency procedures
a diagram indicating position of main isolation valve(s).
16.5.2 Where gas is supplied to a compressor type pre-mix machine, notices similar to
those depicted in Figures 24 and 25 should be affixed, as appropriate.
The valve(s) on the inlet to this meter

installation must be fully open before
starting any gas compressor or gas
engine and must NOT be closed or
partly closed while any such plant is in
operation otherwise the meter and/or
plant may be damaged.
GAS COMPRESSORS AND

GAS ENGINES
FIGURE 24 - WARNING NOTICE NEAR TO THE METER INLET VALVE AND

ANY GAS COMPRESSOR OR GAS ENGINE
90
WARNING NOTICE
DO NOT INTERFERE with any part of this installation
maximum incidental pressure (mbar*)

(MIP) (bar*)
maximum operating pressure (mbar*)

(MOP) (bar*)
HIGH PRESSURE GAS SUPPLY
FIGURE 25 - WARNING NOTICE ON INSTALLATION PIPEWORK
16.6 OPERATING DATA
16.6.1 Operating instructions shall be provided for any machine. These instructions

shall include:

complete description of the machine

installation requirements

appropriate wiring diagrams including sequence logic
simple and clear instructions on stopping and starting the machine (including
emergency shut-down), checking and operation of the safety controls,
routine fault finding and maintenance.
16.6.2 The user shall ensure that plant operators are familiar with operating
instructions and procedures.
16.6.3 Each machine shall be marked in an easily visible manner, for example, on a

plate fixed securely to one of the surfaces, with the following information.

the name of the manufacturer

the serial number, model number or other distinct means of identification
supply voltage, phase and frequency of electrical equipment integral with the

machine
the machine outlet pressure and volume flow rate, power, speed etc.
16.6.4 The manufacturer shall state the size and type of gas inlet and outlet
connections of the machine.
16.6.5 The manufacturer shall supply an operating datasheet to be completed by the

commissioning engineer. It should include such items as:

regulator pressure settings

interlock settings (for example, high and low pressure)

setting of ratio controller (for pre-mix machines)
machine operating data (for example, running speed, coolant temperatures).
16.7 COMMISSIONING, OPERATION, MAINTENANCE AND SERVICING
16.7.1 Commissioning
16.7.1.1 Any booster or pre-mix shall be commissioned only by a competent person. The
manufacturer should make available written commissioning and de-
commissioning instructions for use by commissioning engineers. These shall be
in accordance with IGEM/UP/4.
91
16.7.1.2 Wherever practicable, pre-commissioning on air should be undertaken to carry

out all the dry run checks on the interlocks, to ensure that the lubricating and
cooling system is working correctly and to check/set all relief valve settings.
Care should be taken not to overload the machine.
16.7.2 Operation, maintenance and servicing
Procedures for safe maintenance and servicing shall be obtained from the
manufacturer (advice is also given in BS 8487).
Manufacturer's maintenance instructions and system designer's instructions

shall be followed at all times. The removal or by-passing of any safety
component shall not be permitted.
92
SECTION 17 : PROCEDURES ON COMPLETION OF INSTALLATION
Appendix 15 shows a typical record of a new installation.
IGE/UP/1 and IGE/UP/1A provide requirements for strength testing, tightness testing and
purging of industrial and commercial gas installations. IGEM/UP/1B may be applicable for
smaller installations and IGEM/UP/1C for meter installations.
IGEM/UP/4 provides requirements for the commissioning of gas fired plant.
Normally, the installation of gas supply pipework involves the installer making a connection to
upstream equipment. This would take the form of a meter outlet connection (NG) or pressure
regulator (LPG).
17.1 GENERAL

Before the installation can be considered to be completed, the following apply:
all appliances shall be installed and commissioned with due regard to the
manufacturer’s instructions provided with the appliance

Not e: See Regulat ion 33 of GS( I &U) R.
ancillary equipment such as valves, gas detectors, boosters, check meters
etc. shall be installed and commissioned as per the manufacturer’s

instructions
the installer shall confirm with the owner/operator that the meter/storage
vessel installation is safe to connect onto and is safe to use
Not e: On larger inst allat ions, it m ay be necessary t o liaise w it h t he gas supplier, as t hey m ay
requir e a presence on sit e, wit h t he inst aller, so t hey can com m ission t he gas supply
● a gas supply line diagram shall have been provided (see clause 4.2.13). If
pressure regulat ing and m et ering equipm ent .
the work is in addition to an existing installation, the existing drawings
● any main equipotential bonding shall have been carried out by a qualified
should be amended accordingly
electrician. If practicable, the bonding wiring connection should be installed
● the necessary test and purge points shall have been provided, especially at
within 600 mm of the meter outlet or building entry valve
the ends of pipework sections, taking into account the need for replacement,
● before tightness testing, all joints on underground pipework which remain

repair or maintenance of in-line equipment
exposed shall have been anchored securely, if appropriate, and due care
● all pipe ends shall have been spaded, plugged or capped and the meter and
taken with regard to the safety of personnel in the vicinity of the excavations
other sensitive equipment protected similarly, prior to commencement of a
● a satisfactory strength and tightness test shall be carried out and

strength test
subsequent connections between new and existing pipework tested, for
● where necessary, steel pipework shall be wrapped, for example in situations

example with an approved leak detection fluid
where the pipework is in a corrosive environment, for example underground

or in a damp atmosphere. Care should be taken to wrap all flanges, fittings
and joints
Not e: A plast ic t ape, grease- im pregnat ed bandage or bit um en- based w rap would be
● the pipework shall have been colour coded (see Section 7)

suit able for t his purpose ( see clause 8.4.2) .
● the installation shall be fully purged with gas and any outlets which are not
to be put to use sealed suitably and immediately, for example with plugs or
blank flanges
93
● any remaining excavations shall be back filled and reinstated after wrapping
●
or painting any test connections

any surplus backfill or waste materials shall be removed from site
a hazardous area assessment shall be undertaken to comply with DSEAR.

Not e: Furt her inform at ion is prov ided in HSL138, I GEM/ UP/ 16 and I GEM/ SR/ 25.
It is not a requirement of IGEM/UP/16 to produce drawings of installations
showing hazardous area Zone 2NE classification. However, site technical files
shall include both the risk assessments and information on those sections of
pipework etc that are declared Zone 2NE. This may be identified on the site
line diagram. It is not necessary to display the triangular ATEX sign for Zone
●
2 Installations
a positive reporting procedure should be adopted to ensure that records are
kept, confirming that the completed installation has been checked and that
all necessary steps have been taken to ensure that the installation is
installed correctly. Where appropriate, a commissioning certificate should be
issued at least covering testing and purging results (for a suggested
pipework commissioning check list, see Appendix 14).
17.2 INSPECTION AND MAINTENANCE PLANNING
17.2.1 Upon completion of any gas pipework installation project, a scheme shall be
drawn up for the inspection, maintenance and testing of all pipework to ensure
continued integrity. A risk assessment of each new gas pipework system should
be carried out to ascertain a periodic inspection and testing plan.
Not e 1: GS( I &U) R Reg.35, st at es t hat " it shall be t he dut y of every em ploy er or self em ployed
person t o ensure t hat any gas appliance, inst allat ion pipework or flue inst alled at any place
of work under his cont rol is m aint ained in a safe condit ion so as t o pr event inj ury t o any
person" .
Not e 2: Refer ence can also be m ade t o BS EN 15001- 2.
17.2.2 Pipework with an MOP of 0.5bar and above falling within the scope of the PSSR,
a written scheme of pipework maintenance must be drawn up (or certified as
suitable) by a competent person. It is the duty of the user of an installed system
of pipework to ensure that the scheme has been drawn up. The user can not
allow the pressure system to be operated without a written scheme of
examination. The user is also to ensure that the system has been examined as
specified by the written scheme of examination.
The written scheme of examination needs to cover all protective devices; this
includes every pressure vessel and those parts of pipework which, if they fail,
may give rise to danger.
The written scheme will specify the nature and frequency of examinations, and
include any special measures that may be needed to prepare a system for a safe
examination.
The user is to ensure the pipework is examined in accordance with the written
scheme by a competent person at the frequencies specified. See also HSE
INDG261.
17.2.3 A risk assessment for the gas pipework system must be undertaken for
compliance with DSEAR. Maintenance and testing that is required by the risk
assessment must be performed to comply with the Regulations. Testing will not
normally require pressure testing for systems with an OP below 5 bar and in
most cases will involve physical inspection and the use of gas leakage detectors
or leak detection fluid.
94
17.2.4 A maintenance plan shall be drawn up for the pipework and all ancillary
equipment which would include valves, regulators, boosters and compressors.
Reference should be made to the manufacturer’s literature for the specific
requirements and periods between maintenance.
17.2.5 An inspection plan shall be drawn up for all the pipework and ancillary
equipment as part of the maintenance plan.
17.2.6 AECVs and other valves, as appropriate, should be checked periodically for
effective operation.
17.2.7 Test instrumentation shall be selected for use with the appropriate type of gas.
This is especially important for combustible gas analysers and hydrogen rich
gases.
17.2.8 The maintenance of gas pipework can be done in varying degrees, the following
being the industry accepted methods. Consideration should be given to
● visual inspection (typically annually) - a checklist is used to ascertain if the

implementing the following procedures:
gas pipework is visually being maintained to an acceptable level. A

competent person would report on particular parts and constituents of the
● manual valves used during maintenance operations shall be kept accessible

gas pipework installation, making recommendations as required
for operation and verification of gas tightness before work continues, e.g. by
the use of let-by test. Where the system has OP at above 5 bar (or lower
pressure if required by a risk assessment) the use of double block and vent
valving will require a check for valve seat tightness to be performed prior to

commencement of work
● gas detector test in hazardous areas – using a gas detection instrument that
checking any CP for correct function
can detect to less than 10% of the lower flammability limit (LFL) of the gas
in the pipework, such areas are where small amount of gas can accumulate
●
and linger
gas detector tests at building entries - using a gas detection instrument, as
above, to detect gas tracking in from outside, by taking readings at and
●
around the pipework entry
leak detection fluid or gas detector checks - these may be used at each joint
●
to check for leakage
tightness test of pipework (typically 5 yearly) - a tightness test may be
carried out as specified in IGE/UP/1 or IGE/UP/1A.
In cases of high corrosion, it may be necessary to carry out tests to ascertain

the wall thickness of the pipe. Reference to Appendix 5 should be made when
determining minimum acceptable wall thickness for steel pipes.
17.2.9 Procedure for taking pipework out of service (decommissioning or

alteration)
17.2.9.1 The route and sizes of the pipework, isolation valving and purge point location
and sizing shall be determined.
17.2.9.2 The condition and location of metering equipment shall be determined if the
metering system is also affected by the proposed work.
17.2.9.3 Where the work is associated with demolition, liaison shall take place with the
MAM and/or gas supplier. Where possible the MAM should isolate and
decommission the metering system and, if necessary isolate the site from the
service or gas main before the pipework is decommissioned. At this point the
pipework between the meter and the pipework may be sealed or spaded off
upstream of the meter outlet isolation valve.
95
17.2.9.4 A work procedure shall be developed for all the purging work to be performed
together with a risk assessment for all but the simplest of projects.
17.2.9.5 The pipework shall be purged of gas to below 5% LFL using either air or
nitrogen or both. Where sections of pipework remain in below ground locations
such as cellars or basements, it is recommended the purge should finally be
with air.
17.2.9.6 Flaring may be appropriate prior to the final purge of large installations or
installations above 100 mbar due to the large volumes being released.
17.2.9.7 Information on purging for decommissioning is given in IGE/UP/1.
96
APPENDIX 1 : GLOSSARY, ACRONYMS, ABBREVIATIONS, SYMBOLS

AND UNITS
GLOSSARY

All definitions are given in IGEM/G/4 which is freely available:

upon purchase of any IGEM Standard, as a CD
by downloading a printable version from IGEM’s website www.igem.org.uk.
Downloading from the website ensures access to the latest version.
Standard and legacy gas metering arrangements are given in IGEM/G/1 which is freely

available:

upon request, upon purchase of any IGEM Standard
by downloading a printable version from IGEM’s website.
DIAMETERS AND NOMINAL BORES
diameter Pipes and fittings are specified differently dependent upon

material, legislation, Standards and specifications, with respect
nominal bore (nominal
to diameter. The terms used in this Standard equally vary and,
bore (NB)
for the purposes on this Standard, the following apply:

nominal diameter ()
“nominal bore (NB)” is the specified inside diameter and

inside (internal) diameter may apply to any material
“inside (internal) diameter” is the actual inside diameter

and may apply to any material
“nominal diameter ()” is the specified inside or outside
diameter dependent upon the material type. For
example, for carbon steel and CSST, nominal diameter is
the specified inside diameter whereas, for PE and
copper, nominal diameter is the specified outside

diameter
“diameter” is the actual inside or outside diameter
dependent upon the material type, as for nominal
diameter.
ACRONYMS AND ABBREVIATIONS
ACoP Approved Code of Practice

AD approved document
AECV additional emergency control valve
AIV automatic isolation valve
CDM Construction (Design and Management) Regulations
CNE combined neutral earth
CO carbon monoxide
CoP Code of Practice
COSHH Control of Substances Hazardous to Health Regulations
CP cathodic protection
CSST corrugated stainless steel tubing
DmP design minimum pressure
DP design pressure
DSEAR Dangerous Substances and Explosive Atmospheres Regulations
DT destructive testing
ECV emergency control valve
ESP emergency service provider
GB Great Britain
GS(I&U)R Gas Safety (Installation and Use) Regulations
97
GS(M)R Gas Safety (Management) Regulations

GT gas transporter
HAUC Highways Authority and Utility Council
HMSO Her Majesty’s Stationery Office
HSE Health and Safety Executive
HSWA Health and Safety at Work etc. Act
HV high voltage
IGEM Institution of Gas Engineers and Managers
LFL lower flammable limit
LPCO low pressure cut off
LPG Liquefied Petroleum Gas
LOP lowest operating pressure
LV low voltage
MAM meter asset manager
MBV meter by-pass valve
MHSWR Management of Health and Safety at Work Regulations
MIP maximum incidental pressure
MOP maximum operating pressure
NB nominal bore
NDE non-destructive examination
NDT non-destructive testing
NG Natural Gas
NRV non-return valve
OD outside diameter
OP operating pressure
PE polyethylene
PED Pressure Equipment Directive
PER Pressure Equipment Regulations
PLOP peak level operating pressure
PME protective multiple earth
PPE personal protective equipment
PS Pressure switch
PSR Pipelines Safety Regulations
PSSR Pressure Systems Safety Regulations
PUWER Provision and Use of Work Equipment Regulations
PTFE polytetrafluoroethylene
PVC polyvinylchloride
RD rotary displacement
RIDDOR Reporting of Injuries, Diseases and Dangerous Occurrences Regulations
SDR standard dimension ratio
SP set point
SSOV Safety shut-off valve
STP strength test pressure
TOP temporary operating pressure
UKAS United Kingdom Accreditation Service
UK United Kingdom
UV ultra-violet.
UNITS
barg bar gauge

ft3 h-1 cubic feet per hour
kW kilowatt
m metre
mbar millibar
mm millimetre
m2 square metre
m3 cubic metre
mm2 square millimetre
m3 h-1 cubic metre per hour
98
m s-1 metre per second

MW megawatt
m micrometre
m Ohm metre
N mm-2 Newton per square millimetre
secs second
º angular degree
o
C degree Celsius.
SYMBOLS
< less than

 less than or equal to
> greater than
 nominal diameter dependent upon pipework material
A area
Cd coefficient of discharge
d internal pipe diameter
e efficiency factor
f friction factor
G gauge
h pressure change due to altitude
H altitude change
L length
P pressure
p pressure loss
P 1 , P2 pressure regimes
Q gas flow rate
R resistor
Re Reynolds number
s density of gas relative to air (also represented by )
T time
V volume
X log10 Re –5.
SUBSCRIPTS
air air
gas gas
ign minimum allowable
max maximum
mi meter installation
min minimum
sp smooth pipe
u upstream.
99
APPENDIX 2 : REFERENCES
This Standard is set out against a background of legislation in force in GB at the time of
publication. Similar considerations are likely to apply in other countries and reference to the
appropriate national legislation will be necessary. The following list is not exhaustive.
All relevant legislation must be complied with and relevant Approved Codes of Practice
(ACoPs), official Guidance Notes and referenced codes, standards, etc. shall be taken into
account.
Where British Standards, etc. are quoted, equivalent national or international standards, etc.
equally may be appropriate.
Care shall be taken to ensure that the latest editions of the relevant documents are used.
A2.1 LEGISLATION


Building Regulations (England and Wales) 2000

Building Standards (Scotland) Regulations 2000 and Amendments

Building Regulations (Northern Ireland) 2000

Confined Spaces Regulations 1997

Construction (Design and Management) Regulations 2007

Consumer Protection Act 1987

Control of Asbestos of Work Regulations 2002

Control of Substances Hazardous to Health Regulations 2002

Dangerous Substances and Explosive Atmospheres Regulations 2002

Electricity at Work Regulations 1989

Electricity Supply Regulations, 1998, as amended

Gas Act 1986 (as amended by the Gas Act 1995)

Gas Appliances (Safety) Regulations 1992

Gas Cooking Appliances (Safety) Regulations 1989

Gas Safety (Installation and Use) Regulations 1998

Gas Safety (Management) Regulations 1996

Health and Safety at Work etc. Act 1974

Heating Appliances (Fireguard) Regulations

Management of Health and Safety at Work Regulations 1999

Noise at Work Regulations 1989

Pipelines Safety Regulations 1996

Pressure Equipment Directive 97/23/EC

Pressure Equipment Regulations 1998

Pressure Systems Safety Regulations 2000

Provision and Use of Work Equipment Regulations 1998
Reporting of Injuries, Diseases and Dangerous Occurrences Regulations
1995.
A2.2 HSE ACOPS AND GUIDANCE


HSE61 (Rev 1) RIDDOR Explained

HSG48 Human factors in industrial safety. Guidance
HSG65 Successful health and safety management.
Guidance
100
 HSG227 A comprehensive guide to managing asbestos in

premises. Guidance

HSG253 The safe isolation of plant and equipment
HSL21 Management of health and safety at Work. ACoP

and Guidance

HSL22 Safe use of work equipment. ACoP and Guidance
HSL27 Work with asbestos which does not normally require

a licence. ACoP and Guidance
HSL28 Work with asbestos insulation, asbestos and

asbestos insulating boards. ACoP and Guidance
HSL56 Safety in the installation and use of gas systems

and appliances. ACoP and Guidance
HSL73 Reporting of Injuries, Diseases and Dangerous

Occurrences Regulations. Guidance

HSL122 Pressure Systems Safety Regulations. Guidance
HSL127 The management of asbestos in non-domestic

premises. ACoP
HSL134 Design of plant, equipment and workplaces;
Dangerous Substances and Explosive Atmospheres

Regulations 2002. ACoP and Guidance
HSL135 Storage of dangerous substances; Dangerous
Substances and Explosive Atmospheres Regulations

2002. ACoP and Guidance
HSL136 Control and mitigation methods; Dangerous
Substances and Explosive Atmospheres Regulations

2002. ACoP and Guidance
HSL137 Safe maintenance, repair and cleaning procedures;
Dangerous Substances and Explosive Atmospheres

HSL138 Dangerous Substances and Explosive Atmospheres


HSR25 Electricity at Work Regulations. Guidance
HSL144 Construction (Design and Management) Regulations

2007. ACoP

INDG178 (rev 1) Written schemes of examination

INDG229 Using work equipment safely

INDG261 (rev 1) Pressure systems – safety and you
INDG291 Simple guide to the Provision and Use of Work

Equipment Regulations
INDG370 Fire and explosion; How safe is your workplace? A
short guide to the Dangerous Substances and
Explosive Atmospheres Regulations 2002.
A2.3 IGEM
 IGE/UP/1 Strength and tightness testing and direct purging of

industrial and commercial gas installations

Edition 2 RWA
IGE/UP/1A Strength and tightness testing and direct purging of small
Edition 2 RWA low pressure industrial and commercial Natural Gas
installations
101
 IGEM/UP/1B Tightness testing and direct purging of small Natural Gas

installations

Edition 3
IGEM/UP/1C Strength testing, tightness testing and direct purging of

NG and LPG meter installations
IGE/UP/3 Gas fuelled spark ignition and dual fuel engines

Edition 2
IGEM/UP/4 Commissioning of gas fired plant on industrial and
commercial premises

Edition 3
IGEM/UP/6 Application of positive displacement compressors to
Natural Gas fuel systems

Edition 2
IGE/UP/7 Gas installations in timber framed and light steel framed
Edition 2 buildings
 IGE/UP/9 Application of Natural Gas and fuel oil systems to gas

turbines and supplementary and auxiliary fired burners

Edition 2
IGE/UP/10 Gas appliances in industrial and commercial premises

Edition 3
IGEM/UP/11 Gas installations in educational establishments

Edition 2
IGEM/UP/16 Design for NG installations on industrial and commercial
premises with respect to hazardous area classification and

preparation of risk assessments
Shared chimney and flue systems for domestic premises

IGEM/UP/17
IGE/UP/12 Application of burners and controls to gas fired process

plant
IGE/GM/4 Flowmetering practices. Inlet pressure exceeding 38 bar
and not exceeding 100 bar

Edition 2
IGEM/GM/6 Specification for low pressure diaphragm and rotary
Edition 2 displacement meter installations with badged meter
capacities exceeding 6 m3/h (212 ft3/h) but not exceeding
1076 m3/h (38000 ft3/h)
 IGE/GM/8 Non-domestic meter installations. Flow rate exceeding
6 m3 h-1 and inlet pressure not exceeding 38 bar. Parts 1

to 5
IGEM/TD/1 Steel pipelines for high pressure gas transmission

Edition 5
IGEM/TD/1 Handling, transport and storage of steel pipe, bends and
Edition 5 fittings

Supplement 1
IGE/TD/3 Steel and PE pipelines for gas distribution

Edition 4
IGE/TD/4 PE and steel gas services and service pipework
Edition 4
102
 IGE/SR/10 Dealing with escapes of gas into underground plant

Edition 2
IGE/SR/20 Dealing with reported gas escapes

Edition 2
Risk assessment techniques

IGE/SR/24
IGEM/SR/25 Hazardous area classification of Natural Gas installations

Edition 2
IGE/GL/8 Reporting and investigation of gas related incidents

Edition 2
IGEM/G/1 Defining the end of the Network, a meter installation and

installation pipework
IGE/G/5 Gas installations in flats and other multi-dwelling buildings
 IGEM/G/6 Gas supplies to mobile dwellings
 IGEM/G/8 Handling, transport and storage of PE pipe and fittings.
A2.4 BRITISH STANDARDS INSTITUTION (abbreviated titles)


BS 10 Flanges and bolting

BS 143 & 1256 Threaded pipe fittings

BS 669 Flexible hoses

BS 1552 Taper plug valves

BS 1560-3 Circular flanges

BS 1640 Wrought carbon and ferritic alloy steel fittings

BS 1710 Identification of pipelines and services

BS 1965-1 Butt welding pipe fittings

BS 2051-1 Tube and pipe fittings. Copper

BS 2971 Class II arc welding of carbon steel pipework

BS 3212 Flexible rubber hosing for LPG

BS 3381 Spiral wound gaskets

BS 3799 Steel pipe fittings, screwed and socket welding

BS 4089 Metallic hose assembles. LPG

BS 4368 Compression couplings

BS 4677 Arc welding of austenitic stainless steel pipework

BS 4800 Paint colours for building purposes

BS 4872 Approval testing of welders. Fusion welding

BS 4882 Bolting for flanges and pressure containing purposes

BS 5114 Performance of joints and fittings for PE pipes
BS 5482 Domestic butane and propane gas burning

installations

BS 5588 Fire precautions for buildings

BS 5885 Automatic gas burners

BS 6129 Bellows expansion joints

BS 6400 Domestic-sized meter installations
BS 6501 Metallic hose assemblies
103


BS 6651 Protection of structures against lightning

BS 6891 Low pressure gas pipework (domestic premises)

BS 6956 Jointing compounds

BS 7076 Gaskets for flanges

BS 7361 Cathodic protection

BS 7461 Automatic gas shut off valves

BS 7531 Compressed non-asbestos fibre jointing

BS 7671 IEE wiring regulations

BS 7838 CSST pipe and fittings

BS 8313 Accommodation of building services in ducts

BS 8487 Gas boosters

BS EN 161 Automatic shut off valves

BS EN 287 Qualification test of welders. Fusion welding

BS EN 437 Test gases, Test pressures, Appliance categories

BS EN 676 Automatic forced draught burners

BS EN 751 Sealing materials

BS EN 1011 Welding of metallic materials

BS EN 1044 Brazing. Filler metals

BS EN 1045 Brazing. Fluxes

BS EN 1057 Copper and copper alloys. Tube

BS EN 1092-1 Circular flanges

BS EN 1254 Copper and copper alloys. Fittings

BS EN 1514 Flanges and their joints

BS EN 1555 Plastic piping systems

BS EN 1775 Gas pipework in buildings

BS EN 1759-1 Flanges and their joints. Steel flanges

BS EN 10208 Steel pipes for pipelines

BS EN 10216 Seamless steel tubes

BS EN 10217 Welded steel tubes

BS EN 10222 Steel forgings

BS EN 10226 Pipe threads

BS EN 10241 Steel threaded pipe fittings

BS EN 10242 Malleable cast iron pipe fittings

BS EN 10253 Butt welding pipe fittings

BS EN 10255 Non alloy steel tubes

BS EN 10497 Testing of valves. Fire type-testing requirements

BS EN 12732 Welding steel pipework

BS EN 12954 Cathodic protection

BS EN 14800 Corrugated safety metal hose assemblies
BS EN 15001 Gas installation pipework greater than 0.5 bar for
industrial and greater than 5 bar for industrial and

non-industrial installations

BS EN 15266 Pliable corrugated tubing systems
BS EN 50073 Apparatus for the detection and measurement of

combustible gases
BS EN 60079 Electrical apparatus for explosive gas atmospheres
104
 BS EN 61779 Electrical apparatus for the detection and

measurement of combustible gases

BS EN ISO 5817 Quality levels for imperfections in arc welded joints

BS EN ISO 10380 Corrugated metal hoses
BS EN ISO 15614-1 Special qualification for welding procedures. Arc and

gas welding

BS ISO 15348 Metal bellows expansion joints
PD CLC/TR 50404 Control of static electricity.
A2.5 MISCELLANEOUS (abbreviated titles)
 GIS/PL2-1 General & PE compounds for use in PE pipes and

fittings

GIS/PL2-2 PE pipes for use at pressures up to 5.5 bar

GIS/PL2-3 PE butt fusion tooling and ancillary equipment

GIS/PL2-4 PE fusion fittings with integral heating element(s)

GIS/PL2-5 PE electrofusion ancillary tooling
GIS/PL2-6 PE spigot end fittings for electrofusion and/or butt

fusion purposes

GIS/PL2-7 PE squeeze off equipment

GIS/PL2-8 PE pipes for use at pressures up to 7 bar
GIS/PL3 Self anchoring mechanical fittings for polyethylene

pipe for Natural Gas and suitable manufactured gas
GIS/V7-2 Plastic bodied valves of sizes up to 180 mm suitable

for operations at pressures not exceeding 5.5 bar

ISO R 7 Threads
ECA Guidance on main and supplementary bonding for BS

7671

BG IM/20 (obsolete) Weep by-pass proving systems

ASTM A182 Forged or rolled alloy steel pipe flanges, etc.

ASTM A193 Alloy steel and stainless steel bolting materials
ASTM A269 Seamless and welded austenitic stainless steel

tubing

ASTM A313 Stainless steel spring wire

ASME B31.3 Process piping

ASME B36.19 Stainless steel pipe

API 5L Linepipe
DVGW VP614 Non-detachable pipe connectors for metal gas

pipes-press fittings. High temperature test
HAUC Specification for the reinstatement of openings in

highways
ISO 12176 Plastic pipes and fittings.
105
APPENDIX 3 : GAS FLOW THROUGH PIPEWORK
A3.1 GENERAL
Basic flow analysis problems may be solved readily using a hand held disc
calculator or small computer programme of which the accuracy is acceptable for
most pipework.
Table 21 and 22 may be used for estimating low pressure pipe sizes.
Where calculators/computers are not available or where Table 21 is not

applicable, the following formulae may be used:
(a) For P  75 mbar
Q = 57.1 x 10-5 [p d5(s L f)-1]0.5
(b) For P > 75 mbar  5 bar
Q = 12.7 x 10-3 [(P12 – P22)d5(s L f)-1]0.5.
Q = gas flow rate (m3 h-1)

p = pressure loss (mbar)
d = internal pipe diameter (mm)
s = density of gas relative to air
L = length of pipe (m)
f = friction factor.
P1 = upstream pressure (bar)
P2 = downstream pressure (bar)
106
MOP ≤ 75 mbar. PIPE LENGTHS 5 m to 250 m.
(p AIR = 1.0) AND WITH 2.5 mbar DIFFERENTIAL FOR p GAS = 1.5,
1 mbar PRESSURE DIFFERENTIAL BETWEEN EXTREMES, FOR p GAS = 0 .6
TABLE 21 - APPROXIMATE FLOW IN STRAIGHT HORIZONTAL PIPES WITH
Carbon & Copper PE Pipe length (m)
stainless SDR
steel tube 11/17 5 10 15 20 30 40 50 75 100 150 200 250
15 2.5 1.8 1.5 1.2

15 1.7 1.1 0.9 0.8
20 6.5 4.3 3.4 2.9 2.3 2 1.7
22 6.4 3.8 3.1 2.8 2.3 2 1.7

25 5 3.5 3.1 2.5 2 1.9 1.7
25 12 8 6 5.5 4.5 3.5 2
28 13.1 8.8 6.7 5.9 4.7 4 3.5
32 11.5 8 6.5 5.5 5 4 3
32 19 15.5 13 11 8.5 7.5 6.5 5 4.5
35 19 14 11 10 8 7 6 5 4.5
55 40 30 28 25 21 18 15 12 10
40 38 28 23 19 15 13 11 9 7
42 32 23 18 16 13 11 10 8 7
50 75 52 42 35 28 24 22 18 15 12 10
54 70 49 40 35 28 24 22 18 15 12 11
63 75 57 45 38 28 25 23 18 15 12 10
65 140 95 80 65 55 45 40 32 27 22 19 16
67 129 91 75 64 53 45 40 33 29 33 20 18
89
80 240 170 135 115 90 85 75 60 50 40 35 30

76 179 126 103 89 73 63 56 46 40 32 28 25
90 240 170 135 115 95 85 75 60 50 40 35 30
100 500 370 250 210 170 150 130 110 90 70 60 50
108 470 330 270 235 190 165 150 120 105 85 75 65
125 480 360 300 250 220 200 180 150 120 100 85 75
150 1300 950 750 650 550 460 420 350 300 250 210 180
180 1400 # 1100 850 750 600 530 480 380 340 270 230 200
200 2400# 1900# 1600 1400 1200 1000 900 750 660 550 460 425
250 2300# 2300# 1600 1500 1200 1000 900 750 660 550 460 425
250 3700# 3500# 2800 2500 2000 1750 1600 1250 1100 900 800 700
315 3600# 3600# 3000 2700 2150 1850 1700 1350 1200 1000 850 775
300 5300# 5300# 4900 4200 3500 3000 2700 2200 1900 1500 1300 1200
Not e 1: Mat er ials sizes are show n as nom inal diam et er ( m m ) .
Not e 2: # = higher flow rat es exceed 20 m s- 1 .
107
A3.2 FRICTION FACTOR (f)
The friction factor is very difficult to predict with accuracy. It is dependent on a

number of variables including pipe roughness, velocity and Reynolds number.
For NG, a reasonable approximation for friction factor is:
f = 0.0044 [1+43.5 d-1]

d = internal pipe diameter (mm).
Not e: This form ula is not valid for pliable st ainless st eel pipe t o BS EN 15266.
However, for any gas, a more reliable value may be obtained from:
fsp/e2 for Smooth pipe Law

fsp = (14.7519 + 3.5657X + 0.0362X2)-2 and is smooth pipe friction factor (dimensionless)
e = efficiency factor = 0.86 for steel pipe and 0.97 for coiled or electrofused PE pipe
X = log10 Re – 5
Re = Reynolds No.
In the UK, take Re = 25043 x Q/d for NG and 83955 x Q/d for LPG.
Where Q = flow of gas m3 h-1, gas at S.T.P

d = internal pipe diameter mm
A3.3 PRESSURE LOSS DUE TO PIPEWORK FITTINGS AND COMPONENTS
Allow for pressure loss due to fittings as suggested in Table 22 below, or with
manufacturers’ information, as appropriate. Refer to manufacturers’ information
for details of pressure loss due to flexible connections, secondary meters, check
valves, regulators, etc. Isolation valves, full bore plug and ball valves normally
have negligible pressure loss. Butterfly and other valves may have significant
pressure loss – these need to be confirmed with the manufacturer/supplier.
NOMINAL PIPE SIZE (mm) EQUIVALENT LENGTH (m)

45  bend, 90  bend, 90  elbow,
90  long
Steel* Copper PE Tee Tee
full bore bush & entering entering
bend, valve, socket from a into a
bush & union, (more than branch branch
socket adapter, one (use (use
(one flange joint, change of largest largest
change of through tee size) size) size)
size)
15 18 0.15 0.20 0.40 0.75 1.2
22 0.20 0.30 0.60 1.20 1.8
25 28 32 0.25 0.40 0.80 1.50 2.3
32 35 - 0.30 0.50 1.00 2.00 3.0
40 42 55 0.40 0.60 1.20 2.40 3.5
50 54 63 0.50 0.80 1.50 3.00 4.5
65 67 - 0.70 1.00 2.00 4.00 5.5
80 76 90 0.80 1.20 2.30 4.50 6.6
100 108 125 1.00 1.50 3.00 6.00 9.0
150 - 180 1.50 2.30 4.50 9.00 13.5
200 - 250 2.00 3.00 6.00 12.00 18.0
250 - 315 2.50 3.80 7.60 15.00 22.5
Not e: For CSST refer ence needs t o be m ade t o t he m anufact ur er’s dat a.
TABLE 22 – PRESSURE LOSS IN PIPEWORK FITTINGS AND

COMPONENTS
108
A3.4 EFFECT OF ALTITUDE
Compensation for the effects of altitude is to be made for pipes in high rise
buildings. Lighter than air gases will show an increase in pressure above ground
level due to altitude whereas for heavier than air gas the reverse is true. The
following formula may be used:
h = 0.123 (1-s) H
h = pressure change due to altitude (mbar)

H = altitude change (m)
s = density of gas relative to air (dimensionless)
109
APPENDIX 4 : CALCULATING ALLOWABLE PRESSURE LOSS
Example 1 : A standard installation
A small industrial unit is supplied with gas from a low pressure network (≤75 mbar) via a
meter installation which is marked as having a metering pressure of 21 mbar. The consumer’s
appliances consist of a mixture of heating and catering appliances, and the consumer is not
clear as to what type of appliances he might fit in the future.
What is the allowable pressure drop across the system? And what would STP need
to be?
Being a standard 21 mbar metering pressure, the pressures stated in Note 2 of clause 4.1.2
can be assumed for the meter installation.
STPmi = in excess of 82.5 mbar

MIPmi = less than 75 mbar
PLOPmi = 25 mbar
LOPmi = 18 mbar
DmPmi = 15 mbar.
As the consumer is not being clear about the types of appliances that may be added in the
future, you have to assume that “standard” appliances may be added at some stage in the
future. As such, the pressures below have to be assumed.
STP = 50 mbar
Pmax = 25 mbar
OP = 20 mbar
Pmin = 17 mbar
Pign = 14 mbar (70% OP).
From these pressures, it can be seen that the pipework will need to be tightness tested to
cope with the 75 mbar MIP that the meter installation may subject it to, for which IGE/UP/1
requires STP of at least 82.5 mbar.
The pressure drop is of most significance when the installation is operating under full load
condition and minimum inlet pressure. As such, the important pressures are DmPmi, Pmin, LOPmi
and Pign.
CONDITION METER INSTALLATION APPLIANCE ALLOWABLE

OUTLET PRESSURE INLET DIFFERENTIAL
PRESSURE PRESSURE
LOP. Lowest pressure LOPmi = 18 mbar Pmin = 17 mbar 1 mbar
experienced under
normal operation.
Need to ensure safe
and efficient operation
of appliances.
DmP. Minimum DmPmi = 15 mbar Pign = 14 mbar 1 mbar
pressure expected
under extreme
conditions. Need to
ensure safe operation
of appliances.
Maximum allowable differential pressure (is the worst of the above two 1 mbar
conditions. In this case, they are the same).
110
Example 2 : A non- standard installation
A factory is supplied with gas from an intermediate pressure network ( 4 bar) via a meter
installation which is marked as having a metering pressure of 21 mbar. The meter installation
is dedicated to a set of boilers. The consumer has advised that the boilers will operate safely
and efficiently with an inlet pressure of 12.5 mbar, and that no other appliances will be
connected to this gas supply in the future.
What is the allowable pressure drop across the system? And what would STP need
to be?
Being a standard 21 mbar metering pressure, the pressures stated in Note 2 of clause 4.1.2
can be assumed for the meter installation.
STPmi = in excess of 82.5 mbar

MIPmi = less than 75 mbar
PLOPmi = 25 mbar
LOPmi = 18 mbar
DmPmi = 15 mbar.
From the information provided by the consumer:
Ρmin
Ρign
= 12.5 mbar
= 12.5 mbar.
From these pressures, it can be seen that the pipework will need to be tightness tested to
cope with the 75 mbar MIP that the meter installation may subject it to, for which IGE/UP/1
requires a STP of at least 82.5 mbar.
The pressure drop is of most significance when the installation is operating under full load
conditions and minimum inlet pressure. As such, the important pressures are DmPmi, and Pmin,
LOPmi, and Pign.
CONDITION METER INSTALLATION APPLIANCE PRESSURE

OUTLET PRESSURE INLET PRESSURE DROP
LOP. Lowest pressure LOPmi = 18 mbar Pmin = 12.5 mbar 5.5 mbar
experienced under
normal operation.
Need to ensure safe
and efficient operation
of appliances.
DmP. Minimum DmPmi = 15 mbar Pign = 12.5 mbar 2.5 mbar *
pressure expected
under extreme
conditions. Need to
ensure safe operation
of appliances.
Maximum allowable pressure drop (is the worst of the above two 2.5 mbar *
conditions).
*This example permits 2.5 mbar differential pressure; however if the plant is ON/OFF and
rate of change in demand is rapid, for example for a single appliance, booster or compressor,
a lower pressure drop is advisable.
111
APPENDIX 5 : WALL THICKNESS OF PIPEWORK
A5.1 CARBON STEEL
Table 23 is a guide to the grades and wall thicknesses of steel pipe and that are
recommended (R) or simply acceptable (A).
PIPE PIPEWORK IN DUCTS OR ABOVE BURIED PIPEWORK

GROUND
Spec. BS EN 10255 BS EN BS EN 10255 BS EN

10216/10217 10216/10217
and API 5L and API 5L
Grade Medium Not stated Heavy Not stated
Application
Screwed R A R A
Welded A R A R
Nominal bore Recommended minimum Recommended minimum

pipe wall thickness pipe wall thickness
mm mm mm mm mm
15 2.6 2.6 3.25 3.2

20 2.6 2.6 3.25 3.2
25 3.2 3.2 4.05 4.0
32 3.2 3.2 4.05 4.0
40 3.2 3.2 4.05 4.0
50 3.6 3.6 4.5 4.5
80 4.0 4.0 4.85 5.0
100 4.5 4.5 5.4 5.4
150 5.0 5.0 5.4 5.4
200 5.4
250 5.4
300 5.6
Not e: I n pract ice, a lim it ed range of wall t hickness will be available for each nom inal bore. This
m ay m ean using a wall t hickness differ ent from t he above because of av ailabilit y.
TABLE 23 - WALL THICKNESS OF CARBON STEEL PIPE
A5.2 STAINLESS STEEL
A5.2.1 Table 23 is a guide to the grades and wall thicknesses of stainless steel pipe.
The pipe wall thicknesses quoted in Table 24 are as given in ASME B36.19
Schedule 40S. Schedule 5S and 10S thicknesses may not be adequate for
threading or for use with some types of compression fitting. It is important to
check the required wall thickness with the fitting supplier.
112
STAINLESS STEEL PIPE WALL THICKNESS

Nominal diameter Typical minimum wall
(mm) thickness (mm)
10 2.6
12 2.6
15 2.6
20 2.6
25 2.6
40 2.6
50 2.9
65 2.9
80 3.2
100 3.2
125 3.6
150 4.0
200 4.5
250 5.0
TABLE 24 – WALL THICKNESS OF STAINLESS STEEL PIPE SCHEDULE 40
A5.2.2 Stainless steel tubing is a special pipe product having gauged outside
dimensions for use with specialist compression fittings. The fitting manufacturer
needs to be consulted to ascertain the correct outside dimensions. These
products are normally used for pressure ranges above 0.5 bar and wall
thickness is shown in Table 25.
STAINLESS STEEL TUBE WALL THICKNESS

(mm) thickness (mm)
12 1.0
16 1.5
18 1.5
20 2.0
25 2.5
TABLE 25 – WALL THICKNESS OF STAINLESS STEEL TUBE
A5.3 COPPER
Copper tubing is a special pipe product having gauged outside dimensions for
use with specialist compression fittings. The fitting manufacturer needs to be
consulted to ascertain the correct outside dimensions. These products have wall
thicknesses as shown in Table 26.
COPPER TUBE WALL THICKNESS

(mm) thickness (mm)
12 1.0
16 1.0
18 1.0
20 1.0
22 1.0
25 1.5
28 1.5
32 1.5
36 1.5
42 1.5
50 2.0
65 2.0
80 2.0
90 2.0
100 2.0
108 2.0
TABLE 26 – MINIMUM WALL THICKNESS OF COPPER TUBE
113
A5.4 POLYETHYLENE (PE)
21) are generally suitable for use at MOP ≤ 0.5 bar.

Available diameters of PE 80 (SDR 11, 17, 21 and 26) and PE 100 (SDR 11 and
Nominal Outside Wall Thickness

Diameter Diameter
SDR11 SDR17.6 SDR21 SDR26
Min Max Min Max Min Max Min Max Min Max
20 20 20.3 2.3 2.7 - - -
25 25 25.3 2.3 2.7 - - -
32 32 32.3 3.0 3.4 - - -
50 50 50.4 4.6 5.2 - - -
63 63 63.4 5.8 6.5 4.7 5.3 - -
75 75 75.5 6.8 7.6 5.6 6.3 - -
90 90 90.6 8.2 9.2 5.2 5.9 - -
125 125 125.8 11.4 12.7 7.1 8.0 - -
140 140 140.9 12.7 14.1 8.0 8.9 - -
180 180 181.1 16.4 18.2 10.3 11.5 - -
250 250 251.5 22.7 25.1 14.2 15.8 11.9 13.2 9.6 10.7
280 280 281.7 25.4 28.1 15.9 17.6 13.3 14.8 10. 11.9
315 315 316.9 28.6 31.6 17.9 19.8 15.0 16.6 12.1 13.5
355 355 357.2 32 35.7 20.2 22.4 16.9 18.7 13.7 15.2
Not e 1: For pipe sizes 16m m and 20m m t he act ual values are SDR7 and SDR9 respect ively due t o
m inim um wall t hickness considerat ions.
Not e 2: SDR17.6 wall t hickness dim ensions for pipe sizes 63m m and 75m m ar e act ually SDR13.6.
TABLE 27 - WALL THICKNESS OF PE PIPE
114
APPENDIX 6 : INSTALLATION PIPEWORK WITH MOP ABOVE 0.5 BAR

UP TO 60 BAR (REQUIREMENTS OF BS EN 15001)
This part of IGEM/UP/2 has been written to align with BS EN 15001.
A6.1 QUALITY SYSTEM
A quality system shall be applied to the design, construction, and testing

activities taking into account the requirements for testing, commissioning,
operation and maintenance in IGE/UP/1 and IGEM/UP/2.
Not e: Refer ence m ay be m ade t o t he EN I SO 9000 series of st andards or t o equivalent qualit y
syst em st andard.
A6.2 DESIGN AND TEST PRESSURE
A6.2.1 Design pressure (DP) and STP of the gas installation are based on the MOP of
the point of delivery.
Not e: Where used in t his par t of t he St andard, DP is equiv alent t o t he m axim um allowable
pressure ( PS) as given in PED. PS is t he m axim um pr essure for which pipework is designed
in accordance wit h t he st r engt h requir em ent s which would nor m ally be not less t han t he
st rengt h t est pressure ( STP) .
A6.2.2 MIP shall be less than or equal to 1.1 times DP and pressure testing shall be at
least to MIP.
A6.3 PRESSURE REGULATING AND CONTROL SYSTEMS
A6.3.1 Information on pressure regulating systems is given in IGEM/TD/13.
A6.3.2 Gas pressure regulators installed within pipework systems, other than those on
appliances shall conform to the requirements of BS EN 334 for lighter than air
gases and BS EN 13785 or BS EN 13786 for heavier than air gases. Safety slam
shut devices associated with gas pressure regulators shall meet the
requirements of BS EN 14382.
A6.3.3 The instrumentation applied to pressure safety systems shall comply with the

following requirements:
instrumentation wiring and pipework shall be dimensioned and installed
having due regard for their function. The instrumentation serving the
pressure safety system shall be independent from the other instrumentation.
The setting of the control system which forms part of the pressure safety

system shall be fixed, where necessary
isolation of the pressure detection components of the pressure safety system
from the system which it protects is not permitted, unless it leads to a safety
action.
A6.3.4 If a gas pressure regulating system is installed in an isolated enclosure, the

enclosure shall comply with the relevant requirements of BS EN 12186 or
IGEM/GM/8. It shall also have adequate ventilation in order to satisfy the safety
requirements of IGEM/SR/25.
A6.3.5 A gas pressure regulating system for one or more gas appliances may be
installed in the same room as the appliance(s) provided there is adequate
ventilation. The construction, layout, facilities and location of the room shall be
subject to compliance with the recommendations of risk assessment (see
IGEM/TD/13).
115
A6.3.6 External sensing lines
A6.3.6.1 Each safety device or pressure regulator shall have individual sensing lines
separately connected to the protected system. The connection of the sensing
lines for safety devices should be between the regulator and the first outlet
isolating valve. The sensing lines should be visible for reasons of safe operation.
A6.3.6.2 A valve in the sensing lines serving pressure regulators and safety devices
should not be installed when the connection of the line is upstream of the first
outlet isolating valve. Provisions can be made in sensing lines for switching
between sensing points with a three-way valve or two interlocked valves
provided that one of the sensing points is connected at all times.
A6.3.6.3 The sensing point selected for regulating and safety systems should be
reasonably free from turbulence and any effect resulting from changes in the
gas velocity or from high gas velocities in the installation, such that a
representative pressure condition is imposed on the instrumentation at all times.
Individual sensing lines can be connected to a header welded onto the inlet or
outlet pipework. To ensure strength and static pressure conditions, the diameter
of the header and the connection to the pipework shall be at least 40 mm or
equal to the diameter of the inlet or outlet pipework.
A6.3.7 Materials and components

The following material requirements shall be applied:
instrumentation pipes/tubes shall be in accordance with BS EN 1057 and

BS EN 10088-1
bolts, screws, studs, nuts and compression fittings shall be in accordance

with Table 28

creep relief valves shall meet the requirements of BS EN 334
all other metallic materials for pipes, fittings, and joints in regulating and
metering systems, other than instrumentation pipework, shall meet the
requirements of Clause 5 of BS EN 15001.
MATERIALS RESTRICTIONS
DESCRIPTION TYPE RELEVANT DESIGN
STANDARD PRESSURE
(bar)
11 SMnPb30/1.0718
Compression and 11 BS EN 10087
fittings SMnPb37/1.0737 both 60
 d  100
with a min 8% and 5
All steel designations BS EN 10088-3

Class 10.9 BS EN ISO 898-1
50
Class 10 for nuts BS EN 20898-2
Bolts, screws,
Class 4.6, 5.6, 8.8 BS EN ISO 898-1
studs and
nuts* Grade A2ss, A4ss BS EN ISO 3506-
1 60
BS EN ISO 3506-
2
Classes 5, 8, 9 for nuts EN 20898-2
TABLE 28 – MATERIALS FOR COMPRESSION FITTINGS, BOLTS, NUTS,

ETC.
116
A6.4 FILTRATION
The requirement for filters is set out in Sub-Section 4.2.9.
A6.4.1 For filters larger than 150 mm2 or those operating above 0.5 bar a means of
measuring the pressure drop across the filter shall be installed.
A6.4.2 For filters operating above 0.5 bar, a differential pressure gauge should be
considered to indicate the level of contamination of the filter.
A6.5 MATERIALS
A6.5.1 Carbon steel pipes
A6.5.1.1 Pipes shall conform to BS EN 10220 for diameters from 17.2 mm upwards and
the materials shall comply with BS EN 10255, BS EN 10208, BS EN 10216, BS
EN 10217 or ISO 9329-2 as appropriate for DP of the system.
A6.5.1.2 Pipes with threaded joints are permitted for 5 bar and below, but this is limited
for pipes with nominal diameter less than and equal to 50 mm.
A6.5.1.3 Branches should preferably be formed using tees with dimensions in accordance
with BS EN 10253-2.
A6.5.1.4 Branches constructed using preformed manufactured fittings shall comply with
Table 10.
A6.5.1.5 Site manufactured branches, that is not preformed manufactured fittings can be
up to half the diameter of the main pipe, with a maximum of DN 25 if executed
without reinforcement and a maximum of DN 50 if executed with reinforcement
or using a weldolet fitting.
For information of split tee, branch or welding stubs refer to the hot-tapping
procedure described in Sub-Section 7.12.
A6.5.2 Stainless steel tube (as used with high pressure compression fittings)
Such ‘tubing’ shall be typically manufactured to American Code ASTM A213 or

A269 with the material grade being 316 or 316L. The minimum wall thicknesses
shall be as shown in Appendix 5 Table 26.
A6.5.3 Copper pipes
Pipes shall conform to BS EN 1057 and be grade R250 (half hard, elongation
20%, hardness 75 to 100 N mm-²) and shall have a wall thickness in accordance
with Table 27.
A6.5.4 Material test certificates
All material test certificates for pressure parts shall comply with BS EN 10204.
117
A6.6 FLANGE NUTS AND BOLTS
A6.6.1 Nuts and bolts for carbon steel and PE flanges shall be selected in accordance
with Table 29. For stainless steel flanges, BS EN 1515-2 shall be considered.
A6.6.2 Nuts and bolts for flanges of other materials shall have the normal commercial
quality (see BS 6104-2 for nuts and BS EN 20898-1 for bolts).
A6.6.3 In situations where vibration can occur, the nuts shall be effectively locked.
A6.6.4 In exceptional cases where smaller diameter bolts are used for insulating
flanges, they shall be of sufficiently higher grade so that at least the same force
can be applied.
STANDARD DESIGN NOMINAL BOLT/STUD NUTS

PRESSURE DIAMETER GRADE
(bar) (mm)
1 >150
EN 1515-1 and 4 >125 Nuts may
6
be one
EN 1515-2, >125 >/= 5.6
 10
grade lower
EN ISO 898-1 >100 to prevent
 16
EN 20898-2 thread pick-
>65
up.
>16 All >/= 8.8
TABLE 29 – NUTS AND BOLTS FOR CARBON STEEL AND PE FLANGED

JOINTS
A6.7 INSPECTION OF WELDED STEEL JOINTS
A6.7.1 Inspection criteria of welded joints
Adequate weld quality shall be assured by visual inspection and non-destructive

and/or destructive examination.
The results shall be recorded in writing.
Welding on pipework shall be inspected such that the quality of each welder’s
work can be adequately evaluated.
The minimum extent of non-destructive examination shall be in accordance with

Table 31, with a minimum of three welds.
The number of welds examined by non-destructive examination shall be spread

evenly over the different diameters.
Reports on weld quality shall be available for the welds examined non-
destructive examination.

No radiographic examination is required in the following cases:

if DN is less than or equal to 50 and the OP is less than or equal to 2 bar
if DN is less than or equal to 25.
118
QUALITY TYPE/POSITION VISUAL RADIOGRAPHIC SURFACE

CATEGORY OF WELD EXAMINATION AND/OR CRACK
ON THE BY WELDING ULTRASONIC TEST
BASIS OF EXPERT EXAMINATION
DP AND
PARENT
DP:  5 bar
METAL
Circumferential
pipe fittings Rt0.5 

and welds on pipes and
10% 10%
Parent
metal: 360 N mm-2
Group 1 as Branches, fillet 10% 10%
per welds
EN ISO Longitudinal welds 100% 10%
15614-1
Yield
Rt0.5  360
strength:
N mm-2
DP: Circumferential
5 bar to 16 welds on pipework
20% 10%
Rt0.5  360 N mm-2
bar and pipe fittings
and
Parent Pipework in built- 20% 10%
metal: up areas
Group 1 as Branches, fillet 100% 10%
per welds
EN ISO Longitudinal welds 100% 100%
15614-1
Welds which
Yield 100% 100%
cannot be tested
Rt0.5  360
strength:
hydrostatically
N mm-2
TABLE 30 – MINIMUM EXTENT OF NON-DESTRUCTIVE EXAMINATION
A6.7.2 Examination and testing of welds
A6.7.2.1 The quality of the welding shall be inspected visually as far as possible as work
progresses. The application of equivalent acceptability standards for other non-
destructive examination procedures shall require advance approval on a case-
by-case basis.
A6.7.2.2 The welds shall be examined radiographically and/or to enable the quality of the
welding, and the competence of the welders, to be assessed. If one or more
unacceptable welds are found in the random sample, another 10% of the
unexamined welds and the repaired welds shall be examined.
A6.7.2.3 All welds in pipework at crossings with civil engineering works (roads, railway
tracks, watercourses) and all tie-in welds and weld repairs shall be subjected to
full (100%) non-destructive examination.
A6.7.2.4 Non-destructive examination shall be carried out in accordance with following

standards:

Visual inspection of joints: BS EN 970, BS EN 12732

Ultrasonic examination: BS EN 583-1, BS EN 1714 BS EN 12732
Radiographic examination: BS EN 1435
119


Magnetic testing: BS EN 1290
Penetrant testing: BS EN 571-1.
A6.7.3 Non-destructive examination — Acceptance requirements for welds
Quality levels for imperfections shall be in accordance with BS EN ISO 5817.
A6.7.3.1 Repairing welds
Before proceeding with a repair, consideration shall be given to whether the

repair can reasonably be expected to improve the quality of the weld. If not, the
weld shall be rejected. Rejected parts of welds shall be cut out of the pipe and
re-welded and then re-inspected.
Parts of welds containing unacceptable defects shall be removed by grinding or

cutting down to sound metal before proceeding with repair. Slag and oxide
deposits shall be removed. Repairs shall be carried out in accordance with an
approved procedure. No further repairs are permitted on repaired parts of a
weld. All repairs shall be examined.
A6.7.3.2 Testing personnel
Destructive testing and non destructive testing shall be carried out by

competent persons who are appropriately qualified for the duties they are to
perform according to an appropriate recognised international or national
standard. Non Destructive Examination personnel shall at least be qualified to
level 2 of BS EN 473.
Not e: All com panies providing such personnel w ill be cert ificat ed according t o an appropriat e
st andard ( for exam ple BS EN 17020) .
A6.8 BURIED PIPEWORK
A6.8.1 Buried pipework at crossings with site roads or site rail tracks shall be laid with

least one of these requirements:

depth of cover over the pipework of at least 1 m;
a row of concrete slabs approximately 1 m wide laid above the pipework at

0.3 m to 0.5 m below ground level;
increased pipe wall thickness to accommodate increased external loading
calculated in accordance with BS EN 1594.
Alternatively, the pipe crossing can be installed in a protecting sleeve, taking

due consideration of any cathodic protection requirements for the pipework (see
BS EN 12954).
Not e: These r equirem ent s m ay be less t han t hose specified in Sect ion 8, which would probably
t ake pr eference.
A6.8.2 Insulating joints
The buried and above-ground sections of metal (copper, carbon steel and
stainless steel) pipework shall be galvanic isolated from each other by insulating
joints or ebonited insulating flanges. This separation should be made above-
ground at no more than 0.5 m above ground level or at the point of entry into a
building in accordance with Section 9. Electrical test points shall be provided on
both sides of the insulator. Care shall be taken to ensure that no unintended
bridging of insulating joints is possible.
120
To avoid damage to insulating joints resulting from high voltage due to lightning
or earth currents caused by electric power lines, installing protective devices
(for example, an appropriate spark arrestor) should be considered.
If an insulating joint is to be installed in areas classified as hazardous in

accordance with BS EN 60079-10, it is essential that it conforms to the
certification and operational requirements of the zone.
A6.8.3 Cathodic protection for carbon steel pipework (see clause 8.4.2.3)
General
Carbon steel pipework shall be cathodically protected in accordance with

EN 12954. Short lengths of steel pipework may not need the application of
cathodic protection provided it is coated with a double wrapping or a shrinkable
material to EN 12068.

Cathodic protection is not required if all the following conditions are met:
the specific resistance of the environment is over 100  m;


the acidity is low (pH > 6);
the influence of any stray currents is below the level permitted under the

cathodic interference criteria;
the environment is not anaerobic.
If high contact resistances can occur between components of the pipework

which require cathodic protection (for example at flanged joints) the
components shall be electrically connected.
To enable the cathodic protection system to function effectively, gas pipes shall
be galvanically isolated from their supports by insulating shells.
To ensure galvanic isolation of the pipework, care shall be taken to ensure that
valves are insulated from the earth.
A6.8.4 Insulating joints
If the insulating joint or ebonited insulating flanges are located inside the
building, it shall be possible to test the efficiency of the joint. Where applicable,
test points shall be connected by insulated cables to a measuring cabinet
located above ground and readily accessible. The cabinet shall be at least to
IP54 according to BS EN 60529 and lockable (see Figure 17). All test points and
bare wires shall be covered by an insulating material.
A6.8.5 Attachment of test cables to carbon steel pipes
Test cables shall be connected to the pipe using 10 mm 2-copper cable having
coloured PVC insulation, see Figure 26. The cable should be attached to the
pipework using an appropriate method, e.g. exothermic welding, according to
the relevant instructions (see BS EN 12732). The connection procedure shall not
damage or weaken the pipe surface. On completion of the work, the pipe
coatings shall be repaired.
121
FIGURE 26 – EXAMPLE OF CONFIGURATION OF TEST POINTS
A6.9 DOCUMENTATION
A6.9.1 General
The designer of the gas installation shall provide information concerning its
design, construction, examination, operation and maintenance in form of a
technical file. The file shall contain information appropriate for the size and
complexity of the installation so that the owner/user can operate it safely.
A6.9.2 Technical file

The technical file shall include the following information, as appropriate:

a diagram of the installation pipework
details of design standards used, evidence of testing of materials and
components together with any Certificates issued by test

bodies/manufacturers

DP and temperatures, maximum and minimum

flow rates and discharge capacities

function and duty of protective controls
corrosion allowances.

Not e: Mat erial w all t hicknesses of pipes.

materials of construction and design calculations, where performed

welding standards and test procedures

commissioning procedures
testing and re-testing procedures
122


purging procedures or methodology

setting of pressure regulators and safety devices

operating manual
decommissioning and maintenance procedures including in-service
inspections.
After inspection and testing, the technical file shall be completed with the results
of all inspection and testing.
A6.9.3 Installation drawings for the technical file
The installation drawing shall contain the following information (with a parts list

as appropriate):

the location (route) of the installation pipework

the pipe diameters, MIP, DP, OP, materials and coatings

the location and design of supports
the location and design of wall and floor transits, points where pipework

crosses or runs parallel with other systems, etc.
location of ancillaries, stating the make, type, connection sizes and type of

material

joints, gaskets, bolts, etc.
location and layout of internal gas pressure regulating systems, stating the

required settings for regulators and safety devices

the location and sizes of valved points for testing and purging
maximum flow in pipework sections including any extension, expressed in

m3 h-1 under normal conditions
cathodic protection system, where fitted.
The gas appliances to be connected to the system shall be specified separately,

stating:

supplier/make and type

maximum flow, in m3 h-1 under normal conditions
minimum and maximum operating pressure.
A6.10 COMMISSIONING

Commissioning shall include the following:

verification that the technical file is complete including all test results
verification that all corrosion protection measures have been applied
correctly and any cathodic protection is operational. Coatings on buried

pipework shall be inspected and tested prior to backfilling of any trench

verification that strength test has been completed, see IGE/UP/1

verification that tightness test has been completed, see IGE/UP/1

verification that the purge to gas has been completed, see IGE/UP/1
checking the function of regulators, safety devices and valves.
Not e: Where purging does not im m ediat ely follow t he st rengt h and t ight ness t est as required

by I GE/ UP/ 1t hen prior t o pur ging, an addit ional t ight ness t est shall be perform ed.
the results of the inspections and associated operations are recorded in the
technical file.
123
APPENDIX 7 : PRESSED FITTINGS. JOINTING PROCEDURE
A7.1 For all pressed joints, ensure that operatives have been trained, for example by
the manufacturer, and know the installation procedure for jointing given by the
manufacturer of the fitting or system manufacturer and that they are qualified
according to appropriate procedures as prescribed by national qualification
bodies.
A7.2 Check that the pressing tool is marked to indicate it complies with the
appropriate standard and such that a pressing cycle cannot be stopped without
completion of the whole pressing cycle. Completion occurs when the jaws or
collars of the press tool totally enclose the mouth of the fitting. In the event of
the cycle being abandoned before completion of the pressing action, discard the
joint and fitting and repeat the complete process on new components.
A7.3 Use a method of traceability to confirm the technical compatibility of the press
tools and the pressed fitting, for example by a permanent mark on the fitting.
A7.4 Follow the maintenance instructions as specified by the manufacturer for the
pressing tools, including jaws and collars, and the expanded tools, including the
expander heads.
A7.5 Make the jointing procedure available on site at all times during the jointing
operation.
A7.6 Never fit a pressed joint onto or into a pipe by welding, brazing or soldering.
A7.7 When constructing a pressed joint, take the following recommendations (as a
● visually inspect the pipe for suitability and cleanliness

minimum) into account:
● cut and prepare the pipe according to the manufacturer’s instruction

manual and by using the recommended cutting tool, in order to achieve a
● clean and deburr the outside and inside of the ends of the pipes after
clean and square cut
● mark the pipe to show the correct insertion depth into the fitting
cutting to length (when prescribed by the manufacturer)
● choose the appropriate fitting, the size of which fits the pipe size
● visually inspect the fitting and the pipe ends after preparation
● check the presence of the appropriate seal o-ring for the gas application
● use the pressing tool recommended by the fitting manufacturer and the
[yellow or grey] and not for any water application [black]
● where necessary, use the expander tool with the appropriate expansion
appropriate press sets (jaws, collars) related to the correct diameter
heads recommended by the system manufacturer and follow the specified

procedures.
A7.8 It is important to consider that compatibility and instructions are in place before
using these fittings and to:
 check that the fittings to be used are specifically designed for use on gas
(similar fittings are available for water)
 ensure the fittings are not painted with oil or solvent-based paints.
124
APPENDIX 8 : COMPLIANCE WITH DSEAR
A8.1 INTRODUCTION
This appendix is taken from IGEM/SR/25 Edition 2 Hazardous Area classification

of Natural Gas installations and applies to Natural Gas (see scope) pipework. For
LPG pipework refer to Energy Institute publication EI IP-MCSP-P15.
DSEAR is concerned with protection against risks from fire, explosion and similar
events arising from dangerous substances used or present in the workplace and
applies to all gas installations in industrial and commercial properties. It does
not apply within the domestic dwelling but does apply to common parts of
domestic buildings such as the pipe riser and boiler house in multi-storey flats.

DSEAR requires the site occupier and the employer to:
carry out a risk assessment of any work activities involving dangerous

substances

provide measures to eliminate or reduce the risk

provide equipment & procedures to deal with accidents & emergencies

provide information & training
classify places & mark zones.

The risk assessment is an identification and examination of:

gas systems in a workplace

work activities involving gas
potential failure modes.

Taking account of:

hazardous properties

utilization & storage

possibilities of explosive atmospheres occurring
all potential ignition sources.
Measures identified by the risk assessment have to be put into place. Where a
risk cannot be eliminated Control & Mitigation methods should be applied.

Control Measures:

avoid or minimise releases

control releases at source

prevent formation of an explosive atmosphere

collect, contain & remove releases (ventilate)
avoid ignition sources.

Mitigation Measures:

contain the spread of fires & explosions

minimise exposed employees
provide equipment to contain/suppress.
Correctly installed gas pipework (to IGEM/UP/2) has a good safety record in the
UK. Catastrophic pipe failure is very rare and usually the result of accidental
damage.
125
Pipework leakage due to joints in a well ventilated area such as the boiler-
house, has a very low risk factor.
For more information on this subject see IGEM/UP/16.
The intention of the Risk Assessment is also to define what if any zonal
classification applies to the installation. In this respect gas pipework is normally
classified as requiring Zone 2 protected equipment. However IGEM/SR/25
Edition 2 describes the application of a Zone 2 NE (Negligible Extent)
classification for low pressure pipework described below. In practice this means
that although the zone will be classified as Zone 2 NE, providing the
requirements specified below are met then there will be no requirement for
special equipment or controls.
Not e 1: The Zone Classificat ion m ay be described as being a m easure of t he likelihood of a
flam m able gas/ air m ixt ur e being pr esent in a part icular area, known as a Zone and t he
ext ent of which is “ X” .
The classificat ion m ay be Zone 0, Zone 1 or Zone 2 and could be of Negligible Ext ent ( NE) .
Under DSEAR it is not possible t o have a non- hazardous ( safe) area where a flam m able gas
exist s near pipe j oint s.
Not e 2: Wit h regard t o a hazardous area zone classified as NE ( t hat is where t he vent ilat ion can be
regarded as “ high” and t he leak rat e sm all) , no act ion is required t o cont rol sources of
ignit ion w it hin it . Lim it ing par am et er s apply t o t his sit uat ion. A zone of negligible ex t ent is
not t he sam e as a safe area even t hough neit her requir es act ion wit h regard t o pot ent ial
ignit ion sour ces. I n part icular, it m ay be t hat a zone of negligible ex t ent becom es m ore
onerous if vent ilat ion is reduced during m odificat ions t o buildings and housings.
A8.2 Low Pressure natural gas pipework with OP not exceeding 100mbar.
A8.2.1 Low pressure installation pipework downstream of a primary or secondary gas

meter has been determined to have a hole size for leakage calculations of
0.025 mm2. Where the location is unoccupied such as a duct space, a hole size
of 0.25mm2 is to be used.

But this is only applicable if the pipework:

was initially installed to a recognised standard such as IGEM/UP/2
was initially tested to an acceptable standard such as IGE/UP/1 (or its

derivatives) or its predecessor British Gas IM/5
is maintained according to IGEM/UP/2 including regular validation testing
that leakage is not occurring, for example by smell or by combustible gas

tester or by LDF
is located in a space with good ventilation, typically at least 0.5 air changes
per hour.

A8.2.2 Where the pipework:

is not in an occupied area or

is not ventilated into an occupied area (such as with a ventilated ceiling) or
has an MOP exceeding 100mbar.
then the hole size for leakage calculations is taken to be 0.25 mm2.
A8.2.3 Good maintenance that discovers any potential or actual leakage sources is
essential to maintain Zone 2 NE status.
A8.2.4 During the design it is important to minimise the number of joints and leakage
sources, to ensure adequate ventilation and to provide access for inspection and
maintenance.
Not e : ‘j oint s’ refers t o all leakage sources such as t hreads, union, flanges, press fit t ings,
com ponent casing or shaft seals but not t o soldered, brazed or welded connect ions.
126
A8.2.5 The ventilation of the space shall be sufficient to safely dilute a leak and this is
achievable using Table 4 below. In un-obstructed internal locations, the areas
around joints with an MOP not exceeding 2 bar may be classified as Zone 2 NE
provided they meet Table 4 requirements.
The ventilation of the space shall ensure that there are no stagnant areas
around the gas pipework, which by good pipework design or by the dispersion of
ventilation grilles and/or mechanical ventilation supplies within the space to
ensure air movement across any joints.
Wherever practical, joints shall not be located within 1 m of 3 surfaces (see

Figure 27). The sections marked by RED arrows cannot be classified as Zone
2 NE unless other provisions for safety are taken.
FIGURE 27 - AN EXAMPLE OF PIPEWORK LAYOUTS SHOWING

PREFERRED PIPE LOCATIONS TO ACHIEVE ZONE 2 NE
CLASSIFICATION
A8.3 UN-OBSTRUCTED LOCATIONS
In un-obstructed locations the possibility (depending on the mass release rate

and other factors) exists of applying Zone 2NE. These cases would include areas
with a few simple, possibly large, obstructions, but where there exists a clear
path for the ventilation to purge the area. For example, a pipe running along the
ground next to a wall would fall into this category.
A8.4 CONFINED INSTALLATION
A confined leak location is one where the presence of nearby obstacles can lead
to the initial high momentum of the jet release being reduced and the gas jet
re-entraining flammable gas, leading to a bigger gas cloud volume than
expected based on the enclosure ventilation rate and the gas release rate. In
such cases an assessment of the degree of local ventilation in comparison to the
leak size is difficult and therefore Zone 2 rather than Zone 2NE will generally
need to be applied.
If the leak location is close to three to more significant obstructions, for example
walls then the space around the leak location should be described as confined.
The floor will often count as one of the obstructions, which means that a leak
127
located in the corner of an enclosure (where two walls and the floor meet; see
diagram) will be confined.
A8.5 CONGESTED INSTALLATION
A congested leak location is one where there is a significant amount of small

scale obstacles that compromises the ventilation flow rate through that area. It
is possible that such an area, while congested, may not be described as confined
if there are no (or very few) large scale obstructions to the ventilation flow in
that area.
In cases that are initially identified as congested, but not confined, it is possible
that by further investigation (for example through tracer gas techniques, the
use of artificial smoke or modelling), it may be possible to demonstrate that the
leak location is in fact reasonably well-ventilated. In such cases, assuming that
other requirements are met, then Zone 2NE may be applicable.
An example of a congested installation is a complex and closely-spaced pipe

array in the open air. The bulk of the installation shall be classified Zone 2 with
a discrete zoning distance if it includes pipe joints (and maybe the whole of the
array would be classified for simplicity), but the periphery of the installation may
be classified Zone 2NE if the operating pressure permits.
A8.6 ADVERSE CONDITIONS
To determine whether ‘adverse conditions’ are present, the following factors

shall be considered, whether:
there is any vibrating equipment which may lead to premature failure of any

part of the gas system or components

the gas is clean and dry (see IGEM/SR/25 Edition 2)
the installation is operating in a potentially corrosive atmosphere/
environment, for example a coastal site.
If any of the above factors exist, the installation shall be treated as operating in
‘adverse conditions’.
128
Notional Leak Size

Pressure 0.025mm2 0.25mm2 *3 2.5mm2 *4
(mbar) 1 2 3 4 5 6 7 8
More than one One wall*1 More than one One wall*1 Air flow for More than one One wall*1 Air flow for
wall. wall. 10% LFL wall. 10% LFL
High and low High and low High and low High and low level High and low level High and low level
level vent grille level vent grille level vent grille vent grille free vent grille free vent grille free
free area in each free area in each free area in each area in each wall area in each wall area in each wall
wall wall wall
cm2 cm2 cm2 cm2 m3 h-1 cm2 cm2 m3 h-1
Up to 50 30*2 42*2 290 400 11.4
Exceeding 47*2 65*2 445 620 18.2

50 up to 100
Exceeding 630 880 25 15500 21700 250
100 up to 150
Exceeding 770 1075 31.8 17900 25100 318
150 up to 200
Exceeding 885 1240 36.3 21900 30700 363
200 up to 300
Exceeding 1090 1520 45.4 25300 35400 454
300 up to 400
Exceeding 1250 1760 52.2 28300 39600 522
400 up to 500
Exceeding 1400 1970 56.8 58100 81300 568
500 up to 1000
Exceeding 1860 2610 77.2 77000 107800 772
1000 up to 2000
*1 Vent ilat ors should where possible be spr ead on m ore t han one wall and direct ed t o t he out side. The grille sizes shown are t o be applied at bot h t he high and t he
low level gr illes.
*2 The figures in colum n 1 and 2 can only be used in areas which are regularly visit ed and as such, a gas leak would be det ect ed at an early st age.
*3 For vibrat ing environm ent s w it h an OP up t o 100 m bar where vibrat ion is such as m ay lead t o com ponent / pipe failure use not ional leak size of 0.25 m m 2 ( see
also clause 4.3.2) .
*4 For vibrat ing environm ent s w it h an OP ex ceeding 100 m bar where vibrat ion is such as m ay lead t o com ponent / pipe failur e use not ional leak size of 2.5 m m 2 ( see
also clause 4.3.2) .
Not e 1: Assum es Nat ural Gas w it h an LFL of 4.4% .

Not e 2: For inst allat ions wit h OP ex ceeding 2 bar, see I GEM/ SR/ 25 Edit ion 2.
Not e 3: Colum ns 1 and 2 only apply t o occupied or six m ont hly visit ed spaces or ext er nal areas.
Not e 4: Figur es ar e based upon I GEM/ SR/ 25 Edit ion 2 buoyancy calculat ions w it h vent ilat ors 2 m vert ically apar t , cent re t o cent re.
For ot her vert ical height differences, m ult iply free areas by fact or:
1m – 1.41
3m - 0.82
4m - 0.7
5m – 0.63
6m - 0.58
For ‘all- wall’ or ‘all- door’ vent ilat ion, use full height of vent ilat ion gr ille.
TABLE 31 – ZONE 2 NE MINIMUM NATURAL VENTILATION REQUIREMENTS FOR PIPEWORK
24
APPENDIX 9 : SELECTION OF A GAS SUPPLY PROTECTION SYSTEM
A9.1 INTRODUCTION
Gas supply protection systems may be fitted to any appliance, group of

appliances or the gas supply to a whole building, to protect the gas supplies
system in the event of an incident such as a fire, failure of ventilation fans, etc.
GS(I&U)R require only a manual capability in the supply for isolation purposes.
The application of an AIV in the gas supply, as an additional safety feature, is

often promoted as part of an overall building fire protection philosophy and
sometimes as a protection against misuse or vandalism. However, it is
necessary to consider the potential hazards, as well as advantages, of including
such a valve.
A9.2 POTENTIAL HAZARDS
A9.2.1 A potential hazard could arise from the use of an AIV if it were to close and re-
open without ensuring that any appliance installed downstream is isolated.
Under such circumstances, when the AIV is re-opened, gas would escape from
any appliance which had not been turned off (automatically or manually) thus
creating a potential hazard.
A9.2.2 A potential hazard is most likely to occur on an AIV that restores itself
automatically to an open position on removal of the fault which caused it to
close.

Examples of such an event are:
a transient loss of electrical supplies (which can lead to significant

operational problems)

activation upon testing a fire alarm
a transient or intermittent fault of an interlock that actuates the AIV.
A9.2.3 A potential hazard may also arise on an AIV that requires manual intervention to
re-open if the operator is unaware that any non-automatic appliance installed
downstream had not yet have been turned off.
A9.2.4 Such a potential hazard would not arise if the appliance(s) fitted downstream
were fitted with a full flame safeguard protection of any pilot burners and main
burner, with appropriate SSOVs (this does not include systems where pilots are
not protected by a SSOV, for example as on many domestic heating and cooking
appliances).
A9.3 AVAILABLE GAS SUPPLY PROTECTION SYSTEMS
A9.3.1 Valves
A9.3.1.1 Any plug, ball, sliding gate, butterfly or disc-on-seat valve may be designed to
close automatically. When considering the use of valves with high starting and
closing torques, for example some plug valves or larger ball valves, this
potential will need to be addressed. Some types of valves impose far higher
resistances to flow than others (see Table 17).
A9.3.1.2 Valves complying with BS EN 161 that are electrically de-energised to close can
be used, provided they include either an integral device or an external system,
such as an electric motor starter with “no volt” release, that prevents manual
restoration until the pipework system has been checked for integrity. Automatic
130
restoration may, where fully automatic burners are fitted, be acceptable after a
transient loss of electrical power.
A9.3.2 Integrated systems

Systems that can be used to operate the valves described in A6.3.1 include:
drop weight valves
These are held open either by a fusible link system or, more rarely, thermal
sensors on an electrical solenoid latch. These are not, normally, suitable for
gas installations and are prone to stick in the open position or be held

permanently open by unauthorised interference
fusible link systems
The melting of a fusible link allows the valve to close. Systems may include
fusible links, remote from the valve, which, on failure, release electrical

power from the valve so allowing it to close
electrical systems (recommended)
Any type of electrical valve may be operated via gas detectors, smoke
detectors, heat detectors or panic buttons.
Other systems include a sequential system using a pressure switch and

timer, to check that the gas pipework is not leaking
pneumatic systems (limited to 25 mm diameter availability)
A low pressure cut-off valve, based on a regulator, can act as an AIV when a
electrical solenoid valve is incorporated. This is, probably, the simplest
system that complies with this Appendix and is suitable for gas flow of up to

600 kW
appliance controls
It is possible and quite practical to utilize the facility of the two SSOVs on
forced draught burners in order to achieve isolation. In such a case, the
complete electrical supply to the appliance(s)/burner(s) is isolated by the
fault condition. The pipework upstream of the burner controls is highly
unlikely to be contributing to any incident, nor is it likely to be at risk in the
time prior to the main gas system being manually isolated.
A9.3.3 General
A9.3.3.1 Clear warning and instruction notices are needed at the location(s) where

manual resetting of the system takes place stating:
“Ensure all downstream appliances are turned off prior to restoration of the

supply”, and
“The supply should only be restored after giving consideration to the
possibility that, following a loss of pressure, there may have been an ingress
of air into the system”.
A9.3.3.2 The use of drop weight valves is not recommended.
A9.3.3.3 Simple fusible link valves have to be located within the zone that they are
intended to protect and, therefore, have limited application. A system of remote
fusible links operating an actuating system can be applied with a valve to
BS EN 161.
A9.3.3.4 In general, an AIV need not be of a fire resistant type as, in all cases, a manual
valve will be upstream of the AIV and can be used for isolation purposes.
131
A9.3.4 Specific installations
A9.3.4.1 School laborat ories and workshops ( see I GEM/ UP/ 11)
The manual isolation valve is to be located inside or, preferably, outside the
building or each self contained area, or close to an exit from each self contained
area.
Where the above is not practicable, remote actuation of an AIV can be available
close to an exit from each self contained area.
An AIV system needs to be of the electrical or pneumatic type (see A6.3.2).
A9.3.4.2 School t eaching areas ( see I GEM/ UP/ 11)
The problem of unauthorised entry into such areas render it generally

impractical to locate a manual valve outside a building or even outside a self-
contained area. In addition, the problems of unauthorised tampering with the
valve in teaching areas may lead to hazardous situations.
The application of an AIV, including a system integrity check before the valve
can be re-opened, is an option for such areas. The installation of emergency
buttons, to operate the AIV at discrete points, is recommended.
Electrical or pneumatic normally are satisfactory for this application.
A9.3.4.3 Fum e cupboards ( see I GEM/ UP/ 11)
Fume cupboards may introduce particular hazards, which are not necessarily
protected by the main laboratory protection system.
In such cases, the use of a small valve of the pneumatic type (see A6.3.2) with
a weep solenoid valve linked to a differential pressure switch across the extract
fan, is recommended. Fan type air proving devices are unlikely to withstand the
corrosive environment.
A9.3.4.4 The following safety precautions are required for new educational
establishments and where existing boiler/plant rooms are to be upgraded or
refurbished. A means to automatically shut off the fuel supply in the event of a
fire shall be installed.
This should include an emergency shut-off push-button at the entrance to the

plant room/boiler house, and for any gas system, shut off shall be accomplished
by closure of a valve complying with BS EN 161. The system shall isolate the
electrical power to some or all the plant, as considered appropriate. In the event
of an alarm condition, the system should require manual resetting.
Not e 1: Where shut down is t he result of a power supply failur e, aut om at ic r eset t ing of t he power
supply ( local or rem ot e) is perm it t ed. Alt ernat iv ely, a syst em of alarm not ificat ion t o
rem ot e key holders m ay be used. The risk of int errupt ing power supplies t o rem ot e plant
cont rolled by t he boiler house cont rol panel needs t o be assessed and t he plant designed
accordingly . Many m odern package bur ner s requir e local m anual reset in t he ev ent of loss
of power, as required by BS EN 676.
Not e 2: Pipework int egrit y syst em s ( see Appendix 3) are not norm ally required for m odern
boiler/ heat ing plant incorpor at ing flam e safeguard syst em s.
Not e 3: Many ex ist ing plant room s/ boiler houses are fit t ed w it h a m anual isolat ion valve on t he fuel
supply. The requirem ent for aut om at ic isolat ion of t he gas supply t o new buildings is not
int ended t o be ret rospect iv ely applied t o ex ist ing buildings, ex cept as m ay be necessary as
part of t he conclusions from a risk assessm ent .
Not e 4: I n t he event of fire wit hin a plant room w hich form s par t of a m ain building, it is
recom m ended t hat t he gener al building fir e alarm syst em is act uat ed.
132
A heat detection system should be installed and linked to the fire alarm system
to raise an alarm.
Not e: Heat det ect ion is preferable t o sm oke det ect ion in a plant / boiler room , as sm oke det ect ion
is m ore likely t o cause false alarm s.
A9.3.4.5 Dual fuel boiler plant ( see I GE/ UP/ 10)
It is recognized that oil systems are protected by a “fire valve”. The need for an
AIV on the gas pipework is doubtful, bearing in mind that, in most cases when
firing on oil, the main gas train will be isolated. However, where requested, it is
recommended that emergency push buttons should isolate all fuels and power
to the burners using the SSOVs, rather than the fitting of an extra AIV. In most
control systems, it is possible to achieve this remotely so causing the system to
go to lockout.
133
APPENDIX 10 : WEEP BY-PASS PRESSURE PROVING SYSTEMS
A10.1 INTRODUCTION
Weep by-pass pressurisation systems have over the years been widely used to
prove that the downstream appliance/manual controls and pipework system is
gas tight within practical limitations. The system was initially designed for use
with manually controlled multi-burner plant prior to ignition of the burners for
which IGE/UP/12 applies. In recent years it has also been found useful in a
pipework system supplying several appliances some of which may not be
protected by flame safeguards, for example in catering establishments or school
laboratories. Many systems also provide protection against inlet gas supply
pressure failure that can again be useful with manually controlled plant. The
earlier system using a simple low-pressure cut-off valve has now fallen into
disuse although the valves can still be purchased in smaller sizes.
There are situations such as in schools, catering establishments and laboratories

where there may be a number of appliances installed without flame safeguards
on every burner. Such systems may also be used to protect installations
against the effects of low gas pressures that might lead to loss of flame. They
are also widely used as part of the AIV system logic to check the integrity of the
pipework system before the automatic isolation valve can be reset. A single
SSOV in the main line should be sufficient.
The systems can incorporate other interlocks such as air pressure/flow switches,
damper positions and gas or fire protection relay contacts to shutdown the
protection system.
This revision of IGEM/UP/2 considers the application of such systems and now
refers to them as Pipework Integrity Systems (with a weep solenoid valve) and
Pipework Testing System (without a weep solenoid valve) to prevent confusion
with the use of weep by-pass systems that are detailed in IGE/UP/12 for furnace
and oven applications.
Systems complying with this Appendix are not normally used with an MOP above
100 mbar. Systems not using a weep by-pass are not be used with an MOP
above 25 mbar for NG or 40 mbar for LPG.
Not e: These pressur e lim it at ions r ecognise t he difficult y of lim it ing energy flows t hrough valves
and leak sour ces at higher pressures. I t does not how ever preclude t he designer from
developing a syst em t hat ensures safet y .
A10.2 DESIGN REQUIREMENTS
A10.2.1 Weep By Pass System
This system is specified in IGEM/UP/2 and IGE/UP/12 and checks that a leak
does not exist greater than the smallest gas jet orifice in the system. This
system is fully specified in Appendix 11 of IGEM/UP/12. They can nevertheless
still be used in for many catering, schools and laboratory applications as an
alternative to this described in A10.2.2. and A10.2.3 below.
A10.2.2 Pipework Integrity System
This is a version of the weep by-pass system (above) and this design
incorporates an extended test period which provides additional security and
detects small leakages. This system may be reset immediately following a failed
gas test as the release of gas downstream is controlled through a limiting
orifice. Such a system shall be able to detect a natural gas leak of 0.3 m3 h-1
(0.1 m3 h-1 for LPG). The test time or purge volume adjustment shall not be
readily accessible to the user.
134
The pressurisation period shall not exceed 10 seconds for systems using a weep
by-pass with a limiting orifice not greater than 1 mm diameter.
This system ought not to be applied for natural gas systems with MOP above
25 mbar or LPG systems with MOP above 40 mbar unless a controlling pressure
regulator is installed within the by-pass line.
A10.2.3 Pipework Testing System
The third system is one that performs a test of the pipework for a
predetermined time depending upon the pipework volume but the system is not
pressurised via a controlled weep by-pass valve. Such a system shall be able to
detect a natural gas leak of 0.3 m3 h-1 (0.1 m3 h-1 for LPG). The design will be
such that the pressurising safety shut-off valve is not energised for more than
two seconds as controlled by a ‘fixed’ timing device of high reliability. The timing
device will fail safe to zero.
In this system the pressurising safety shut off valve will not normally need to be
open for more than two seconds but where the time has to be extended for a
specific application, calculations will need to be made to ensure that there is no
excess of gas released to the atmosphere that could create a dangerous
situation.
The test time or purge volume adjustment will not be readily accessible to the
user. After pressure test failure there will be a purge delay time of at least two
minutes before reset can take place.
Pressure switches and transducers will be suitable for Natural Gas and for LPG
and comply with BS EN 1854.
This system ought not to be applied for natural gas systems with MOP above
25 mbar or LPG systems with MOP above 40 mbar.
All automatic gas shut-off valves (including weep by-pass and drop handle
valves) are to comply with the requirements of BS EN 161, as appropriate.
Timers and pressure transducer settings are only to be accessible to a

competent commissioning engineer.
Pressure switches are to be sealed against unauthorised interference.
The control panel will display useful operating parameters such as power on,
initial test pressure made, test time progressing, test failed/lockout or test
completed AIV opened.
Emergency stop and reset buttons/switches will be provided. Stop buttons may
be shrouded if their location exposes them to inadvertent operation.
A10.3 OPERATIONAL REQUIREMENTS
Prior to light-up of manually operated plant without a full flame safeguard

system, it is essential to ensure that all manual valves on burners or appliances
are in the closed position. This can be performed by permitting a small, and
controlled, flow of gas through a limiting orifice to by-pass the SSOVs (see
Figure 28). If any of the downstream valves are not closed, the pipework will not
pressurise and, thus, the circuitry will prohibit the opening of the SSOVs.
The weep valve can be a mechanical push button valve suitable for operation on
gas or a solenoid valve operated by a panel-mounted manual push button. Other
135
combinations can include key operated switches with timers set to the test
period used in the calculations in A10.2.2.
The quantity of gas that is allowed to flow and the time that it is allowed to flow
has to be such that, if any of the valves are in the open position, no hazard will
arise.
SSOVs
Weep push button
ForFor high
high pressure
pressure Pressure
regulator
regulator outlet
outlet Valves to
gauge
pressures, fitaalow
pressures low Limiting orifice
individual
pressure regulator Push button operated appliances
pressure regulator solenoid
should
in the be fitted
by-pass loopin or burners
the by-pass loop
Alternative electrically-operated weep valve
FIGURE 28 - TYPICAL LAYOUT FOR A WEEP BY-PASS OR PIPEWORK

INTEGRITY PROVING SYSTEM
A10.3.1 Method of Calculation
(a) Calculate the volume of pipework to be pressurised - VP (m3)
(b) Decide the time for pressurisation (normally 45 to 180 secs) - T (secs)
(c) Calculate the quantity of gas necessary to raise the downstream

pipework volume from zero to line pressure from:
V 
Vp .Pu
Pu  1000
(m3)
V is the quantity of gas required (m3)

Pu is the upstream line pressure (mbar)
(d) Calculate the required flow rate to pressurise the pipework in the selected
time T secs
Q1  m 
3600V 3
h 1
T
136
(e) Calculate the orifice area from:
Q1  0.0458Cd.A .
Pu
or 0.0417Cd.A Pu for NG
2s
Cd is the coefficient of discharge of the limiting orifice (see below)

A is the area of the limiting orifice (mm2)
Pu is the upstream line pressure (mbar)
s is the density of gas relative to air.
It is recommended that a correctly-designed and drilled jet is used for the orifice
(see Figure 29). A pre-drilled jet could have a Cd of typically 0.85 while a
homemade orifice may have a Cd as low as 0.6. Lower Cd orifices will have the
effect of increasing the test time.
FIGURE 29 - TYPICAL LIMITING ORIFICE
A10.3.2 Ensuring the flow rate is safe if a valve is open
A10.3.2.1 To ensure that the maximum flow rate through the limiting orifice will not lead
to a hazard, it is necessary to estimate what this flow rate would be if the
downstream pipework vented directly to atmosphere, i.e. the room, and at
atmospheric pressure.
The flow rate through the orifice will then be:
Q 2  0.0458Cd.A .
Pu
or 0.059Cd.A. Pu (m3 h-1) for NG
s
A10.3.2.2 The value of Q2 has to be compared with the purge air flow rate (forced draught
type burners) on the total number of burners in the sector/zone being tested.
Q2 has to be limited to a flow rate such that the gas concentration in the
combustion chamber will not exceed 10% of lower flammability limit (LFL).
Therefore, Q2 has to be no greater than Q3 = cold air flow rate through the
sector or zone/200 (m3 h-1).
A10.2.3.3 If Q2 exceeds Q3 the orifice size needs to be reduced and a new value of T taken
as follows:
A.Q3
The new area of the orifice An = (m2)
Q2
137
The new value of T will be Tn 

T.Q2
(secs).
Q3
A10.2.3.4 If the burner is of natural draught design where the purge flow rates are not
easy to determine:
Q3 = the actual burner gas flow rate/20 (m3 h-1).
This calculation assumes that free air flow conditions exist within the
combustion chamber.
A10.3.3 WEEP BY-PASS PRESSURE PROVING USING A LOW PRESSURE CUT-OFF

VALVE
A10.3.3.1 General
The valve is shown diagrammatically in Figure 30. Operating the re-set pull ring
causes a small flow of gas to pressurise the downstream pipework. When the
pressure equals approximately 50% of the upstream pressure, the pressure acts
upon the diaphragm causing the valve to open. The required orifice area can be
calculated in a similar manner to as before except that the downstream pressure
is 50% of the upstream pressure. During commissioning, it is essential that the
valve does not reset at a pressure below 50% of the line pressure and that the
burners continue to operate safely right down to the set “drop-out” pressure of
the valve.
FIGURE 30 - LOW PRESSURE CUT-OFF VALVE
138
A10.3.3.2 Method of calculation of limiting orifice size
(a) Calculate the volume of the pipework to be pressurised, Vp (m3)
(b) Decide the pressurisation test time (normally 45 to 180 secs) T (secs)
(c) Calculate the quantity of gas necessary to raise the downstream

pipework from atmospheric to 50% line pressure using:
V 
0.5Pu .Vp
Pu  1000
V = quantity of gas required (m3)

Pu = upstream line pressure (mbar)
(d) Calculate the required flow rate to pressurise the pipework in the selected
time T secs.
Q1 
3600.V
T
m 3

h1 .
(e) Calculate the orifice area from:
Q1  0.0458Cd.A
1.5Pu 3 -1
or 0.059Cd.A. Pu (m h ) for NG
2s
Cd = coefficient of discharge as before

A = limiting orifice area (mm2)
Pu = the upstream pressure (mbar)
s = density of gas relative to air.
A10.3.3.3 Ensuring the flow rate is safe if a valve is open
A10.3.3.3.1 To ensure that the maximum flow rate through the limiting orifice will not lead
to a hazard, it is necessary to estimate what this flow rate would be if the
downstream pipework vented directly to atmosphere.
The flow rate through the orifice would then be:
Q1  0.0458Cd.A
Pu
or 0.059Cd.A Pu (m3 h-1).
s
A10.3.3.3.2 The value of Q2 has to be compared with the purge air flow rate (for forced
draught burners) on the number of burners in the sector/zone to be tested. Q2
has to be incapable of giving a flow rate such that the gas concentration in the
combustion space is greater than 10% LFL.
That is to say:
Q2 has to be greater than
Q3 = cold air flow rate through the sector or zone/20 (m3 h-1).
A10.3.3.3.3 If Q2 exceeds Q3, the orifice size needs to be reduced and a new value of T taken
as follows:
A.Q3
The new area of the orifice An = (m2)
Q2
139
The new value of T will be Tn 

T.Q 2
(secs).
Q3
A10.3.3.3.4 If the burner is of natural draught design where the purge flow rates are not
easy to determine
Q3 = the actual burner gas flow rate/20 (m3 h-1).
This calculation assumes that free air flow conditions exist within the
combustion chamber.
A10.4 APPLICATION TO INSTALLATION PIPEWORK
A10.4.1 There are situations such as in schools, catering establishments and laboratories
where there may be a number of appliances installed without flame safeguards
on every burner. Proving systems may be used to protect such installations
against the effects of low gas pressures that might lead to loss of flame. They
are also widely used as part of the AIV system logic to check the integrity of the
pipework system before the valve can be reset. In these systems, a single SSOV
is acceptable, subject to a risk assessment.
A10.4.2 The application of weep by-pass systems on such installations may be limited by
the smallest valve or burner on the system or the sensitivity of the pressure test
on an AIV system before restoration.
A10.5 FURTHER REMARKS
A10.5.1 It is recommended that the pressure switch in Figure 30 is set such that its
contacts close at the maximum safe operating pressure at which burner stability
can be assured. Typically, this will be some 80% of the line pressure. The effect
of reducing the pressure switch setting to below this value, while minimising
nuisance shutdowns, is to increase the leakage potential, i.e. to reduce the
sensitivity of the test.
A10.5.2 It is recommended that a dial type pressure gauge is fitted adjacent to the push
button, downstream of the orifice, in order that the operator can observe the
state of the system.
A10.5.3 The time to pressurise the system will be almost zero if the pressure has not
decayed prior to reset. It will be at its longest if the system has vented to
atmosphere.
A10.5.4 If the time is considered to be excessively long, it will be necessary to divide the
pipework into smaller test volumes.
A10.5.6 Where full sealing flue or air inlet dampers are fitted, the damper has to be
proven in the open position before operating the proving system.
A10.5.7 Where the gas flow exceeds 2 MW net heat input, a safe start check of the
pressure switch has to be applied, for example by using a normally-open
solenoid valve.
A10.5.8 When shutting down plant, it is recommended that the plant main isolation valve
be first closed followed by closure of the individual burner valves.
A10.5.9 The use of two safety shut off valves is not considered necessary when applied
in association with an AIV system protecting installation pipework.
A10.5.10 The weep by pass system can incorporate other interlocks such as air pressure
switches, damper positions and gas or fire protection relay contacts, in cases
where flame protection is not required by these procedures.
140
APPENDIX 11 : GAS DETECTION SYSTEMS
The use of gas detectors is optional unless, under DSEAR, a risk assessment indicates that
certified electronic equipment is necessary which, consequently, means a gas detection
system is required. The advantages and disadvantages of a gas detection system are outlined
below. Advice on selection and application of detectors is given assuming the overriding
preference for good ventilation of pipework and appliances.
Not e: I nform at ion on appropriat e aut om at ic valves is given in BS EN 161, BS 7461 and Appendix 9.
There are several situations in which gas detectors may be applied in commercial or industrial
installations, either directly associated with gas equipment or supplies where gas leakage
normally, obviate the need for gas detection systems at MOP  0.5 bar.
could cause a hazard. Good pipework maintenance regimes and good ventilation will,
Careful examination of individual circumstances and proper consideration to the role of gas
detectors is required.
Gas detectors may be used as early warning devices indicating the occurrence of small leaks,
where manual checks for leakage and good maintenance is inappropriate or as executive
devices taking action in the unlikely event that a dangerous leak exists. Consequently, the
siting of detectors and their sensitivity are of considerable importance, as is the application of
regular maintenance and calibration procedures.
The advantages and disadvantages of installing gas detectors are given below:

A11.1 ADVANTAGES
may improve safety by affording protection against eventualities that cannot

be guarded against in the gas installation

can detect the presence of gas in unattended location

can supplement other measures taken in manned installations
can be located in positions not normally accessible to personnel if provision
can be made for routine calibration of the detector sensing head.

A11.2 DISADVANTAGES
require regular maintenance and calibration if reliability in operation is to be
maintained – but these would normally be remedied following a risk

assessment
may encourage a reduction in the primary aspects of safety in gas

installations, for example, servicing
lead to a false sense of security unless an adequate number of appropriate
sited detector sensing heads is fitted to cover all potential sources of gas

leakage
may lead to less attention being given to providing satisfactory standard of
ventilation and maintenance.
A11.3 CONCLUSION

A11.3.1 The installation of gas detectors will only improve safety where:
personnel are available to take corrective action when an alarm is sounded

or
the detector takes executive action i.e. operates a SSOV in the gas supply.
Not e: Such execut ive act ion would be of lim it ed pract ical value if t he source of gas escape w ere
out side t he building. A loss of power for a short durat ion can lead t o nuisance shut - dow n
and sever e inconvenience t o gas users.
141
A11.3.2 Only detectors meeting the requirements of the relevant parts of BS EN 61779,
which are maintained and calibrated regularly, would make any contributions to
safety.
A11.3.3 If gas detectors are installed as a substitute for a satisfactory level of ventilation
or other reduction in installation standards, any perceived improvement in
safety may be offset by increased potential hazard.
A11.3.4 The siting of gas detectors and the number employed needs to be considered
carefully in order to ensure that they are used to best effect and the potential
for false alarm is minimised.
A11.4 ADDITIONAL REQUIREMENTS

In applying gas detectors, the following factors needs to be taken into account:
any executive action to isolate gas supplies needs to incorporate an
automatic gas tightness check on downstream pipework in situations where

the equipment/plant supplies does not have fully automatic flame safeguards
drop weight isolation valves for automatic isolation of gas supplies are not
recommended. It is essential that these are regularly checked and

maintained
any AIV used needs to comply with the intent of BS EN 161.
142
APPENDIX 12 : TYPES OF FLEXIBLE CONNECTIONS
A12.1 DESCRIPTION
A12.1.1 Semi-rigid coupling and flange adaptor (see clause 13.3.2)
A12.1.1.1 Figures 31 and 32 illustrate the mechanically jointed coupling and flange
adaptor.
FIGURE 31 - MECHANICALLY JOINTED SEMI-RIGID COUPLING
FIGURE 32 - FLANGE ADAPTOR
A12.1.2 Bellows
A metallic tubular component consisting of one or more annular corrugations,

designed primarily to permit axial movement (see also BS 6129-1 and
BS ISO 15348).
143
A12.1.3 Swivel joint
A joint, in otherwise firm and rigid pipework, that allows free turning of one side
of the joint relative to the other (see Figure 33).
FIGURE 33 - SWIVEL JOINTS
A12.1.4 Quick release couplings
A two part fitting which may be connected or disconnected quickly without the
use of tools.
A12.1.5 Non-metallic tubing or metal hose
A tube or hose designed to allow non-torsional movement between pipes or pipe

fittings.
A metal hose may consist of annular or helical formed convolutions.
Flexible tubes or hoses are available with or without braiding and sheathing.
A12.2 APPLICATIONS
A12.2.1 Thermal expansion
A long length of pipework may be subject to appreciable thermal expansion

along its length normally below-ground pipework is not affected and it is only in
very large above-ground installations that provision may have to be made for
longitudinal expansion. Connections to furnace burners may pose special
problems.
Thermal expansion is length and temperature related. For example, a 100 m

length of steel pipe in a 0oC to 30oC environment will vary by up to 33 mm.
Suitable pipe supports which do not chafe the pipe or damage its corrosion
protection are essential (see Section 12).
A12.2.2 Structural movement
Certain types of building are known to be subject to structural movement,

indeed some are designed to move. High rise buildings tend to "sway" in the
wind and all large buildings are liable to settlement. In these instances, the
pipework in the building may move relative to the incoming supply pipework.
A12.2.3 Vibration
Vibration will be present in all moving machinery, especially in such as gas

engines, compressors, mixers and pressure die-casting machines. To prevent
144
vibration being transmitted throughout the whole gas installation and to avoid
fatigue fractures of the pipework; a flexible connection may be fitted in the
pipework to such equipment. Reference is required to be made to the
manufacturer to confirm application. Further guidance is provided in BS 6501
and BS EN ISO 10380.
A12.2.4 Rotation and torsional strain
Where pipework feeds rotating equipment through the hinge axis of hinge
mounted burners or along the trunnion axis of tilting equipment, it will be
necessary for the pipework to rotate or swivel. If allowance has not been made
for rotation or torsional strain on the plant design, a flexible connection is
necessary.
A12.2.5 Mobility
Mobility refers to the need for pipework to be capable of appreciable movement

without being disconnected. Examples of such a requirement are adjustable
width tunnel ovens, integral burners on tilting furnaces, retractable burner units
and connections to appliances that have to be moved for access or cleaning.
Further examples are moored floating structures such as restaurants and public
houses which, especially when situated on tidal waters, are subject to
considerable vertical movement together with multi-directional sway.
A12.2.6 Portability
A12.2.6.1 Portability refers to equipment, which is moved physically from place to place,
being used at each place in turn. Typical examples are the trolley burners used
for continuous kiln firing and the temporary burners used on glass tanks for
initial heating up from cold. In these applications, it is convenient to use a
flexible connection at each point of use rather than connecting with rigid
pipework, so avoiding problems of misalignment when making connections.
A12.2.6.2 An additional important consideration is that such portable equipment will be

disconnected continually and reconnected by persons not deemed to be
"competent". It is essential that self sealing quick release couplings are used in
such applications (see clause 13.3.5.).
145
APPENDIX 13 : LOW PRESSURE CUT-OFF SWITCHES
The Gas Act enables a gas supplier to require a consumer using an engine, gas booster or
compressor to fit and maintain a device to prevent inconvenience or danger to other
consumers. It is normal good practice to fit a low pressure cut-off switch or transducer to
comply with such a requirement.
This appendix provides guidance on complying with the requirement when using a pressure
switch. In addition, the procedures indicate other factors to be taken into account to protect
other appliances within the consumer’s premises where a booster or similar equipment is
being used.
The term “switch” can refer to a pressure switch or a transducer.
A13.1 ESSENTIAL FEATURES OF A LOW PRESSURE CUT-OFF SWITCH


no built-in mechanical or electrical by-pass of the pressure switch
no latching pressure switches unless the design is such that failure of or

tampering with the mechanism cannot lead to unsafe conditions

Switch to be capable of on-site shut-off pressure adjustment

a reproducible switch setting within + 5% of the set point
capable of being sealed to prevent unauthorised adjustment.
A13.2 INSTALLATION
Refer to Figure 34.
A13.2.1 Set the low pressure switch setting as high as possible, to provide maximum
protection of the gas supply without causing nuisance shutdown of the engine
system.
The minimum acceptable cut-off pressure for normal low pressure supplies is
10 mbar (NG).
Not e: This m inim um value is subj ect t o t he gas supplier’s specificat ion. The cut - off pressure for
inst allat ions, supplied at ot her t han nor m al pressur e, will norm ally be specified individually
by t he gas supplier. I n addit ion, where boost er s are sit uat ed m ore t han 30 m above ground
level, t he gas supplier needs t o be consult ed.
Low pressure
cut-off switch Start
Stop
L N
Over-
load
Supply phases
}
FIGURE 34 - TYPICAL SCHEMATIC WIRING DIAGRAM FOR 3 PHASE
STARTER
146
A13.2.2 In certain cases, the minimum set points stated in A9.2.1 may cause nuisance
shut down. This problem can be overcome by damping the action of the
pressure switch for a short period. If damping is deliberately used or the
response time of the switch exceeds 0.5 secs (see A9.3.2) it is important to

ensure:
the pressure at any point in the supply pipework remains above a level

which could affect the safe operation of other gas appliances
the response time is not more than 3 secs.
Not e: Pneum at ic dam ping is oft en achieved by insert ing a shor t lengt h of larger size pipe int o t he
supply t o t he pressure sw it ch. A 1 m m orifice m ay also be fit t ed on t he inlet side of t his
dam per volum e.
A13.2.3 Where gas appliances are fed from upstream of a machine, the appliances have
either to be protected against a low pressure condition or have to conform to an
appropriate standard. This may mean the pressure switch on the machine is set
at such a level that it cuts out the machine before other plant is affected.
A13.2.4 The impulse pipe to the pressure switch has to be fitted upstream of the
machine inlet but downstream of the machine isolation valve. Ensure that,
where possible, the distance from the machine inlet to the impulse pipe
connection is greater than 5 times the diameter of the pipe supplying the
machine.
A13.2.5 Do not fit the impulse pipe upstream of any connection other to any an engine,
a gas booster or compressor pressure relief by pass. Where it is on the
immediate outlet of a rotary displacement (RD) meter and there are no
upstream off-takes to other plant, the LPCO switch may be impulsed upstream
of the meter subject to written agreement from the gas supplier.
A13.2.6 Do not fit a valve in the impulse pipe (that is the gas pipe between the main
supply pipe and the pressure switch) which would permit shutting off the gas
supply to the pressure switch. In the exceptional case of a valve being fitted,
ensure it is capable of being locked and sealed in the open position.
A13.2.7 Ensure the impulse pipe is as short as possible.
A13.2.8 Ensure that the operating instructions draw attention to the need to investigate
the cause of any repeated low pressure valve condition.
A13.2.9 Fit pressure test points to permit testing.
A13.2.10 Install the switch shall be fitted where it is not liable to be damaged or be
subject to excessive vibration.
A13.2.11 On installations having more than one booster, it is recommended that each
booster be fitted with a separate pressure switch.
A13.2.12 It is recommended that a pressure switch indicator light or outlet pressure

gauge be fitted in a position that is clearly visible from the normal operating
position.
A13.2.13 Seal any conduit entry to prevent gas passing back up the conduit in the event
of a diaphragm failure.
A13.3 OPERATION AND TESTING
A13.3.1 It is the responsibility of the user to ensure that the LPCO switch operates
correctly at all times.
147
A13.3.2 Before a machine is first operated, the consumer (or the installer on their
behalf) is to check the setting and operation of the pressure switch and seal the
setting.
A13.3.3 The consumer has to check the setting at least annually and re-set if necessary.
A13.3.4 By-passing of the pressure switch, even temporarily, would be a breach of the
Gas Act and could cause serious hazards to other consumers.

A13.3.5 On completion of a satisfactory test, record:

date of test

cut-off pressure

response time

no automatic re-start
tested by.
148
APPENDIX 14 : COMMISSIONING
New gas installation pipework commissioning check list

Pre-checks prior to test Yes / No / Not applicable Action points
Has the load been checked and the
meter and pipework sized accordingly
If a new gas supply has been
provided, has the gas meter/ storage
vessel been installed, tested and
purged by the gas supplier?
Is the vessel/meter outlet pipework
adequately supported and safe to
connect?
Has adequate cross bonding been
installed within 600 mm of the meter
bulk storage vessel, regulator or
building entry valve?
Is the gas line diagram fixed at the
primary meter location (if required)?
Is the gas line diagram accurate and
up to date? (applies to additions to
existing systems)
Are all purge and test points
provided?
Are all unconnected outlets plugged,
capped or provided with blank
flanges?
Are all necessary emergency and
section isolation valves installed?
Are all AECVs clearly labelled?
Is the method of operating any AECV
clearly labelled?
Do all lever type valve handles fall to
safety?
Is the pipework adequately
supported?
Is the pipework sleeved where
required and sealed with a fireproof
compound?
Are all ducts and voids through which
the pipework passes adequately
ventilated?
Are all pipe-line components of
approved construction and jointed in
an approved manner?
Test and purge
Has the installation been tested and
purged in full compliance with
IGE/UP1/ 1A,1B?
Has a test and purge certificate been
issued?
Checks after purge
Is all pipework painted and colour
coded as per BS 1710?
Are the bulk storage vessel/meter
pressure regulators providing the
required pressure?
Has all ancillary equipment been
commissioned as per the
manufacturers recommendations?
Checked by (print)
Position
Signature
149
APPENDIX 15 : TYPICAL RECORD OF NEW INSTALLATION
Risk assessment Ref. No.
Site address Site contact

Tel. number
Installation of new gas supply pipework
Description of works:
Significant risks
(from general risk assessment)
Control item Details of control measures
Documents and 1 GS(I&U)R
Procedures 2 IGEM Standards
3 Other related standards
4 Specific company policy on installation procedures
Information Operatives advised of risk of injury and damage:
List specific risk areas
1
2
3
Instruction Operatives instructed in safe systems of work required to protect against
risks described.
Training Formal competence training and qualifications ACOPS/ACS/NVQ/SNVQ

induction on safe working and job awareness for specific job
Supervision Work under control of competent person:
Name....................................
Access Ladders/steps
Scaffold
Mechanical access equipment
Environment
Equipment
Emergencies
Communications
COSHH
PPE
Other procedure
150
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INSTITUTION OF GAS ENGINEERS AND MANAGERS IGEM/TSP/12/123

INSTALLATION PIPEWORK ON INDUSTRIAL AND

DRAFT FOR COMMENT

4 This is a copyright document of the Institution of Gas Engineers and Managers.

I n st a lla t ion pipe w or k on in du st r ia l

Dra ft for Com m ent

I n st a lla t ion pipe w or k on in du st r ia l

Dra ft for Com m ent

Price Code: C6S

ISBN 978 1 905903 XX X

 16.7.2 Operation, maintenance and servicing

1 Glossary, acronyms, abbreviations, symbols and units 97

3 Gas flow through pipework 106

4 Calculating allowable pressure loss 110

5 Wall thickness of pipework 112

6 Installation pipework with MOP above 0.5 bar up to 60 bar

7 Pressed fittings. Jointing procedure 125

8 Compliance with DSEAR 126

9 Selection of a gas supply protection system 131

10 Weep by-pass pressure proving systems 134

11 Gas detection systems 141

12 Types of flexible connections 143

13 Low pressure cut-off switches 146

15 Typical record of new installation 150

1 Operational pressure limits 2

2 Typical gas supply line diagram 21

3 Example of an AECV label 41

4 Lever-operated AECV with on/off labels fitted 45

5 Positioning gas marker tape 46

6 Yellow Natural Gas tape 46

7 Yellow LPG tape 46

8 Yellow gas tape 46

9 Typical section of pipe in footways 52

10 Typical buried pipework under a roadway 55

11 Marker plate for syphons, valves and purge points 56

12 Typical above-floor entry – steel and PE pipework 57

13 Typical above-ground PE to steel building entry fitting 58

14 Typical below-floor level entry - steel pipework 58

15 Typical pre-fabricated below-ground entry.

16 Using unrestrained laterals to accommodate thermal expansion and

18 Suggested in-floor duct ventilation system 64

19 Single booster installation 88

20 Parallel booster installation 88

23 Schematic drawing of possible wiring circuit (boosters) 90

25 Warning notice on installation pipework 91

26 Example of configuration of test points 122

27 An example of pipework layouts showing preferred pipe locations to

29 Typical limiting orifice 137

30 Low pressure cut-off valve 138

31 Mechanically jointed semi-rigid coupling 143

32 Flange adaptor 143

33 Swivel joints 144

34 Typical schematic wiring diagram for 3 phase starter 146

1 UK and EU pipework standards – purpose, pressure, position 5

2 Maximum allowable pressure drop 16

3 Maximum gas velocity related to filter size 16

4 Jointing of carbon and stainless steels 28

5 Screwed and welded carbon and stainless steel connections 28

7 Inspection and testing of steel welds 31

8 Inspection and testing of PE fusion welds 32

9 Inspection and testing of brazed and soldered joints 33

10 Standardised branches for carbon steel pipes 48

11 Minimum proximity of buried pipe parallel to buildings 50