11. Technical Standards and Specifications including Safety Standards for City or Local Natural Gas Distribution Networks, Regulation, 2008

[~II-~3{i)] PETROLEUM AND NATURAL GAS REGULATORY BOARD NOimCATION New Delhi, the 27th August, 2008 G.S.R. 612(E).-ln exercise of the powers conferred by Section '61 of the Petroleum and Natural Gas Regulatory Act, 2006 (19 of2006), the Petroleum and Natural Gas Regulatory Board hereby mues the following regulations, namely :- · . 1. Short t~,.and commencement.

(1) These regulations may be. caned the Petroleum and Natunil Gas Regulatory Board (Technical Standards and Spectflcatlons Including Safety Standards for City .or Local Natural Gas Dlstrtbution,Networka) Regulations, 2008.

(2} They shall come Into force on the date of their publlcatlOn In the Offlclal Gazette ..

2. • Definitions.

(1) In these regulations un~u the context otherwise 1'9qulrea,- .

(a) •Act." means the Petroleum and Natural Gas Regulatory Board Act, 2006;

(b) •active regulator" means a regulator In presaure regulating station (PRS) that normally controls ~he outlet pressure;

(c) •authorized person• means a competent person who la assigned by the owner or operator to carry out a specific job baeed ()n his competency level aa- laid down by the Board under regulations;

(d) •city or local natural gas distribution network" (hereinafter referred to as CGD network) ·means an Interconnected network of gas pipelines and the associated equipments used for transporting natural gas from a bulk supply high pressure transmission main to the medium pressure distribution grid and subsequently to the service pipes supplying natural gas to domestic, Industrial or commercial premises and CNG stations situated In a specified geographical area; "

(e) •consumer meter" means a meter that measures gas· delivered to a consumer at the consumer's premises; ·

(f) •creep relief valve" i:neans a relief valve installed to retleve over pressure · caused by creep In the downstream system and having maximum 1 % flow capacity;

(g) · •ctty gate station (CGS)" means the .point where custody transfer of natural gas from natural gas pipeline to the CGO networi< takes place and this may also be referred to as City Gate Measuring and Pressure Regulating Station;

(h) •competent person" means .. an Individual' recognized by the CGD network

4.5 46 .TIIE GAZEITEOF INDIA: EXTRAORDINA\lY [PAirr II-Soc. 3(i)) owner/operator. based on his proficiency and skill set· achieved by appropriate combination of education, training and practical expeJience in the critical traits as laid down by the Board under regulations;

(i) "Distribution Pressure Regulating Station or Di~trict Regl:Jlating Station (DPRS)" means a station located within authorized area for CGD network having isolation, pressure regulating and overpressure protection devices;

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(j) · . "electro fusion joint" means a joint made in thermo plastic piping by passing the current through the electrical coil provided in the fitting and heating the parts sufficiently to permit adequate flow and fusion of the materials between the two surfaces put in contact;

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(k) "Monitor and Active Regulators" means an arrangement of two regulating devices in series whose pressure settings are stepped so as to allow one (Active).

normally fo control the outlet pressure and the other (Monitor) to assume control in the event of failure of the active device:

(I) "operator" means an entity that operates CGD network with the authorization of the Board; ..

(m) "owner" means an entity that owns the CGD network and has been authorized by the Board;

, .. . ' . (n) ·"primary network" means a part of CGD network that operates at pressure above 100 psig (7 bar) and below 711 psig (49 bar) and ·pipelines forming part of this network called Gas Main· or Distribution Main or Ring Main shall be. designed to ensure' uninterrupted supply of gas from one or more City Gate Stations to supply.

gas to the secondary gas· distribution network or service lines to bulk customers thro1,1gh service lines; · \o) "Slam Shut Valve" means a valve that is designed to 0,10~ quickly in the event of an abnoi;mal-pressure _(whether excess or low) being detected at a selected point in a gas system; ·

(p) "secondary network" means a part of CGD network that operates at a pressure below 100 psig (7 bar) ~-above 1 .. 5 psig (100 mbar) and pipelines forming part of this network shall be called loW-Pressure Dfstribution Mains which shall be designed to ensure uninterrupted. supply to tertiary network or to industrial consumers through servtee lines;

(q) "sub-transmission pipeline" means a high pressure pipeljne· connecting the main transmission pipeline to the city gate station but is owned by the CGD entity; ·

(r). "tertiary network" means a part of CGD 'network that operates at pressure less than 1.5 psrg(100 mbar) and pipeUnes forming part of this network to service Pressure Distribution Mains shall be designed to ensure uninterrupted gas supply to service lines;

(2} Words and expressions used and not defined in these regulations, but defined in the Act or in the rules or regulations made thereunder, shall have the meanings respectively assigned to thei:n in the Act or in the rules or regulations, as the case may be; · · · ['lFTII-WJg3(i)]

3. Applies~.

Definitions, . design, materials and· equipment,. welding·, fabrication, mstaUation, testing, operation and maintenance and corrosion control of CGD network shall· be in accordance with· requirements. of ASME 831.8 except · insofar as such requirements are specifically cancelled, replaced or modified by the requirements specified in these regulations.

4. Soope .

. {a) These fegulations cover the design,· materials, fabrication, ·installation, · inspection and testing, commissioning, operation, . maintenance, .modifications and abandonment of CGD network ·for domestic. commercial and industrial users.·

(b) Requirements of these regulations shall apply to all pipelines, distribution mains and piping facilities downstream of inlet isolation valve of city gate station {CGS) up to·. and~cluding consumer meter for commercial or indu$trial customer and up to final isolation valve including cannecting hose to gas llPPliance for domestic consumer.

(c) Design, materials, fabrication, . installation, inspection· and testing, commissioning, operation, maintenance, modifications and abandonment of steel pipeline between city gate station and natural gas pipeline (sub transmission pipeline) shall be as per separate regulations.

{d) =The CNG Station, CNG Mother Station, CNG On-Line Station and CNG Daughter Station.shall be designed, operated and maintained in line with the requirements of the Chief Controller of Explosives as detailed in the Gas Cylinder Rules, 2004 as modified or amended from time to time. This includes compression, handling and transportation activities of compressed natural gas. · {e) These regulations also cover safety aspects of operation and maintenance of CGD network and the requirements covered herein the~ regulations are meant to supplement the safety requirements already covered under ASME B 31.8. .

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5. Intent.

(a) It is intended to ~pply these regulations to· atl new and such aspects of.

already existing networks as design, fabrication,· installation, testing at -the time of construction and commissioning, However, if an entity has laid, built, constructed or expanded the -cGD infrastructure based .on . some other standard or is not meeting the stand,ard$ specified in these regulations, the · entity needs to carry out a detailed technical audit of its infrastructure · through a.J ~oard authorized or approved third party agency by the Board.

The entity thereafter ~hall submit· the recommendations made by the third party along-with its time-based mitigation. plan and implementation schedule te> the_ Board for authorization within six. months from the date of notification of these regulations. · · ·

(b) The continuation of· operation of existing. CGD network ·shall be allowed only if it meets the following requirements, namely:- 48 nm GAZBTI"BOFINDIA: EXTRAORDINARY {PARr I~sc. 3(i)]

(i) The CGD system downstream of city gate station shall have been tested initially at the time of commissioning hi accordance with ASME B 31.8.

Chapter IV (with minimum teat pressure of 1.4 times, of MAOP for steel network and 1.4 time MAQP or'50 PSI whichever is higher for PE network).

The entity should have proper ·l'e®f'CfS of. the same. Such test record shall have been valid for the current operation: Alternatively, if such a record is not available, the entity should produce in ·service test record of the CGD network having tested at a pressure of 1.1 time of MAOP as per ASME B.

31.8;

(ii) The· CGD system has leak detection system in position anc:Ms operative. For pipeline network it shaH be odorisation baaed and for enclosures such as' CGS, above ground DPRS, it shall be gas leak detection based.

{iii) The CGO system has in position necessary pressure relief valves; and

(iv) There shall be protection of the system against third party damages both ln respect to Steel pipe, PE pipe and copper tubing.

Provided that-

(a) The entity shall submit self-certification in support of meeting the above requirements within a month ··of notification of these regulations and in addition the certification by the approved or authorised third party shall be made available to the Board within six months of notification;

(b) Certifications referred to in para (a) shall be done both for operation and maintenance and Infrastructure of the entity and shall be submitted to the Board with mitigation plan and implementation schedule; ,

(c) The critical components of. the'8ystem as identified by the Board··for such existing networks ·shall be complied with these regulations within a period specified at Appendix-I and the authorized entity shall maintain the integrity of the existing system at all time&; and . '

(d) Provisions of these regult11tions related to operation and maintenance procedures shall also be applicable to all such existing installations.

6. The standard~ Technical standards and specifications including safety standards (hereinafter referred to as standards) for city or local natural gas distribution networks. are as specified in Schedule-I which cover material and equipment (Schedule-1A), welding (Schedule- 18), piping system components and fabrication (Schedule- 1C), design, installation and testing {Schedul .. 10), operating and. maintenance procedures (Schedule-1E), corrosion control (Schedule-1F) and miscellaneous (Schedule-1G).

7. Default and consequences.

i - , ( 1) There shall· ·be a system · for ensuring compliance to the prov1s1on of these regulations through conduct of technical and safety audits during the construction, commissioning· and operation· phase, as well as on ·an on-going basis as may be specified from time tQ time.

(2) The Board shall monitor the compliance to Technical Standards and Specifications ,.

[~II-~3(i)] including Safety Standards either diroctfY or by accredited third party through separate regulations on third party conformity assessment.

(3) In case pf any deviation or shortfall, in achieving the· targets, for implementing the · specifiecf standards, the entities shall be liable to face the following consequences, .namely:- · ·

(i) in case of critical activities~ at Appendix-I, the entity shall be given a single notice by the Board $pacifying the time limit to remove the specified shortcom~ and ensure compliance and if the entity fails to .comply within the specified 'flme limit, immediate suspension or termination, · as deemed appropri~te, of authorization shall be done;

(Ii) in other cases, the Board may issue a notice to defaulting . entity aHowing it a reasonable time to remove the specified short coming and ensure compliance and in case the entity fails to comply within the specified time or in case the entity .. defaults on more than three occasions, its aLlthorization to lay, built, operate or expand the CGD network shall be liable for . suspension· or termination ·apart from taking legal action under the provision of the Act and regulations thereunder. · ..

8. Requirements under other statutes.

It shall be necessary to ·comply with all statutory rules, regulations and Acts in · force as applicable and requisite approval•.·· shall be obtained from the relevant · competent authorities for the CGD network.

9. Miscellaneous.

3225 Gl/08-7

(1) These standards are intended to ensure uniform application of design principles and to guide selection and application of materials and components. Though the standard primarily focuses on safety of employees, public and facilities associated · with city or local natural gas distribution networks, · it does not eliminate the need for a competent designer and good engineering judgment.

(2) If any dispute. arises with_ regards to the. interpretation of any of the provisions of these regufations, the decision of the Board shalt be final. i=urther, the Board may at any ti'"': sffect appropri~te niodffiCations kl these r9Q:~7· 49 50 nreoAZETrn o.FINDIA; ID'ITRAoRDINARY [PARf II-SEC. 3(i)] . . . . . . . . . .

. APPEND.IX-I LIST OF· CRITICAL ACTIVITIES In CGD NETWORK {See regulation 7(3} (i)} Sr. Critical Infrastructure/ activity/ No. . processes _ 1 2 3 4 5 Pressure reducti.on skid CGS (active I monitor combination) with a minimum ' 50% redundancy including slam shut valve for over pressure protection and creep relief valves. · · On line odorisation equipment .designed to minimize- fugitive . emissions ·during loading, operation and maintenance.

Height of the vent shall be minimum 3 meters above working level Gas detectors shall be installed at critical locations Pressure reduction for DRS· {active I monitor combination) skid with minimum 50% redundancy including two safety devices at.least one of ttiem shall be a slam shut · valve for over pressure protection/under-pressure and inlet and outlet isolatiOn valves.

6 Steel reinforced rubber hose conforming to lS 9573 Type IV .J 7 Pipeline test record and joint radiography and cover in the form of Dioe .book 8 · HSSE Manaaement System _ 9 Emergency Response Plan, . ·Disaster • Management Plan and written emergency procedures .. Also, provide for an Emergency Control Room, manned round · the clock and equipped with effective communication system and emergency vehicles fitted with communication facilities, first aid equipment, fire extinguishers, gas detectors, repair kits and tools, maps, .

plans, material safety data sheets etc. at its disposal.

* commencement of implementation . Time period for lmJWementatlon plan . lmplem,ntatlon • 1 year 1 year 6 months ., 1 year 2 years 6months * 3 months 6months 6 months Modification of CGS skid .

Automated odorisation systems to be used · lncrease height of vent lnstall gas detectors in the CGS and District Pressure Regulating Station.

Modification/ replacement Replacement qf all rubber hoses l5'l fiftv thousand oer vear Can be submitted in stages To be implemente.d To be implemented ['q!lTil-~3(i)] • 51 • ' -- " Schedule - I (See regulation 6) Technical Standards ·and Sp~cifications .

including Safety St,an<;lards .- - · for . ·· City or "Local Natural Gas Distrib·ution ~etwork i'.

Schedule - 1A MAT·ERIALS AND EQUIPMENT· Schedule - 1 B WELDING . ' Schedule - 1c. PIPING SYSTEM.COMPONENTS AND FABRICATION D'ETAILS Schedule - 10 DESIGN,. INSTALLATION AND TESTING · Schedule - 1E OPERATING AND MAINTENANCE " PROCEDURES . · Schedule-1F ·CORROSION CONTROL . .

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Schedule - 1G M:l·SCELLANEO.US ' ( .~ .

S2 • THEGAZBITEOFlNDIA: EXTRAORDINARY . (P Ai« II-Soc. 3(i)] Schedule - 1A ( .

MATERIALS AND EQUIPMENT ,. .

MATERIALS AND EQUIPMENT All materials ,. and equipm~nt forming a.

permanent part of the any piping system constructed according to this stand;ird shall be qualified for conditions in which it is to be used.

MATERIALS FOR USE . IN COLD CLIMATES Materials to be used in facilities exposed to low ground or low atmospheric temperatures or low operating temperatures shall have adeqUate impact pl'.Operties to prevent brittle fracture at low temperatures.

·MATERIAL SPECIFICATIONS In addition to standards and specifications .

covered in AS_ME B. 31.8, standards and specifications listed in Annexure-1 shall also be acceptable for manufacturing of various piping components forming part of the CGD network.

Stee .. Pipe Carbon steei used in CGD networks shall meet following requirements:

Carbon Equivalent For pipes having Csrl:J~n Content > o. 12% CE(llW) = C + Mn + Cr+-Mo+V: • ~ 6 . 5 ... 15 CE (iiw) value shall be 5: 0.43%.

For pipes having Carbon Content s 0.12% CE(Pcm) =C + Si +Ml! + Cu + Ni +Qr+ Mg_+ 1( + 58 30 20 20 6Q 20 15 10 CE (Pcm) value shall be ~0.25%.

Notch Toughness . For· carbon· steel pipes of size NPS 2 and above, notch toughne$s shall ·be specified.

Electric welded pipf,s used shall also meet additional requirements specified under Annexure--111 of this standard.

Ductile Iron Pipe Use of ductile iron pipe is not permitted for CGD networks for transport of natural gas.

Plastic Pipe and Cornpopents Thermoplastic pipes, tubes and fittings are recommended for use in city · gas distribution networks.

Polyethylene (PE) 1 pipes CQnformlng to IS 14885 or · ISO 4437, and PE . fittings conforming to ISO .8085 Part 3 shall be acceptable.

. Reprocessed material shall not be used.

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Colour of pipes used for gas service shall be yellow for PE 80 arade and Orange for ·PE 100 grade.

I • .PE pipes shall be perman~ly marked · (either impressed or embossed to a depth I · height of 0.02 to 0.15 mm).

Pfpea and tubing for above ground service lines up to meter set aa .. mbly.

Galvanized Iron (GI) pipes shall be used in above ground service -lines up to consumer meter or meter· control valve. The usca of copper tubing shall only be after consumer meter such that this is not accessible to third party. GI pipes and copper tubing shall conform to the requirements given in Annexure-IV of this standard. Use of [~11-:l§q3(i)] non-galvanised . pipes should. be restridecl as far as p(>sstble; however, in case theY · are ueed they' shall be properly protf#Cted and ~inteGI. · PE pipe shall not be used for above ground gas pipes.

Tubing I Hose pipe for ' connecting consumer meter set asaemblY and consumer a~ianca .

The connection between consumer meter set as5embly _and gas appliance (provided.

by consumer) may be made by GI ·1'iPes or copper tubing meeting requirements ·given in Annexure-IV of this standard or steel . reinforced rubber hose·.

Steel reinforced rubber hbse shall· conform to lS: 9573 Type IV:

EQUIPMENT SPECIFICA 110NS . Equipment used in CGD network manufactured . to standards listed in • 53 Annexure-U ¢ this . standard shall . also be _acceptable.

CONDITIONS FOR REUSE OF PIPE Reuse of Ductile Iron Pipes Reuse of ductile iron pipes is not permitted.

Reuse of Plastic Piping Reuse of plastic· pipes is permitted subject to the following. · a. . Its original and manufacturing · specifications are known and documented.

b. . It meets the requirements of new pipes conformi.ng to its manufacturing specification~.

. c. The pipe is free from visible defects.

d. · rt is installed and tested in acc6rdance · · · . with rE9Quirements of this standard. All testing shall be carried ·out at recognized independent laboratory and records of the same are maintained Schedule - 1 B ,,WELDING \ GENERAL These requirements apply to steel pipe and components only.

Notches or laminations on _pipe ends are not pennitted and must be removed by .

cutting the pipe as a· cylinder .and re­ beveling of pipe end prior to welding. . / .

·QUALIFICATION AND PROCEDURES OF WELDERS Welding procedurea and welders for welding of gas pipelin~ shall be qualified as · per · API 1104 and shall · include toughness · testing requirements as applicable for the line pipe.

INSPECTION OF WELDS All Non Destructive T eating (NOT) including radiographic. ·examination shall . be performed . in accordance · with . the JlMIUirements of API 1104 except that no root crack shall be permitted.

Regardless of operating hoop stress as wall as IQCation cl&Ss all carbon steel· butt welds shall be 100% radiographed. In case - radiography ill not possible due to safety reasons, weld shall be examined 'by using · ultra sonic t.mniques.

REPAIR OR REMOVAL OF DEFECTIVE WELDS 54 THEGAZETFBOFJNDIA: mRAORDlNARY [PAKT ~ 3(i)] Welding procedures and welders, for etatk>n piping shall be qua~ified as per ASME Boiler and Pressure. Vessel (BPV) Code Section IX or API 1104.

When welders qualified under API 1104 are employed for · station piping, . ~eir qualification shall be based on destructive mechanical testing as per API 1104.

Welds having·~ sh~H be removed or ret-ired in accordance With API 1104 or ASME BPV code Section IX as applicable.

WelderS employed for repairs shall be qualified in accOrclance with "Qualification and Procedures of Welders".

Weld repair areas shall be subjected to additional radiography or ultrasonic testing after~ir.

Schedule - 1 C PIPING SYSTEM COMPONENTS AND FABRICATION-- DETAIL'S PIPING SYSTEM COMPONENTS.

General In addition to standards and specifications covered under ASME B 31.8 for various piping components, piping components manufactured conforming to standards and specifications listed -under A{lpexure-1 of this standard shall also be acceptable.·. · Valves and Pressure Reducing Devices Valves body, bonnet, cover and/or end flanges components made of cast iron and I ductile iron (as per ASTM A 395) shall not be used in CGD networks. · ·· · Valves used in service lines of siZe NPS 2 and below shall conform to BS EN 331.

Flanges Flanges made of cast iron, ductile iron and non.;ferrous · materials (brass or bronze) shall not be used in CGD netviorks. . • Use of flanges in natural gas transmissio.n and . distribution piping . ls not permittE!O except for station piping e.g. CGS, DRS, MRS etc.

· Fittings other. than Valves and Flanges Fittings made of ca$t iron and ductile iron shall not be used in CGD networks.

All plastic fittings used in CGD networks must ·have been type tested by an internationally recognized testing agency prior to their use.

Thermoplastic I thermosetting fittings shall not be used in above ground piping system. · Thermoplastic fittings conforming to 1$0 8085 Part 3 shall be acceptable and shall meet following requirements:

a. Polyethylene resin used for.

manufacture of thermoplastic fittings ~shall . be vir9in, cadmium free pigmented compound. Anti-oxidant and UV stabilizers used in· PE· resin . shall" not e~ceed 0.3 and 0.5 percent respectively. ijeprocessed- material shall not be used. · b. · Gra'tie of PE compound used for the fittings should not· be less than that of PE pipes. In case fittings Are of different ·grade than that of pipes, compatibility of the same with pipes shall be established prior to their use.

, t:iowever, in case of higher grade flftihgs separate· compatibility test shall not be required. Heating element shall / ['lPTII-~3(i)] . 'flUP.fil~: ~·. 55 For piping class 15(). or above all the . not be exposed and all coils are flanges shall be with raised face. embedded into the body of the fittings.

c. Colour of fittings shall be yellow or Bolting black.

d. , Electro--futipn fittings complying with All stud bolts and nuts used in · CGD ISO 8085 Part 3 I EN- 1555 -3 shall . networks shall be hot dipped galvanized as. be used for all sizes of PE pipes.

per ASTM.A 153 or equiv~lent. Fittings fabricated ftom pipe shall not be· used. ·only injection moulded fitting$ are recommended.

of the body of the fitting and for size . above 63 mm external alignment clamp shall be used.

f. Each "E:lectro Fusion fitting shall be bar · coded. Fusion fittings shall have permanent fusion indicator or .a data card conforming to 1s0-1e1011so-

7811.

g. The fusion jointing shall be carried out a~ per .the procedure outlined in the standard DVS .2202 or equivalent.

h. Carbon steel . part of transition fittings used for connecting PE system with Carbon Steel system may have butt weld/plain/flanged ends. .

Special Fittings Mec~nical fittings for . making hot. taps on pipelines and mains . shall not be used.

Fittings for hot taps ·shall be welded type {for steel pipelines and mains) and electro fusion· type {for thermoplastic mains and service lines).

e. For fusion fitting upto 63 mm, pipe fixation device shalf be an integral part EXPANSION AND FLEXIBILITY Flexlblllty Requirements When maxipium gas temperature expected· · during operation is below 65°C, thermal"'-.

expansion and stresses in the above ground steel piping shall be evaluated considering pipe temperature of 65°C.

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1llE GAZE'ITEOFINDIA:EXTRA.ORDINARY [P ARI' II-SEC. 3(i)] Schedule - 1 D DESIGN, INSTALLATION AND TESTING DESIGN INSTALLATION AND TESTING General Provisions The selection of design for city gas distribution network shall be based on the gas properties, required flow , rates, operating pressures and the environment.

CGD network Description .

A typical CGD Network should comprise of one or more or all of the following:

i) Primary network:, A medium Pressure Distribution System comprising of Pipelines, · Gas Mains or Distribution Mains normally constructed using steel pipes and connects one or more Transmission Pipeline to respective CGS or one or more CGS to one or more DPRS. The maximum velocity· in the pipeline network should be limited to 100 ft I sec (30 mlsec) immediately after pressure regulating instrument.

As far as practical, primary network should .

be fed through more than one city gate stations I sources of supply. The operating pressure shall be as defined under General Terms, ii) Secondary Network: A /ow Pressure Distribution System comprising of Gas Mains or Distribution Mains usually constructed using thermoplastic piping (MOPE) and connects DPRS to various service regulators at commercial, industrial, and domestic consumers. The network shall be sized for maxim uni flow velocity of 100 ft · I sec (30 m/sec). , iii) Tertia,Y Network: A service Pressure Distribution System comprising cf Service Unes, Service Regulators. ahd customer/ consumer Meter Set Assemblies constructed using a combination of thermoplastic, {MOPE} piping and GI/ copper tubing components ..

/ [Note: for Italicized tenns used In description of above network$, deftniti<>M as per ASME· B 31~8 shall apply] iv) City gate.' station (CGS): typically comprising of, but not limited to, the following facilities:

Filters · , Separators {if required) .

Metering facilities.

He~ter {if required) Pressure reduction · skid comprising active· and monitor combination with- a · m1mmum 50% redundancy with stream ctiScrimination arrangement, including slam shut valve for over and under pressure protection and creep relief valves (stream redundancy shall not be less than 2+1). · · Online odorization equipment designed to minimize ~itive emissions during . loading, operation and maintenance.

v) Distribution Pressure Regulating Station or District Regulating Station (DPRS): Located at various demand centers for domestic I commercial users typically consists of:

Gas filter.

. Heater (if required) .

Pressure ~reduction skid comprising active and monitor combination with ·i:ninimum 50% redundancy with stream discrimination arrangement, including slam shut valve for over and under pressure protection with additional feature of under pressure protection if required( stream redundancy shall not ·be less , than 2+1).

Inlet and· outlet isolation valves.

.· • . ['WT II (5fUS 3(i)] l vi) Individual Pressure Regulating Sta(ion (IPRS): Located at the premises· ·of an individual customer and having facilities similar to DPRS howev~r. monitor regulator may or' may not be provided. Meteri~g · facilities may or may not be· part of this station.

vii) Service Regulators: Usually f oca~ed at customer premises for maintainirtg supply pressure and designed to maintai~ safe condition even in the event of rupture in the regulator downstream section. , Network Design Requirements The design. of . CGD Networks and its components shall be such that it ensures:

Supply of gas at constant volume into a system, which fluctuates in pressure between pre-deterrtlllned upper and lower limits in the distribution network, m· .

Supply of gas at a constant' pressure at consumer end, and The design should cecognize th.e ne:ed _·· for safe guard against malfunction of , any equipment and ·provide sufficient redundancy to ensure that the supply is secured against such malfunctions.

·Facilities forming 'part of CGD networks shall be designed considering:

Range of flow rates and pressures required in various sections · of the .

network Quality of gas, including cleanliness in respect ·of both solid· and liquid particles.

Metering requirements.

Noise control and Corrosion Protection Necessary calculations shall ·be carried out to verify structural integrity and stability of the pipeline for the combined effect of pressure, temperature, bending, soil/pipe interaction,· external loads, and other environmental pararheters as applicabte, during all phases of work from· installation to operation. Such calculations shall include, but not limited to, the following:

3225 G//08-8 57 Buoyancy control and stability of pipeline in areas . subjected · to flooding I submergenc1, River crossing to · be installed by trench less techniques, wherever soil data is favorable for . such installationS', Damage potential for steel pipeline from hazards associated with ·earthquake, if applicabl~.

Layout of Station Faciliti~s The following aspects are• to be considered in deciding layout of facilities at CGS, DPRS, I PRS, etc. .

i. Type and size of equipment.

ii. P&IDs iii. Utility requirement.

iv. Venting wherever required ..

v. Operation· and Maintenance ·philosophy.

(a) City Gate Station As far as possible the city gate station (CGS) shall be insta!led at the periphery of populated area. The entity sl')ould make · best endeavor to have more than one CGS for supply security.

Inter distance between · various facilities required at CGS shall be as per Table - 1.

Table-·1 : Inter-distance between Facilltlent CGS Sr. ' From /To 1 2 3 4 5 • 6 No.

1 Compound Wall - 6 6 6 6 6 Control Room I 2 Office Buildi11g I 6 - 12- 12 2 15 1 I Store ..

Pressure 3 Regulation and 6 12 - 2 12 15 (or Meterinil ·4 Odorant 6 12 2 - 12 15 System Electrical Sub - 2 12 12 - 15 5.

Station # 6 Gas fired 6 15 15 15 15 -heaters - ·- 58 nm OAZBTI'E OF INDIA:· EXTRAORDINARY [P.w II-Sac. 3(i)] .

NotH:

1. All dl1tance1 are In meters. All dlatancei 1hall be meaaured between tlie neareat polnta on the perimeter of each facility.

2.

# For all the dletance from the compound wall, the dletance mentioned In thle table and the local .

byelawa, whichever 11 high•~ II to be conaldered.

A• per State recommend•tlona. • ., Electricity' Board Properly laid out roads around various facilities shall be. provided within - the Installation area for· smooth vehlcul.ar access.

Facility shall be provided with proper boundary wa11 · / fencing with gate(s) In line with MHA (Ministry of Home Affairs) guldellnes., · · Burled piping Inside the CGS area shalt have a. minimum depth of·. cover of 1.2 m.

Where burled pipes come out of the ground, the underground coating . on the 'pipe wlll.

continue for a length of at least 300 mm above ground.

Platformi and crossovers ahall be provided for ease of operation and maintenance of equipment and piping where required.

Provlslcm should be made for venting, purging and draining all sections of pipe work and equipment that may have to be isolated during construction · or maintenance.

All vents· shall be routed to a safe area and in ·a manner that gas vented out is blown away from the nearest bulldlng. Height of vent shall be minimum th~e (3) · meters above working level. Distance between vent and boundary wall / fence shall be minimum five (5) meters.

Gas detectors shall be Installed at strategic 1'lcatlons covering to detect any. gas leakage.

In case fired gas· heaters. are Installed for h•ating of gas, all other facllltl•s handling gas should be located down wind from heaters.

(b) Distribution · Pressure Regulating Stat/on (DPRS) and Individual Pressure Regulating Station (IPRS) · DPRS facilities can be located above ground or below ground.

In case DPRS is located below ground, the facilities shall either be inside a enclosed chamber with a provisions for entry of authorized p•rsonnel or. be a buried hermetically sealed module type with proper cathodic protection.

For below ground installations, the vent line shall be terminated at a minimum height of three (3) meters above the ground tevel. · IPRS shall normally be located above ground.

DPRS/IPRS installed above ground shall be provided with proper security fencing as per requirement of local · authorltle_1. The dls~ance between fencing and the wall of nearest building J structure shali not be less than two (2) meters.

[NOTES:

' I. Tht coMumer, ahall be reaponalble for enaurlng the Hparatlon dlatancea for cuato,mer owned IPRS · · II. Cuatomer ahall ·•naura that IPRS lnatallatlon haa. bffn · lndepindently approved by certified third party agency before the entity auppllea ttw gaa. .

Ill. Tha conaumer ahall enaure recertification once In 3 yeara.

Requirements for Electrlcal Installations In CGD Network All \electrical equipment I Installations shall meet fotlowlng requirements:

Electrical area classification of Installation, as basis for selection of Electrical Equipment, shallfollow IS-

5572.

The specification I. of Electrical equipments shall be In llne with IS - 5571, "Gulde~ for selection of Electrical Equipment for Hazardous Area". · ["'1111--aq 3(i)] Fire protection In Electrical installations shall be provided as per requirements specified in this standard.

•• All electrical equipment, systems, 'Structures and fencing, etc. shall be suitably earthed In accordance with IS 3043. The earthing system shall have an earthing network grid with required number of eleetrod••· All Electrical equipment operating above 250 volts shall have two separate and distinct connections to earth grids .. , Separate earthing grid shall be provided for instrument and electrical power.

Lightening protection shall be provided as· per the requir-ements of IS:2309. Self conducting structures having metal thickness of more than

4.8mm may not require lightning protection with aerial r6d and down conductor&. They shall, however, be connected· to the earthing system, at least, at two points at the base.

Instrument and Control System Instrumentation and control system for the CGD networks, shall in general meet the requirement of API Standards: APl­ RP-551, 552, 553, 554, 555 and 556 "Manual on Installation of Refinery · Instruments and Control Systems" to the extent applicable.

Buildings Intended for Human Occupancy and· Location Classes for Design and Construction For the purpose of determining number of buildings for human . occupancy and Location Classes, 1 - mile distance shall be · replaced by 1600 m and fractions thereof.

In case ·of cluster of buildings, Location Class 2 . or Location Class 3 may be • terminated a distance of 200 m from the nearest building in the cluster.

Location Class 2 or 3 shall be terminated at least 200 m from the ·end dwelling i.e.

59 dwelling located at the boundary . of the Location Class 2 or 3 as the case may be.

. When presence of multi-story buildings alone result . in Location Class 4, the Location Class 4 ends 200 · m from the nearest building with 4 or more stories above grol!nd.

This standard does. not allow Design of pipelines and piping a~ per Location Class· 1, Location Class 2 and Location class 3. .

location Claas 1, 2 and 3 shall be used only for. re-certification of existing Installations and facilities, which were laid/built/constructed before the date of notification of these -regulations.

STEEL PIPE Additional Requirement for Nominal Wall Thickness Consideration shall also be given to loading .

due to following while selecting nominal wall thickness t as per ASME B 31.8 as appropriate:

Overburden loads Dynamic and seismic loads Cyclic and vibratory loads Internal pressl;lre fluctuations Geo-technical loads (including slides, differential settlement of piping, loss of support, and thermal effect of the · pipeline ori soil properties).

In any case minimum thickness of Qipe .

· permitted as per this standard shall not be l~ss than 6.4mm, irrespect~ve of the grade of the pipe material. ' In all existing cases where thickness of pipe is less than 6.4 mm, Quantitative Risk Assessment shall be carried out and the risk level shall be reduced to ALARP (As low as reasonably possible).

Design Factors F and Location Classes Design factor corresponding to Location Class 4 shall only be used.

, THE GAZETTE OF INDIA: EXTRAORDINARY [PART II-Soc. 3(i)] All exceptions to basic design factors to be used in design formula shall be as per Table ~ 2 of this standard.

Pipelines or Mains on Bridges Pipeline on bridges should be avoi,1:ied.

Under unavoida.ble conditions, pipeline installed on railroad, vehicular, pedestrian, or other pipeline bridges, a design factor of · 0.40 shall be used for Location Class 4.

In cities where crossing the river through HOD crossing is not possible, pipeline laying on river bridges is permitted. · Metering Facilities Upstream dry gas filter(s) shall be installed when rotary or turbine meters are used.

Pressure I Flow Control Faciliti&$

(a) Protection against over pressure of . pipeline or mains .. downstream of ·city gate station (CGS) shall be provided as follows:

(1) The provision .of Active I MonitoF Regulator System (i.e. monitor regulator in series with a controlling (active) regulator) shall be the principal method of controlling pressure.

[Note : To avQid problems associated with a regulator being at rest for prolonged periods it is recommended that the monitor regulator is. so · impulsed that it can also operate as a first stage regulator.] ··

(2) Adequately sized pressure relief valve(s) could be used for overpressure protection downstream of controtting regulator(s) provided Quantitative Risk Assessment is made for environmental hazards (fire I explosions) associated with large reiease of gas volume of gas release and the risks . are· found within . acceptable level.

Pressure relief valve(s) should be carefully sized to meet· their required duty and ·to minimize the volume of gas released. The speed of relief valve opening should be adequate and they should re-seat cleanly when normal pressures are restored. The relief valve should be installed and provided with . test connections in the impulse pipe work in such a way as to enable them to be set up·and tested in-situ. ·

(3) .. Over pressure shut-off valve(s) or Slam-Shut · Valve(s) upstream of the · controlling regulators are preferred as overpressure protective devices instead of.

pressure. relief valves. Being ultimate overpressure protection for the pipeline system, ·it is essenti~ that the Slam-Shut valves are fast closing, highly reliable and secure valve. · ·

(b) .The isolation valve of the .. sensing lines of regulators and slam shut valves should have provision for' locking in open position.

(c) · Additionally suitable gas heaters upstream of ·regulators l control valves/ .pressure reduction system should . be provided in case after pressure let down operating oonditions would re.suit in low temperatures beyond d&sign conditions of · downstream facilities.

(d) Sound pressure levels shall be limited to the values prescribed by Environmental Authorities but in no case it shall exceed

110dbA.· ' . - Table 2 - Design Factors for Steel Pipe Construction Facility Location Class 1 *' 2* 3* 4 Pipelines . 0.72 0.60 0.50 0.40 Crossings of roads, \IVithout casing:·

(a) Private roads 0.72 0.60 0 .. 50 0.40

(b) Unimproved public roads /0.60 0.60 0.50 0.40

(c) Roads, highways, or public streets, with hard 0.60 0.50 0.50 0.40 surface Crossings,of roads, with casing:

(a) Private roads 0.72 0.60 0.50 0.40

(b) Unimproved public roads. . , , , 0.72 ~ 0.60 0.50 0.40

(c) Roads, highways, or publi" streets, ·'Mth hard • 0.72 0.60 0.50 0.40 surface and Railwav crossinas Pipelines on bridges '

0.60 ; .0.60 0.50 0.40 Parallel Encroachment of pipeline on roads and railways

(a) Private roads

(b) Unimproved public roads . 0:72 0.60 0:'50 0.40·

(c) Roads, highways, or public streets, with hard 0:12 0.60 0.50 0.40 surface and Railwav crossinas 0.60 0.60 . 0.50 0.40 Pipeline on bridges 0.50 0.50 0.50 0.40 River Crossing- open cut l'J 0.72, 0.60 0.50 0.40 Horizontal. Direction Drilling (HOD) " 1 0.72 0.60 0.50 0040 Compressor station piping 0.50 0.50 0.50 0.40 ·Fabricated assemblies (scraper traps, SV stations, 0.60 0.60 0.50 0.40 pressure/flow control and meterina facilities ·etc.l f.21 Near concentration of people In Location Clasees 1 and 2 ~ - '

0.50 0.50 0.50 0.40 Notes:

1 Higher thickness may be used if required to control stresses or stabiHty during installation and operation.

2 Thicker pipe in Location Class 1 is required throughout the assembly and for a distance equal to lesser of 5 diameters or 10 ft in each direction beyond the last fitting.

3 Near concentration in Location Class 1 and 2 means places of public assembly (school, temple, church, hospital, club, markets places etc.). used by 2Gor more people frequently.

* Location Claas 1, 2 & 3·ahall be used for the purpose of recertification of Existing Installations only. , • 61 62 THEOAZETI'E OF INDIA: EXTRAORDINARY [P ARI' II-Sac. 3(i)]

(e) Gas velocities in piping up to 20 m/sec before filter and 40 m/sec (120 ft I sec) after filter, at peak flow conditions, may be permitted provided care is taken to .ensure that allowable sound pressure values are not exceeded and materials selected are suitable to prevent erosion at such high velocities.

However, the gas velocity shall not cross the recommended velocity given by the Original Equipment Manufacturer ·.for the equipments used in the PRI.

(f) Gas filtration facilities ·with 100% redundancy shall be provided to avoid damage to inatrumentation and other facilities.

(g) Immediately downstream of regutators or control valves, use of conical reducers is recommended. ·

(h) ·In order to prevent over pressurization of piping downstream of regulators I control valves, creep relief valve should be · provided, if required.

(i) For isolation of the CGS during emergency, quick closing .valve (with remote operation facility in case of unmanned station) shall be installed at the inlet of CGS.

Protection of pipelines. and mains from hazards When steel pipelines or mains are installed in areas that are normally .under water, anti­ buoyancy measures adopted shall be such that specific gravity of resulting installation is 1.10 or more.

Pipelines and mains installed on bridges and other locations where they are exposed to accidental damages due to vehicular traffic, suitable. barricades I crash guards shall be installed for their protection.

The pipeline in .close proximity to unstable structures, · landfill sites or where construction could lead to damage to pipeline, should be avoided.

Pipelines and mains 'installed in the areas • normally under water or subject to flooding (i.e. lakes; bays, or swamps etc.) shall be provided with addition . anti-buoyancy measures such as concrete weight coating, geo-textile bags filled With graded stones .or anchorages, etc. to prevent floatation.

Minimum specific gravity of Installation shall be 1.2 afte[ providing anti-buoyancy measures.

Cover, Clearance and Casing Requirements for Burled Steel' Pipelines and'Malns . .

Minimum depth of cover for buried steel pipelines shall be as per the table given below;

Table-3 : Minimum Cover Requirements for Steel PIPellnes Location Min. Cover'-11 (ml Normal I rocky terrain 1. 0 Minor river I unlined canal I.

nala. crossings, tidal areas 1. 5 and other watercourses121 " ·Major river crossingsl21 2.5 Rivers with rocky bed 1.5 Lined canals I drains I nalas 1.5 etc.

Drainage ditches .at 1. 0 roadways and railroads Rocky Areas 1..0 Cased I uncased road 1. 2 · orossings131 Cased railroad qrossingsl3l 1. 7 NOTES:

1 ; Cover shall be mea$ured ~om the top of ·coated pipe to the top of the undisturbed surface of soil or- the top. of graded working strip, whichever is lower. The fill material in the working strip shall not be cansidered in the depth of cover.

2. For river l watercourses th1rt are prone to scour and I or erosion, the specified cover shall be measured from the expected lowest bed profile after scouring I erosion. Where scour · level cannot be established, an additional cover of minimum 1 meter shall be provided from the · existing bed of the river/water course.

3 The cover shall be measured from the top of .

' road or top of rail, as the case may be. · _.

['WT II-111'ti 3(i)] Whenever the above provlalona ()f cover cannot be. provided due to alte constraints, additional protection in form of casing/ concreting etc. shall be provided. · .

. - Clearance between Plpellnes or Mains and other underground structure•

(a) yvtien a buried steel pipeline or main has to cross any existing underground pipeline, cable, drain. or other services, the pipeline shan be laid at ~east 300 mm · below from such services.

· (b) VVhen laid parallel to any existing underground cable, drain or other utllitles, the pipeline or main shall be laid with a clear distance. of at least 300 mm from existing utlllty.

(c) . As far as ·practical, a minimum · separatfon of. three (3) meter should be maintained between the steel pipeline or main and footing of transmission tower.·

(d) A clearance sufficiently 1 large .· to avoid ele~rical fault current interference shall be maintained between the pipeline and the ,grounding facilities of electrical transmission lines.

/

(e) Clear distance between new steel pipeline or main running parallel to . existing pipeline should be minimum s·.o meters when heavy conventional construction equipment is expected to be utilized. This distance may be reduced, after careful assessment of construction methodologies, to three (3) . meters, provid~d it does not result in unsafe conditions during construction~ Existing plpellne should be clearly marked on the ground during construction. Bi-language (local language and Hindi l English) caution signs should be !nst•lled while working in such areas.

. (f) VVhlle laying more than one new hydrocarbon pipelines or mains . in the same trench, clear separation of minimum 500 . mm shall be maintained · between adjacen~ pipelines.

(g) ' No steel pipeline or main should be -, located within three (3) meters of any .

habitable dwelling or any Industrial· building unless it. is provided with at least 300 mm ·of cover over and ·above· minimum cover specified under Table - 3 above or · special protective · measures such as .concrete slab, steel casing are provided. · , Casing Requirements und•r Rallroads, Highways, .Roads or Streets Steel casing at road/railway crossings, when provided to meet statutory requirements, shall be designed in accordance with AP1 1102. Casing pipe djameter shall be minimum two pipe sizes bigger ttian carrier pipe. In case of PE, the casing· can be RCC pipe of min NP3 class.

Bends, Elbows and Miters In Steel Plpellnes and Mains · · Miters bends and wrinkle bends are not permitted in pipelines and mains used in CGD networks regardless of operating hoop stress. .

Cold field bend radius for pipes of size NPS 20 and. larger shall be minimum ·40 · times the pipe diameter.

AS far as possible use of short radius elbows should be avoided .

Hot Taps Split tees designed to fully encircle the pipe shall be used for making· hot taps. The split · Tees shall be . designed considering a minimum design factor F = 0.40.

However, in case of Hot taps of size upto 1/41h · of the nominal bore of. the main pipeline, use of weldoletr is permitted in place of split tees.

Full bore ball valve shall be used when making branch connections using hot taps.

Recommendation• as per API RP 2201 - Recommended Practice for Safe Hot Tapping Practices In the Petroleum and Petrochemicals Industry shall be followed whlle carrying out hot tapping works.

64 TIIB GAZETTE OF.INDIA·: EXTRAORDINARY [PART II-Soc. 3(i)] Where it is not possible to maintain the clearances, cover, vent locations etc.

mentioned in this standard, the entity shall carryout special design and construction . methodologies through experienced · personnel/consultant and seek clearance from the Board.

Testing after Construction General Provisions,.

. Proper communication facilities shall also be arranged for during testing.

Testing equipments I instruments shall be properly inspected and shait have valid calibration certificates before they are used for testing.

Test . Required to Prove Strength of Pipelines and Mains to operate at Hoop Stresses of 30% or more of Specified . Minimum Yield Strength of Pipe All buried steel pipelines and mains shall be pressure tested after installation using water ·as a test medium, Minimum test pressure shall be equal. to 1.4 times.

Maximum Allowable Operating Pressure.

lest ·procedure as per ASME B .31,s Appendix N "Recommended Practice for Hydrostatic Testing of Pipelines in Place" · shall be followed.

Hold-up time for the . pressure testing shall be minimum 24 hours for underground and four hour aboveground pipeline.

Safety During Tests Relevant Warning Signs shall be displayed at the test area.

The test area shall be properly cordoned to prevent any accidents.

A proper Emergency Response Plan shall be in place and emergency contact numbers of relevant agencies should be viSible.

Commission_ing ~f Facilities .

Appropriate Work Permit· should be issued based on the kind of activity.

Fire fighting equipments ·. should be available during commissioning.

Proper communication facilities should also be arranged for.

A proper Emergency Respon~e Plan should be .. in place and emergency contact numbers of relevant agencies should be available.

OTHER MATERIALS Ductile Iron Piping System Requirements Use of ductile iron piping is not permitted for· CGD networks as per this standard.

Design of f»lastic Piping Plastic pipe shall not be used for Pipeline and Distribution Mains operating at pressure ·in excess of 100 psig.

Use . of thermosetting plastic piping· is not· permitted as per this standard. · Plastic Pipe and Tubing Design Formula Nominal wall thickness. of plastic pipe shall be calculated as per following formula:

P·= 2S * (t I (D-t)) * 0.32 Where D = Specified outside.diameter in mm P = Design pressure in psig t = Nominal wall thickness in mm S = Long term hydrostatic strength in barg (psig) determined in 'accordance with , ,. applicable pipe . specification at temperature equal to 73°F, 100°F or 120°F.

• . '.

Thermoplastic Design Limitations The design pr~ssure shall not exceed 100 psig (7 bar).

Thermoplastic pipa, tubing and fittings shall not be used where operating temperature of the materials will be:

1) Below 32°F(O degree centigrade) or 2) Above 120°F (50 degree centigrade) or temperature at which long term hydrostatic strength use~ in design formula in para 842.31 of ASME B /

31.8 is · determined, {whichever is lower). · ' Minimum thickness shall not be less than • 2.3mm.

Pipe wall thickness selected shall be such · that it corresponds to Standard Dimension Ratio indicated in Table - 4 below. Pipes with non ·standard SOR should not be used.

Table 4 - Wall Thickness and Standard Dimension Ratio for Thermoolastic pipes Nominal Minimum wall thickness in Outside mm for Standard Diameter Dimension .Ratio, SOR lnmm D 17.6 13.6 11 9 16 2.3 . 2.3 2.3 2.3 20 2.3 2.3 2.3 2.3 25 2.3 2.3 3.0 3.0 32 2.3 2.3 3.0 3.6 40 2.3 3.0 3.7 4.5 50 2.9 3.7 4.6 5.6 63 3.6 4.7 5.8 7.1 75 4.3 5.5 6.8 8.4 90 5.2 . 6.6 8.2 10.1 110 6.3 8.1 10.0 12.3 125 7.1 9.2 11.4 14.0 140 8.0 10.3 12.7 15.7 160 9.1 11.8 14.6 17.9 180 10.3 13.3 16.4 20.1 200 11.4 14.7 18.2 22.4 3225 Gl/08-9 .'

.._ -... ··,· ...... - 65 . Design Pressure of Plastic F.i~ing All fittings used shall be electro fusion type.

Other types of fittings are not permitted. All · PE fittings shall conform to ISO 8085 -Part

3. The wall thickness of the .fittings shall be more or equal to the wall thickness of the pipe jointed. · Protection from Hazards In addition to requirements specified under Para titled Prote.ction of Pipelines and . Mains .from Hazards in this standard, _following additi.onal requirements shall be · complied with.

The relative position of CGD network with . respect to other und~rground utilities shall be as given in Figure 1 :

Where open cut techniques are used, a warning tape of Yellow colour shall be laid 200 mm above the pipe.

E6 THE GAZEITE OF INDIA: EXTRAORDINARY [P AKI' II-SEC. 3( i)) Road Berm I Footpath ~--.··.

1 2 30 0 ! .

4 0 0 • .o 0 1 / 2 - El8e. ;able (LowVoltage) 3 Telecom Cable 4 Elec. Cable (High Voltage) 5 Gas Pipeline · 6 Water Pipe!ine I sewage line 7 Other hydrocarbon product pipelines Figure 1.- Relative Position of Gas Pipeline and Distribution Mains Figure 2 (a) - Concrete Slab . ___,... - - - -- - - - ·-,.-_.-°"""""' .. · ~ ::r:::::~=----l .--- V.nlcodt.ptobe ... _... ....... ...,c.,....,... ....

to be QIVen to reinforC9f'Mld ot vtnieal memt.n.......-J.-- 1 h, 250mm Figure 2 (b) - Concrete Slab with supports When insisted by the authorities at identified locations, a layer of brick ·/ concrete or impact resistant tape may be laid ·over pipeline as a protection against excavating machinery as indicated in the Figure - 2 (a) or (b).

Plastic Pipe and Tubing Joints and Connections General Provisions· Threaded joints in plastic pipe are not permitted. - Plastic piping joints shall be made by Electro Fusion fittings only. Fusion fittings shall have inbuilt positioning provision upto 60 mm and beyond external clamp system.

Jointing of plastic .Piping by buit fusion method, solvent cement method, adhesive method,· heat fusion niethod or by means of compression couplings or flanges is not permitted. Recommendations of the fitting manufacturer shall be followed. in this regard.

All electro fusion fittings shall be bar coded and the control unit shall be equipped with bar code reader to directly transfer fusion data to· control unit: Bar -coding shall be long lasting even when the joint .is buried in corrosive soil, alternatively each fitting shall have a data card which can be read by the computer and thereafter the card is positioned with-the joint.

Installation of Plastic Piping Installation Provision Use of thermoplastic piping in above ground piping is not permitted. unless the piping is completely protected against deterioration (e.g. · hign temperature, ultra violate degradation) by corrosion protected metallic . or reinforced concrete· or Glass Reinforced Plastic (GRP) enclosure.- ['WTII-~3(i)] Direct Burial Directly buried thermoplastic pipe shall have a minimum thickness of 2.3mm.

Trench width shall be at least 300 mm., The bed of the trench shall be free· of sharp objects .. stones etc. In rocky areas trench shall be padded with soft' soil or sand to minimum depth of 150 mm below the pipe.

Bends and Branches Branch connections shall be made only by socket type electro fusion tees or electro fused Saddle connections.

Hot Taps · Use of special saddle or split tee type electro fu~ion fittings for hot tapping ls permitted. • Testing Plastic Piping after Construction General Provisions Testing equipments I instruments shall be properly inspected and . shall have valid calibration certificates before they are used for testing.

Proper communication facilities shall be available during testing.

Test Requirements Thermoplastic piping shall not be tested at material temperature above 120°F (50 degree centigrade):

Test me-dium shall be air or nitrogen for test pressure up to 100 psig. For test pressure higher than 100 psig, water shall be used as test medium.

Test duration shall be minimum 24 hours for plastic distribution mains of length greater than 1 km and minimum 4 hours for length shorter than 1 km.

In case water is used as test medium, tett duration shall start after achieving thermal stabilization.

67 Suitable relief valve \set at 5% higher than test . pressure shall be fitted at the test heads to avoid over pressurization durinq testing.

Test Requirements for DPRS and IPRS Piping DPRS and IPRS piping shall be subjectE-d to strength test and leak test, before commissioning; as given in table-5 below:

Table 5 ..... Testing Requirements for DPRS and i · . IPRS Piping , __ I Design Min. Test Test Min. Test Pressure Pressur~ medium Duration Up to 138 3.45 barg i:nbarg Air 2 hours (2 DSia\ (50 pslg) From 138 mbarg to 1.5 times

4.14 barg Design Air 2 hours (2 to 60 Pressure osig) .Above 1.5 times '

4.14 barg Design water 2 hours (60 DSia) Pressure Acceptance criteria shall be no pressure toss after accounting for temperature variation.

Safety During Testing Relevant Warning Signs shall be displayed along the test section.

The test area should be properly cordoned to prevent any accidents.

A proper Emergency· Respon~e Plan shall be in place and emergency contact numbers of relevant agencies should be available. - · · CONTROL AND LIMITING OF GAS PRESSURE.

Control and Limiting of Gas Pressure in High Pressure Steel, Ductile iron, Cast Iron or Plastic Distribution system Use of automatic shut-offdevice (slam shut valves) as a means of accidental over­ pressure of high pressure distribution system is preferred · over pressure relit~f !

I 68 THE GAZETI'E OF INDIA: EXTRAORDINARY [PART II-SEC. 3(i)] valves or weight-loaded relief valves or spring loaded diaphragm type relief valve. · DPRS/IPRS shall normally be equipped with minimum two safety devices. At least one of them shall be a slam shut valve · operating on . over pressure for those installations whose inlet operating pressure is more than 60 psig.

To prevent over pressurization of downstream system during periods of low flow, creep ·relief valve can be used. If a monitor regulator is installed in the system, it shall be such that it is the first acting· device in the pressure safety system.

Control and Limiting Qf Gas Pressure In low Pressure Distribution Systerns A combi·ned Over Pressure Shut-Off (OPSO) regulator with built-in creep relief is also acceptable device for control and limiting of gas pressure in low pressure distribution system.

Control and limiting of pressure of gas delivered to domestic, small commercial, and small in·dustrial consumers from high - pressure distribution· system.

Service regulator with a built-in Under Pressure Shut-Off (UPSO) regulator is also acceptable device for control and limiting of gas pressure to consumer.

VALVES \ As far as practical, the valves in the distribution mains should be installed below ground with the· valve operating device readily ac.cessible. A stem extension may be used to elevate the valve operator above ground provided it does · not cause obstruction to traffic and I or pedestrians. In such cases, sealant I lubrication points and vent pipe work shall also be extended ~bove ground for ease of operation.

Valves of size 4 inches and above shall be· fitted with double block and bleed facility.

Spacing between valves on distribution mains, whether for. operating or emergency purpose shall be decided as follows:

(s) High Pressure Distnbution System:

Based· on operation and maintenance flexibility requirements, valves may be provided on:

· Either side of water body crossings.

Strategic take-off points including future developments.

Based on risk associated with emergency situations requiring speedy isolation and resulting . number and type · of customers "' affected by such emergencies etc.

In· steel distribution mains valve spacing · should normally not be . more than 3 km, · In plastic distribution mains valve spacing should normally not be more than 1 km.

The above spacing, however, may be increased or decreased based on risk assessment and to allow location of valve at an easily accessible location.

(b) Low Pressure Distribution System:

Valves in low pressure distribution· system may be provided at locations requiring isolation for ease of maintenance in addition to those required as· per following Para.

Distribution System Valves A valve shall be installed. on the ihlet and outlet piping of each regulator station contro!ling flow or pressure of gas in distribution system. The distance between the valve and regulator(s) shaTI be adequate to allow operation of t~e valve during emergency (such as large leakage or fire).

These valves should be located in a manner that they are easily accessible during emergency.· ' VMJLTS ··. · · Accessibility ln case part of Vault or Pit extends above ground (e.g. to avoid water flooding in low lying areas that c~mnot t>e avoided), then, it . . .

shall be located such that it causes minimum interference I hindrance to the traffic'/ pedestrians.

CUSTOMERS' REGULATORS METERS AND Location for Customers' · Meter and Regulator tnstallatlons ' Customer meter shall preferably be located on the wall outside the kitchen, however,· when customers.' meters and regulators are located inside the building, it should be· located in a well ventilated area.

GAS SERVICE LINES General Provisions Appllcable to Steel, Copper and Plastic Service Lines· Service lines shail be· sized for a maximum flow velocity of 15 m I sec.

Installation of Service Lines All plastic pipe and fittings shall be laid underground an~,shall not be exposed;

The buried service lines shall· be provided · with, a minimum cover of 1.0 m. Where it is· impractical to provide 1.0 m cover due to physical constraints, additional protective measures· such as concrete slabs or high impact resistance plastic sheets shall be installed at least 300 mm above the service line. In no case the depth of cover shall be less than 600mm.

For transition from plastic pipe to GI pipe, transition fittings shall be used. Plastic part of transition fitting protruding above ground shall be protected by encasing · it with concrete guard.

In case carbon steel section beyond transition fitting .is below ground, it shall be protected against corrosion by ~ minimum 400 micron thick 2,' pack higll build epoxy coating.

Above ground service piping shall be Galvanized Iron or copper or carbon steel protected by anti corrosive coating.

Wherever the service line riser is installed in confined . spaces like basements, · only welded risers shall be used. The gap betwe~n ris~r and wall shall be minimum 25 mm to and shall be supported at every 2 m.

. Ventilators shall be provided in confined space.

Type of Valves Suitable for Service Line Valves Soft seated valves .in service line~ are not permitted.

Steel Service Lines Design of Steel Service '-Ines ( All underground ~teel service lines shall be joined by welding using qualified welding procedu're and welders.

Installation of Service Lines into or Under Building Use of sleeve for laying steel pipe through wall, or under outer wall foundations of building or under the building is not recommended. Sucli underground lines shall be protected against corrosion by minimum 400 micron thick 2 pack high build ·epoxy coating:.

Ductile Iron Service Lines .Use of ductile iron service lines is not permitted.

Plastic Sertice Lines · Design of Plastic Service Lines Only electro fusion fittings shall be used in plastic service piping including pipe to pipe joints.

THE GAZETTE OFlNDIA: EXTRAORDINARY . [PART II-Soc. 3(i)] Installation of Plastic Service Lines Installation of plastic pipe above ground is not recommended. In case any section of plastic pipe extends above ground, it shall be completely encased in a concrete casing. Use of flexible conduit is not permitted.

Installation of Plastic Service Lines into or Under Buildings Installation of plastic service lines under or inside the building is not permitted as per this standard.

Service Line Connections to Mains Service Lines Connections to Steel Mains Service line connection to steel mains shall be as follows:

In case of plastic service line, · connection to underground steel main shall be by use of transition fi~ting in plastic piping with steel part of transition fitting welded to steel main piping. · Direct connection of galvanized iron or copper service lines to underground steel mains is not permitted.

Service Lines Connections to . Plastic Mains In case of plastic service line, connection to plastic main shall be by . use of electro fusion fittings only.

Direct connection o(galvanized iron or copper service lines .·to underground plastic mains is not permitted. · PIPING BEYOND . CONSUMER METER SET ASSEMBLY TO GAS APPLIANCE 'Piping connecting · consumer meter set assembly to consumer gas appliance shall be either GI or copper up to last valve located near actual appliance.

A metal seated leak detection cum excess flow shut off valve shall be provided near the appliance located at easily accessible location by the authorised entity. The valve shall be designed to shut · off in · case of sudden leakage of gas from the hose or in case of burner flame-off condition, Appliance shall be connected to gas line · with a flexible and braided hose as per IS

9573. The hose shall not be exposed to internal or external temperature exceeding the recommended limits. Care shall be exercised not to exceed permissible bend radius specified in IS: 9573 .(Table 1 - Dimensions and bend radii for rubber hoses}.

Length of this hose shall be kept minimum.

However, in no case the length shall be more than 1.5 meters. Both ends of the hose shall be firmly clamped on the nozzle by metallic clamps.

,... ___ / ..

·.

.

. ., ·1 ' 71 Schedule 1E OPERATING AND MAINTENANCE PROCED'URES The present standard covers the City· Gas Distribution, Design, Installation$, Commissioning 1;1nd Operation in general.

The . Operation and Maintenance Procedures prescribed herein und~r are for general guidelines ··to be. implemented as per the . prov~ions of the standard. The entities engaged in laying, · building, operating and expending City or Local Gas . DistributiGn Network will create an organization handling . operating and maintenance including meeting the emergencies arising in the system.

The main operation area would be to handle gas receipt, odorisation and pressure reduction (including heating the · gas, if required} and managing the district regulating station, field regulators and gas metering for all kind of customers such as domestic, commercial and industrial.

The gas measuring billing including energy balance shall be part of the operation. The safety, health and environment including compliance of regulatory measures shall be a part of the responsibility of the operating group. The maintenance activity shall cover the maintenance and upkeep of the City Gate Station(s), District Regulating Stations, Field Pressure regulating Stations and end consumers facmties, sectionalising valves and other· assets and. facilities. This inter-alia will evolve regular maintenance, route patrolling to contain third party damages and maintenance of· safety provisions including offsite emergency plan and onsite emergency plan, mutual aid and disaster management plan. The following .

sections briefly refer to such activities:-.

1. Operating and Maintenance Procedures affecting the safety · of gas transmission and distribution facilities .

2 . External Corrosion Control

3. · Odorisation OPERA TING AND MAINTENANCE PROCEDURES AFFECTING THE SAFETY OF GAS TRANSMISSION AND DISTRIBUTION FACILITIES Basic Requirements The entity operating a CGD network shall have an effective Health, Safety and Environment Management System (HSE Management System) and Management. of Change System in place to ensure overall safety during operation and emergencies.

The HSE Management System shall cover the following key elements ..

• HSE Policy Statement • Organizational objectives to · ensure implementation of the policy • Set of detailed processes supporting each activities of the HSE rnanagement system • Implementation of control and monitoring activities • Periodic monitoring, review and rept>rtihg of performance • Audit of internal and external activities Following processes shall be prepared as ·' part of HSE Management System:

• · Emergency Management System to safely handle emergencies with mihimal risk.

• Disaster Management Plan encompassing offsite and onsite emergency response plans and mutual aid system • Hazard Identification Processes such as HAZOP • Risk Analysis · and Ri~k Assessment Process such as QRA • Safety and Technical Competency System .

7l. THE GAZEITE OF INDIA: EXTRAORDINARY {PART TI-Soc. 3(i)]/ • An Operational Health ·and Safety updated in GIS with gee-referenced Legal applicability Matrix as well as co-ordinates for better identification.

Operational . Health and Safety C) lmmediate av~ilability of the new - {OH&S) Legal Compliance matrix. constructed pipeline locations and • An Environmental Legislative Register customer ba·se information to the (ELR) to provide the user a register of user groups allowing related practical implementation in terms of analysis, planning and . future day-to-day .. activities· with which the projections of new possibilities of operation ~·:to comply. Of particular pipelines, . customers, gas volumes relevance are the details of consents I and revenue including jobs to be permits I authorization or licenses undertaken by third party. · required for an activity and from whom and how it is obtained. . GIS shall be. used during the entire life cycle of tne asset.

• Additional practices · like carrying out periodic Work Place Inspection of alt Critical Activities by senior management team, implementation of Behavior Based Safety Programs and · implementation of Safety Intervention System should be . considered to improve the safety culture of the organization.

For Safe Control of Operations · (SCO), a systematic Management of Change process shall be developed to identify and consider.

the impact of, changes to pipeline systems and· their, integrity. Management of C,hange should . address· technical, physical, procedural and organizational changes of the system, whether · permanent or temporary GIS based asset management syst~m: ..

The entity operating a CGD network shall put · in . place a · GIS (Geographical Information System) based system with the intention · of capturing the · entire underground · gas network and customer database. This system shall include details Qf the e!'ltire pipe-network. All the pipelines laid shall be identified in GIS through geo­ referenced co-ordinates. All failures in the pipelines shall be· mapped . in GIS . for investigations.

The system shall include the following features:- A) Entire network view ability on one platform to manage the huge database.

B) All network extensions and expansions to be mapped and - . Easential Features of the Operating and Maintenance plan Operating and Maintenance procedure should also address the following;

• Preventive maintenance plan and procedures reqµired in accordance . with recommendations of Original Equipment Manufacturer(s) (OEMs).

• A well-designed system of periodic inspection for all facilities. .

• Calibration plan for meters, gauges and other instruments affecting quality and safety of system. r • Plan for functional testing of pressure regulation and control equipment .

(Active I Monitor Regulator, Slam Shut Valve, Pressure Relief Valves, control valves etc.).

• Isolation scheme . (complete with - drawings showing the. orientation of the facilities, · - location of major services, power switches, entry and · emergency exits, fire assembly points etc.). It should cover main components, including their identification number.

• Limits of operating parameters (pressure, temperature, flow, levels etc.)

• An Alarm Management System to.

monitor, analyze, · segregate and appropriate action.

• "Work Permit" procedures to be followed by maintenance personnel for protection of property from damage and fire etc.

• Procedures to log . operation and maintenance activities.

*. . .. ·- [~II-1§US3(i)] • • Personal Protective Equipments (PPE) to be used by all. operating .

personnel.

Do's and Don'ts and safety prec;autions during operation and maintenance.

Provisions· of periodic inspections along the route of steel · pipelines or mains· shall · include all sections of pipelines and mains irrespective of operating hoop stress.

Essentia! Features of the Emergency Plan.

Entities operating CGD Networks shall provide for an Emergency Control Room, manned round the 'clock and equipped with effective communication system and emergency vehicles fitted with · . '. communication facilities, first aid · ' . .equipment, fire . extinguishers, gas detectors, ·repair kits and tools, maps, plans, material safety data sheets etc. at its d . . I . 1sposa1.

.. The CGD entity shall put :n place an · : Emergency · Response Plan, a Disaster · Management Plan and a Pandemic Plan.

• While preparing these plans the entity shall take into · confidence the various · loca·1 authorities (i.e. Jrye Fire authorities, Police authq_rities, . Health authorities, local administration, Disaster Management authorities, Mutual aid, Factory inspector~te etc) and clearly elaborate on their role in case of an incident.

Accident I emergency . procedures .

reporting The entity shall put in place a documented in house accident reporting procedure and its response plan for all kind of accidents/emergencies such as (i) near miss accidents, {ii) accidents without loss· of production, · supply or human life, (iii) accidents with Joss of production, supply or human life, (iv) fire. (v) explosion or other emergencies leading to disaster effecting • outside public. The level of reporting shall also be mentioned in the procedure. The Board shall be informed in respect of the accidents/emergencies under category '(iii),

(iv) and (v} above with remedial measures 3225 Gl/08-10 ..

73 . for avoiding recurrence in the format placed at Enclosure-I of Schedule -1 E. The entities shall investigate and . report eact) of the ·above incident/accident to different level as specified in the above enclosure.

Notwithstanding anything contained herein under, in case any incident escalates and gets media attention or get~ published in newspapers, the entity shall proactively inform the Board of the same immediately wittl preliminary investigation ·report.

Further, detailed report of the findings shall be f.umished to the Board within a period, of thirty days.

Written Emergency procedures Special attention should also be given to foJlowing . while preparing Emergency procedures:

• "De's and Don'ts" during and emergency · and other safety instructions.

• Telephone. numbers of emergency response team members, emergency services, mutual aid industries, district authorities, law enforcing agencies, contractors i vendors, fire services, . district civic authorities, etc. · • Actions to be taken during an emergency including. warning ·I cordoning ·off of affected area and informing the civil autho;ities and I or · other utility compar;iies affected by any emergency.

, - Training • · Training shall be. imparted to the .CGD Network operating and maintenance staff at the time of induction followeq by periodic refresher courses .. The training program should cover following:· · • Hazardous characteristics of Gas.

• Familiarization with commissioning, operation and maintenance procedures ..

• Hands on experience on operation of emergency and manual shut down systems.

• Effective isolation of any gas leak.

• Safety regulations and accident prevention.

74 • . THE GAZETfEOF INDIA: EXTRAORDINARY [PART II-SEC. 3(i)] • Firetighting equipment operation and its upkeep.

· • First Aid and Housekeeping The training process should be subjected to periodic internal audits to ensure effective implementation and improvement.

Training shall include mock safety drills, at least twice a year.

Training program shall.~ also envision imparting training to employees and contractors of other utility companies sharing the same corridor to make them aware about ha'zards associated with leak I damages. · ' Liaison Entity owning or operating CG.D networks sh.ould have designated personnel to liaison with other existing utility companies, district local administration and gas supplying companies. A utility co-ordination team consisting of representativ~s from all other utility companies and civil authorities can substantially improve safety records.

Educational Programs:

Entities operating CGD . N~tworks shall undertake a comprehensive public awareness program for consumers and general public. The educational material shall be prepared in local, Hindi and English language. Local audio visual , media available should be · used for such educational programmes. ' Pipeline Failure Investigation Bes.ides reporting an.d recording of all instances of asset related failures, damage to the environment and third party property shall also be recorded.

Failure investigating team shall comprise personnel trained in failure investigations.

The data from all failure occurrences should be analyz~d for trends so that proper initiatives including·training could Qe taken to minimize failures.

Prevention of Accidental Ignition ..

Site · Specific Risk Assessment shoL1ld be carried out before commencing any repair · activities. . The outcome · of such risk assessment should be documented . and considered while preparing safety plan for the repair work.

No hot work shouk:I be undertaken without proper work permit issued by authorized pers~rinel.

Blasting Effects No blasting should be carried out within city limits and near any third party structures or faciliti~s. In any case blasting shall only be used after proper autho~ization from civil authorities even if it i's safe to carryout such operations. · DISTRIBUTION PIPING MAINTENANCE.

Markers Markers shall be positioned -along entire network at a maximum spacing of 100 meters in urban area and 200 meters within industrial parks for steel -mains.

Additional warning signs or markers shall be installed to indicate the presence of a pipeline at road, highway, railroad, stream, canal, nala crossings and other locations where there is a possibility of damage or interference.

A marker shall be marked in bold and legible local language and Hindi I English with at least the following:

• · Name of CGD Network Operating Company • . Contact Telephone Number to report emergency. __ • Location Area Code • Warning - "High Pressure Gas Line, Dial before Digging;, etc.

Markers may ·not be installed for service pipeline within consumer premises, however, the. Operating; Company shall maintain such service pipeline routing drawings for easy reference. The operating [m<r 11-@0,$ 3(i)] company shall provide minimum safety · information to the ·consumer/customer before starting the gas supply.

It shall be. mandatory for the group housing societies/cluster of houses etc. Which are providing the inbuilt facilities for the natural gas connectivity. to each and every. dwelling unit in · such buildings · to have the line diagrams of the connection piping fixed at the main entrance of such premises.

Patrolling Patrolling schedule shall be such that entire I primary network is inspected at least once in three (3) month and secondary network is inspected at' least once every month to observe surface conditions, construction· activit,;; encroachments, soil wash outs and any other factors that may affect the safety .

and operation of the network.

Leakage Surveys Operating company must have an effective method to identify and locate leakages in the system. Any one or .combination of methods described in ASME B 31.8, Appendix M can be adopted based on their effectiveness for the specific areas.

Highly congested areas shall be surv~yed using gas detectors at least once in three months. Other less congested areas shall be surveyed at least once a year.

Leakage Surveys using gas detectors shall be . done in accordance with the requirements of ASME 8 31.8.

Gas detectors, duly calibrated, · shall be available at all times in· ready use conditions for emergency surveys and use. ' Requirements for Disconnecting, and Distribution Facilities Abandoning, Reinstalling Abandoning, disconnecting, or .. reinstalling distribution facilities shall be as per ASME

831.8. . .

Any activity associated with abandoning, disconnecting, or reinstalling of distribation 75 facilities shall require Work Permit issued by the authorized person. , Plastic Pipe flftaintenance The following safety precautions shall be ensured during emergency repairs or breakdown maintenance of pipelines:

• All n~ked flames, sources of' ignition and . mobile phones shall not be · allowed in the immediate work area.

• Gas level should be monitored during the repair work -with gas detectors.

The repair shall not be carried out in atmosphere which contains natural gas.

• Adequate fire extinguishing equipment shall be available during such repair.

Squeezing-off and Thermoplastic Pipe Pressure Control · reopening or Tubing of for Location where Squeezing and reopening is done once shall be marked appropriately to identify that the pipe has been squeez:ad and reopened.

- .

Squeezing of reopened pipe at the same ·location is not permitted. Minimum distance between consecutive squeeze-off locations shall not be less than five (5) meters.

Repair of Plastic Pipe or Tubing Damaged or defective plastic pipe shall be cut. and replaced with new pipe.

Repair of damaged plastic pipe by using repair patches is not permitted.

. .

. Only repair method allowed is use of f u!I encirclement split sleeves which shall be 1n accordance with ASME B 31.8.

I .

MISCELLANEOUS FACILITIES MAINTENANCE Fl,exible steel braided hose used to connect consumer appliances should. be inspected at least once every year for leakage, kinking, corrosion. abrasion or any other signs of wear and damage.

76 THE GAZE1TE OF INDIA: EXTRAORDINARY [PART II--SEc. 3(i)J Any hose worn out or damaged must be • Surveillance inspection and removed from service and· replaced. maintenance records .PIPELINE SERVICE. CONVERSIONS Steel pipelines and mains used in CGD Network shall notbe used for duel service.

Conversion of . existing steel pipelines, previously used for service other than natural gas, for use in CGD Networks is not permitted.

RECORDS Besides the details ·of leak recoras as covered under ASME 831.8 Para 851~6 and · 852.6, the CGD Network Company shall also maintain following records/ documents:

• • . Design s·pecificatjoh Alignment sheets for primar-Y network of steel pipeline and associated pipe book and other installation and test records • Material certification including dimension, metallurgy, destructive and non-c;iestructive testing . records, performance and functional test reports • • Welding records including PQR, WPS and welder qualification records Commissioning reports • . Non-conformance I deviation records • • • • • • Calibration records of Inspection, Measuring, Metering and Test equipment· Audit compliance reports Statutory clearances Approved drawings /documents HAZOP I Risk Assessment reports · and compliance to recommendations of such reports AU operation . and maintenance manuals 77 - --- ---- -- '" ------- - - -- - - - -- --- Enc l.o sure -1 ~of Schedule-1 E R epo rf f 1ng orma t -. " Type-I I Type-II Type-Ill Type-IV Type-V ·Near Without With Loss of fire Explosion ·Miss Loss of Production, /Fire/Gas Incident Production, Supply or Leakage/ot~er Supply or Human Life I emergencies l. Human life involving public _ ', ·Location " " " .-../ l " ~ .

TI me " " " ...} " .

First " v " " , " Witnessed by , ~ Details of " " ...; " " Incident Action Taken " " -..j· " " Reporting Operat. Operator Shiftl/C HSE Section l/C Authority or (O&M) Officer ' fO&M) .internal Head Head Head Head Head of Station Investigating {HSE} (HSE} (O&M) {HSE) Authority i External ' x x " " " Investigation J !

Report to x ~ . x ...; (*) '1(*) .../(*) PNGRB , .../ To be filled in/reported X Not required to be reported (*) Shall also include the history of Type-I & Type-II incidents 78 THE GAZETTE OF INDIA: EXTRAORDINARY f p AKf II SEC. 3(i)] Schedule - 1F CORROSION CONTROL EXTERNAL CORROSION CONTROL New Installation/Buried Steel Facilities Coating Requirements, , Coatings shall fulfill following requirements: • • Coating shall provide good electrical isolation between external surface of the pipe and environment.

• Coating shall have . sufficient resistance to moisture transmission.

• Coating shall have sufficient ductility to resist cracking;

• Coating shall have· good mechanical strength or otherwise· be protected to resist damage due ·to normal handling . (inclu9ing concrete coating .

application where applicable) and soil stress.

• Coating shall be compatible with Cathodic Protection system and field joint coatings.

For carbon steel pipelines or· mains of size NPS 2 and above, 3 Layer Polyethylene or Fusion Bonded · Epoxy coating is recommended.

All buried bends and fitti.ngs shall be coated with Heat Shrink . Sleeves or two pack high build liquid epoxy coating with minimum OFT 450 microns.

Cathodic Protection Requirement Electrical Isolation VVhere ·insulating devices are installed to provide electrical isolation of pipeline systems to facilitate the application of corrosion control, they shall be properly rated for te~perature, pressure, and electrical properties and shall be resistant to the gas carried in the pipeline systems.

These devices shall not be installed in enclosed areas where combustible atmospheres are likely to be present . unless precautions are taken to prevent arcing.

Pipes shall be installed ~o ·that the below grade or submerged portions are not in electrical contact with any casing, foreign piping systems or other metallic structures. This shall not preclude the· use of electrical bonds where necessa!Y. ,,...

~lectrical Connection and Monitoring Points 'Mlere a higher current· carrying capacity is required, a multi-strand conductor shall be used and the strands shall be arranged into groups no larger than No.6 AWG. Each. group shall be attached to pip~ with a separate charge. . Attaching test . leads directly to the pipe by other methods ~f qrazing is prohibited.

When thermit welding proc~ss is used for· electrical lead installation ~:m pressurized pipelines or mains, precautions shal1 ·be taken to avoid possible failure of the · pipeline or mains during installation due to loss of material strength it the elevated· welding temperatures. Vvhere a thermit welding process is not deemed suitable,· .

consideration shall be ·given to other ' methods of installation.

Electrical Interference Electrical interference due to following shall also be considered in cathodic protection design:- · Fault Currents Fault current interference shall be tak~n into consideration.

Fault current resulting from lighting or upset conditions of electrical facilities I , ..

[~II-~ 3(i)] could result in serious damage to coating and pipe wall and danger to personnel.

These adverse effects may occur where a pipeline or main is close to the grounding facilities of electrical transmi~sion line structures, sub~stations, generating stations or other facilities that have high short circuit current-carrying grounding networks.

Where a buried pipeline or main is close · to grounding facilities, remedial measures may be necessary to control the effect of these fault currents in order to reduce the resultant rise in potential gradient in the · earth near the pipeline or . main to an acceptable lev,el.

Induced Potential Interference Pipelines or mains paralleling alternating .current electrical transmission lines are subject ·to · induced pptentials. When studies or tests show that alternating current potentials will be or are being induced on a buried pipeline or main, devices shall be installed to reduce these potentials to a tolerable level.

When such pipelines or mains are under construction, or when personn~I are in contact with the pipelines or mains, special precautions shall be taken to nullify the possible effects of induced alternating current potentials.

Install. bonding across points where. the pipeline or main is to be separated and maintain this connection. while tlie pipeline or main is.separated.

Make a study in collaboration with the efectric company on the common f:?roblems of personnel safety, corrosion, electrical interference and . lighting .

problems. · Existing Installations Cathodically Protected Pipeline Systems Temporarily out of Service Cathodic Protection systems shall b~ 79 maintained on any pipeline. or main · temporarily 04t of service ..

Temporary Cathodic Protection System When considered necessary; a temporary· Cathodic· Protection system with sacrificial anodes shall be installed to ensure adequate protection of pipeline cir mains from external ·corrosion from the · ti!:lle the pipeline or main is laid in the trench till • the permanent Cathodic i Protection system is commissioned.

The temporary · cathodic protection system. shall preferably be installed simultaneously keeping pace with the pipeline or main laying/installation work and shall be monitored periodically.

RECORDS CGD Network Company shall · also maintain following records I documents related to corrosion control:

• Cathodic Protection Design documents • Soil Resistivity Survey Report.

• ·Electrieal Interference Report • Inspection and maintenance reports • Material certification including · dimension,. metallurgy, p~rformance and functional report · ·• Material test reports • Approved drawings/documents ( THE GAZETTE OF INDIA: EXTRAORDINARY [PART II-SEC. 3(i)] Schedule - 1 G MISCELLANEOUS ODOURISATION Natural gas supplied thro,ugh CGD Network shall have a distinct odour, strong enough to detect its presence in case of leakage.

A pre - determined quantity, equivalent to a max 12.5 ppm Ethyl Mercaptan, of any other odorant shall be dosed into the gas stream.· Odour level tests shall be carried out to recognise the odour imparted by the gas supplier/distribution company. These tests a(e to be parried. out at various defined • locations on the network and at network extreme ends. If odour level falls below the minimum acceptable level same .shall have fo be intimated to the control room of the' gas supplier and accordingly corrective actions are t~ be ta~en.

The odorizing equipment shall be located in a separate area at CGS. There should be a clear safety distance of 1.5 m around the odorizing and other .facilities at the station to facilitate easy maintenance and personnel movement.

The odorant unloading should be done in a safe way. Precautions for handling odorant .

shall be prominently displayed.

Odourant absorber like activated carbon saw dust, dry sand and odorant neutralizer like sodium . hypochlorite for spillage handling of odourantshall be provided.

Provisio~ should be made for eyE:;l wash or emergency shower near odorant handling and injection systems, in case ethyl mercapton is used as odourant.

Use of personal protective equipment like face shield, mask, rubber hand gloves, ·gumboot, safety goggles etc. for ha-ndling of · odourant spillage shall be ensured.

References ASME B 31.8 - · Gas Transmission and Distribution Piping Systems (ASME 3 Park Avenue, !':Jew York, NY USA 10016.

www.asme.org).

API . 1104 - Welding · procedures and welders for welding of gas pipelines.

ASME Boiler and Pressure Vessel (BPV) Code Section IX - Welding procedures and welders, for station piping.

!

ASTM A 395 - Valves having shell (body, ; bonnet, cover and/or end flanges) components.made of cast iron and I ductile iron (as per shalr not be used in CGD networks).

BS EN 331 - V~ves used in service lfnes of size NPS 2 and below.

ISO 8085 - ~lectro-fusion . fittings for sizes up to NPS 8.

IS-5572 - Electrical area classification of Installation for selection of E1ectrical Equipme~t IS - · 5571, "Guide for selection of Electrical 1 Equipment for . Hazardous Area"· IS 3043 - For earthing of all electrical equipment, sy&iems, structures and fencing, 'etc. .

IS:2309- for Lightening protection IS 9573 ..:.. Steel braided Hose •• . .

.

• I ~ ['1Pl 11-"F&J(i)] 81 ANNEXURE -1 List of Specifications of Piping Materials ustt~jn · CGD .Network Steel Pipe APf 5L ASTMA106 ASTMA333 . Specification for line pipes Seamless Carbon Steel Pipe .for High Temperature Service Seamless and Welded Steel Pipe for Low-Ten,perature Service , ' Galvanized Iron Plpea ts 1239 {Part-1) Valve9 Af>1so ASME 816.34 BS 5352 as sas1 BS 1873 ..

Flanges and Blanks ..

Steel Tubes, Tubular and Other Wrought Steel Fittings - Specification - Part 1 : Steel Tubes Pipeline Valves Valves Flanged, Threaded ancfWetding End ' .

Speeif{cation. for steel wedge gate, glObe and check valves 50 mm and smaller for the petroleum, petrochemical and aUied. industries · Specification for steel ball valves for the petroleum, petrochemical and allied industries - Small Floating ball va!Ve .

Specification for Steel globe and globe stop and check valves (flanged and butt-welding ends) for the petrolet.lm, petrochemical and allied Industries · ASME 816.5 Steel pipe flanges and flanged fittings - Size upto 24" NB.

ASME 816.36 Orifice Flange MSS SP-44 Steel Pipeline Flanges API 590 Steel Line Blanks · Fittings ASME 816.9 MSS SP-75 MSS SP97 IS 1239 {PART-2) Factory-Made Wrought Steel Butt welding· Fittings Specification for High Test, Wrought. Butt Welding Fittings Integrally Reinforced· Forged Branch Outlet Fittings - Socket Welding, Threaded and Butt welding Ends Steel Tubes, Tubular and Other Wrought ·Steel Fittings - Specification - Part 1 : Mild Steel Tubular and other wrought steel pis)e fittings Stud Bolts and Nuts ASTMA194.

ASTMA193 3225 Gl/08-11.

Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High Pressure or High Temperature Service, or both.'

Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High Temperature or High . Pressure Service and OthEJ 1 . Special Purpose Applications . _ · \ , ·:

82 .. [PART II-SEC. 3{i}J ·ASTMA153 ASME 818.2.1 ASME 818.2.2 ,- - . - - -· Standard Speciftcation. for Zinc Coating (Hot-Olp) on Hardware . .

Square and He~ Bolts-and ScreW&, lndl Sen,s $qt.tare and Hex Nuts Iron and Steel Gaskets· ASME 816.20 C~pper Tubes BS EN 1057 .Copper Fittings Spiral-wound metal gaskets and metal jacketed gaskets for use with raised. face and flat face ftariges.'

Copper and copper alloys. Seamless, round c:opper tubes for water and · gas in sanitary and heating applications • BS EN 1254PART1 Copper and copper alloys. Plumbing fittings. Fittings ·with ends for · capHlary soldering or capillary brazing to copper tubes Pluth:P~ IS0~37.

IS 14885 Plastic Valves ASME 816.40 EN 10204 EN 1555-4 Plastic fittings / IS0-8085-3 EN-1555-3 Buried polyethylene (PE) pipes for the supply of gaseous· fuels - Metric series· - Specifications · Specifications for palyethylen~ pipes !he supply of Gaseous Fuels Manuallr Operated Thermoplastic Gas Shutoffs .. and Valve~ in ·Gas Distribution Systems Excess flow check valve Plastic piping system for supply of gaseous fuels polyetl'lylene - Part 4 -International Standard for thermoplastic fittings European standard for plastic piping system for supply of gaseous fuels - · Polyethylene (PE) Part -3 : fittings · ISOITC-138/SC4 N 521 & 523~1990 Thermoplastic fitting procurement requirements .

. _ High Prdsure SS Tubing and Fittings · .

ASTMA269 Standard Specification for Seamies$ and Welded Austenitic Stainless , Steel Tubing forGeneral Service Brass Ball Valves (Up To 2") BS EN 331 Bran Fittings IS 319 Manually operated ball valves and closed bottom taper plllg valves for . gas installations in buildings- · Free Cutting Leaded Brass Bars, Rods and Se~ions - Specification , • ['1PTil-l§q3(1)] 83 .

ANNEXURE - ll ·.

List of Specifications for Equipment used in CGD · · · Network / . Pressure Safety Equipment (Regulators, Slam Shut Valves and Creep Relief Valves) Gas pressure regulators for inlet pressures up to 100·bar . EN334 EN 14382 Safety .devices for gas pressure regulating stations · and API 526 Filters installatio'1s - Gas safety shut-off devices for inlet pressures up to 100 bar Flanged Steel Pressur6 ~elief Valves ASME Section VIU Boiler and Pressure Vessel Code . Metering Equipment AGA Report No. 3 Orifice Metering of Natural Gas and Other related Hydrocarbon fluids AGA Report No. 5 Fuel Gas Energy.Metering AGA Report No. 9 Me~surement qt Gas by Multi-path Ultrasonic Meters OIML R6 / Qlf\,1L R31 Diaphragm gas meters BS 1359 I BS 4161 ·. Diaphragm gas meters .

EN 12480 Gas meters - Rotary displacement gas meters OIML R32 Rotary. pistoo gas meters. and turbine gas meters AGA Report No.· 7 Measurement of Gas by Turbine Meters · EN 12261 Gas met~rs - Turbine gas meters I Pressure Measuring Equipment ~as EN_a31-1 BS EN 837-2 BS EN 837-3 · Pressure· gauges - Part 1: Bourdon tube pressure gauges; dimensions, metrology,_requiremel'Jts and testing · · _· '~ Pressure Gauges··- Part 2: Selection and Installation Recommendations ·for Pressure Gaoges '! • · Pressure gauges - Part 3: Diaphragm ·and capsule pressure gauges;

dimensions, · metrology. requirements and testing · i".:i;,1 · Electro fusion machine for jointing PE pipe and fittings EN-~55014 I EN-50081-1 EN-50082-1 EN-61000-3 EN-60335-1 EN - 60335-2-45 .

IS0-12176-2 WE GAZBTI'E OF INDIA: EXTRAORDINARY Cf ARI' 11-&c. 3(i)] ANNEXURE -- Ill Additional Requirements for Ele_ctrlc Welded Pipes Electric Welded pipes shall meet following ·requirements.

Reverse Bend T.._ I .Reverse bend tests shall be· performed on the pipe piece cut from the crop end, selected from . the front end of the first length and· the back end of the las~ngth \ produced from each coil. The specimen shall be 1 OOmm to 11 Smm long and shall be reverse bend tested in accordance with procedure and figure given hereinafter.

I I .II The reverse bend test shall be carried out with a mandrel., Radius (R) and width (A) of mand_rel shat! be calculated for any· combination of diameter, wall thickness· and.

grade with the formula.

. 1.4 (0-t) t A=2R=~ -t where, D t

1.4 e e (D-2t)-1.4 t Outside diameter of pipe Wall thickness of piptl­ Peaking factor Strain Minimum values of 'e' shall be as folloYis: · Grade Qf. Steel API 5LGr. B· API SLX-42 API SLX-46 · API 5L.X-52 API 5LX-60 Prdcedure Min 'e' value

0.1425 .

0.1375

0.1325

0.1275

0.1225 - ..

The ·mandrel is to be plugged into the specimen, .with the weld in contact with mandrel, to such a depth that the angle of engagement betWeen . ·mandrel· and specimen reaches._60° (See Figure). If the combination of diameter and wall thickness of. pipe, and radius of mandrel is such tnat the· angle ·of engagement doM not reach 60°, the mandrel shall be plugged into the specimen. until . opposite wattS of the specimen meet.

Acceptance Criteria A specimen . which fractures completftty prior fo the specified engagement of I mandrel and specimen, or which reveals cracks and', ruptures In the weld or· heat · affected zone _ longer than 4mm. shall be rejected. 'Cracks less than 6mm long at the edges of the specimen shall not be cause for rejectiQn. - Micrographtc and Hardness Examination A test· specimen ahaR be taken across the longitudinal weld ftom one ·tength of finished 1pipe from each lot of maximum 100 lengths from the same heat manufactured ftorn the same process.

These specimens shall be polished and etched for miCr~xaminatlons. 'The examinatic>nS shall . provide evidence that heat treatment of weld zone is adequate · and ttlere is no un-tempered martensite left.

i' [ qrr II '{Slq' 3{i)] Hardness measurernenta on each specimen shall be made a• indicated in figure given herein after ln accordance with ASTM E-~2. The. maximum difference in · hardness" between base material and any reading taken in the Heat Affected Zone (HAZ) shall be less than 80 points Vickers . HV10.

Hut trntll'd Zone .

' . ' \ • 86 . TIIB GAZEn'E OFINiAA. cxfRAoRL [P ARI' ll--SBC. 3(f)l Minimum Requirements for GI Pipes and Copper Tubing used i'n service lines up to consumer.</ .appliance Galvanized 1.ron (GI} Pipes . Pipes shall be conforming to IS: 1239 (Part-1) - 1990. The manufacturer shall have a valid license to use ISi Monogram for.man'ufacturing of piJ)es in accordance .with the requirements of IS: 1239 (Parf-1)-1990. · NOMINAL 15mm 25mm 50mm. 80mm BORE GRADE MEDIUM MEDIUM MEDIUM MEDIUM ('B' CLASS)· or {'B' CLASS) Qr HEAVY ('B' CLASS) or ('B' Cl.ASS) or HEAVY HEAVY • ('C' Cl.ASS) HEAVY ('C'CLASS) re· CLASS) ' . ('C' CLASS) O.D.mm max. 21.8 34.2. 60.8 89.5 .Min. 21.0 33.3 59.7 88.0 THICKNESS mm 2.6 for B Class and 3.2 for B Class and4.0 for C • 3.6 for B class4.5 4 for B class and4.8 for

3.2 for C Glasa Glass forC Glass ,:; Glass NOMINAL WEIGHT 1.21 for B Class 2.41 for B Class and2.93 for 5~03 for B class6.19 8.36 for B class Ka/mtr: and1 .44 for C Glass C Glass forCGlass and9.90 for C Glass Note:

·Maximum tolerance. on thickness (-) 10°k, Tolerance on weight for single tube ± ·10% . and for quantities per load of 10 tones, ± 7 .5% • Pipes shall be designed.to withstand a test pressure of 5 MPa (50 bar), maintained.for at least 3 second without showing any kind of defects. · · • Eddy Current test may be done in place of hydrostatic test as per the procedure given 'in Annex - C of IS: 1239 (Part-1) - 1990.

• All Galvanized Tubes shall be Zinc coated by hot dip galvanizing in accordance with IS:

4736-1986 & its relevant parts. · • Minimum mass of zinc coating d&termined as pe~ IS: 67 45-1972 shall be 400 gms I m2 · • The zinc coating on external and internal surfa~s shall .be adhenmt, smooth and free from such imperfections as flux, ash and dross inclusions, bare patches,. black·· spots, . pimple~. lumpiness, runs, rust stains, bulky white .deposits and blisters. · • Rejection and acceptance for these defects shaU be as per Appendix-A of IS: 2629-1985 • The galvanized coating when determined on a 100 mm long test piece in accordance with IS: 2633-1986 shall withstand 4, one-minUte dips.

• lhe adherence pf zinc coating on tubes above 50 mm nominal bore, ~~aft be" determined by the pivoted hammer test given in IS : 2629 - 1985 .

• Each pipe shall be legibly and durably marked at Intervals of not more than one metre with the following information (i) Manufacturer's name or trade mark, \;i) Class of Pipe - HEAVY, (iii).

Indian Standard mark - ISi, (iv) Batch No. of Production, if any.

Fittings conforming to the requirements of IS 1879: 1987, IS 14329: 1995 are permitted to .be used in Tertiary network,· operating at pressures 100 mbarg and below :

\ ~.

[~II-~3(i)] Copper _Tubing For a copper service in domestic natural gas installations, materials supplied shall be -in accordance with BS .EN 1057:1996. It has replaced the copper tube standard BS 2871 Part 1.

BS _EN 1057 ensures the quality of the copper product by specifying the pipe in terms of its chemical composition, mechanical properties e.g. tensile strength, hardness, elongation etc., dimension and tolerance, surface quality, freedom frpm defects and suitability for pipe bending.

Copper pipe work shall be jointed by soldering or brazing, using mechanical compression or capillary type fittings. Fittings for use in joining copper tube $hall be as per BS EN 1254 Parts 1· 'and 2. Fittings· for capillary soldering and brazing are specified in Part 1 and compression fittings are specified in Part 2. · Soft soldering utilizes filler metals with melting points at temperatures up to 450°C. Filler metals shall be as per BS EN 29453:_1994 - Soft solders aJloys - ChemicalcompQSitions and forms.

· _ Solders for use with copper. tube and fittings generally melt within the temperature range 180°C to 250°C. Comr;ession fittings shall comply with BS 864 Pllrt 2 or BS 2051 Part 1.

-For capillary fittings:

• Soft solder shall not be used for pressure in-excess of 75 mbar. _ • If the operating pressure is to exceed 75 mbar, then, a solder with a melting point of not less than 600 degrees C shall be used. "fhis shall also apply to brass fittings.

· Height limit for copper risers: Although there is no ,specific guidance regarding maximum height - of copper risers, IGE/UP/2 only allows the use-of steel for risers above heights of 15 meter.

Thus, unless local information is· available to the contrary, 15-rneter maximum height shall be considered safe due to weight and mechanical strength of material.

General guidance 'in BS 6891 also states that eopper pipe work is not acceptable inside a protected shaft. Requirements for ventilation and fire stopping shall apply to ducts conveying copper pipe work. For an external copper Fiser system, protection against lightning_ conductors shall b9 considered.

A copper gas line shall never be used as a ground for an electrical \system.

[F.No. S-Admn/II/8/2007-Vol. I].

RATAN P. WATAL, -Secy.

Printed by th(Manager, Govt. of India Press, Ring Road, Mayapuri, New Delhi-110064 and _Published by the Controller of Publications, Delhi-110054 .

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