Documente Academic
Documente Profesional
Documente Cultură
Undertaken at
SITI ENERGY LIMITED, Moradabad
Under guidance of
Mr. Jeet Ram Verma (Chief Manager- Projects)
M. A. Azeem (Chief Engineer)
Submitted by:
Vibhu Yadav
R010208064
FORWARDED BY:
(Pipeline)
---------------------------(SIGNATURE)
Deputy
(CNG)
---------------------------(SIGNATURE)
Place: Moradabad
Date: 05 August 2011
2 | Page
ACKNOWLEDGEMENT
I am very thankful to SITI ENERGY LIMITED for providing me this opportunity to
practically see all these things which we had studied during the last 3 years of our graduation.
We are especially thankful to Mr. JeetRam Verma (Chief Manager-Projects) and M.A. Azeem
(Chief Engineer) for giving us this project and for their continuous guidance during the
course of our training. My sincere thanks to Mr. Tarang Arora (Deputy Manager CNG) and
Mr. Sabir Ahmed Siddique (Manager Pipeline) who made all the possible effort for providing
me the necessary practical/technical exposure and all the departments in the company
(Management/Accounts/C&P and O&M.) which provided the necessary statistics to make the
project more useful.
I am grateful to Mr. Neeraj Joshi (Deputy Manager Pipeline), Mr. Gaurav Kumar Arya
(Sr. Engineer Pipeline), Mr. Nishant Jain (Engineer Pipeline), MR. Gaurav Arora
(Engineer CNG), Mr. Dhruv Pal Negi (Engineer CNG), for their encouragement and cooperation. They took painstaking effort in helping me to complete my project, a fruitful
learning experience.
Submitted By:
Vibhu Yadav
R010208064
Table of Contents
S. No.
TOPIC
PAGE NO.
1.
Certificate
2.
Acknowledgement
3.
List of tables
4.
Abstract
5.
Introduction
7-9
6.
10-12
7.
13-15
8.
Company profile
15-18
9.
Technical standards
19-20
10.
20-62
11.
Conclusion
63
12.
References
64
13.
Annexure
65
4 | Page
List of tables
S.No. Table no.
Page
1.
2.
3.
other fuels
Table 3-Demand of natural gas in India
10
4.
11
5.
11
6.
12
7.
21
8.
25
9.
25
10.
33
11.
12.
station
Table 12- Economics of CNG usage
34
13.
36
14.
37
15.
39
16.
46
17.
48
18.
50
19.
65
5 | Page
6 | Page
Abstract
City gas distribution is an interconnected network of pipelines used for the distribution of gas
to domestic/commercial/industrial consumers in the form of PNG (low pressure distribution
network) and to the automobiles in the form of CNG (high pressure distribution network).
PNG deals with the distribution of natural gas from bulk supply high pressure transmission
grids and subsequently to medium pressure distribution mains through service distribution
mains to the domestic consumers(at a pressure of 21 mbar) and to the commercial/industrial
consumers at a pressure depending upon the demand of the consumer.
On the other hand, CNG system deals with the dispensing of natural gas into vehicles at a
pressure of 200 bar.
The project throws light on the following points:
applicability)
Fire & Safety aspects in CGD Business
7 | Page
INTRODUCTION
Natural gas
Natural gas is a gaseous fossil fuel consisting primarily of methane and other heavier
hydrocarbons like ethane, propane, butane etc. until Heptanes along with some non
hydrocarbon components like Hydrogen Sulfide, Nitrogen, Carbon Di Oxide and traces of
Helium. It is formed from organic material that was formed as a result of deposition of dead
plant and animals under high pressure and temperature beneath the earths surface.
88%
Ethane:
5%
Propane:
1%
CO2:
5%
Others:
1%
Value/significance
Appearance
Boiling point
Flash point
Explosive limit
5 to 15 % in air
8 | Page
Color
Colorless
Odor
Odorless
Calorific value
8500 kcal/scm
Specific gravity
0.65(approx)
Note: The energy derived from natural gas is a result of the energy released by the
breaking of molecular bonds in the presence of oxygen.
Natural gas
LPG 1 kg
HSD 1 kg
Kerosene 1 kg
11750
10500
10420
80
55
40
(1 scm)
Cal.
Value
in 8500
k.cal/kg
Heat
transfer 85
efficiency in %
9 | Page
9400
5775
4168
k.cal/kg
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Gasoline
80-90
92-98
110
14.6
1.38
CNG
120
120
16.04
16.79
1.24
43.6
2.83
47.377
2.72
1.3-7.1
480-550
5-15
645
Natural gas
117000
40
92
1
7
0.000
Oil
164,000
33
448
11,222
4
0.007
Coal
208,000
208
457
2,591
2,744
0.016
11 | P a g e
Year
Oil(MTOE)
GAS (MTOE)
GAS (BCM)
2007-08
140
40
33
20011-12
166
44
49
2016-17
214
64
71
2021-22
278
97
108
2026-27
365
135
150
2031-32
486
197
219
% growth
5%
7%
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Year
2010
2015
2020
2025
2030
CAGR
Oil
45
45
55
55
50
0.53
Natural gas
39
49
56
58
58
2.00
218
220
230
235
250
0.70
14
22
29
32
7.18
23
29
36
41
44
3.22
333
357
399
417
434
1.34
Coal
Nuclear energy
Hydroelectric
Total
Year
2011-12
2016-17
2021-22
2026-27
2031-32
CAGR
Demand
496
665
907
1222
1651
Supply
333
357
399
417
434
Gap
163
308
508
805
1217
11
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The gas produced in the western offshore fields is brought to Uran plant (ONGC) in
Maharashtra and partly in Gujarat (ONGC-Hazira). The gas brought to Uran is utilised in and
around Mumbai. The gas brought to Hazira is sour gas which has to be sweetened by
removing the sulphur present in the gas. After sweetening, the gas is partly utilised at Hazira
and the rest is fed into the Hazira-Vijaypur-Jagdhishpur(HVJ) pipeline which passes through
Gujarat, Madhya Pradesh, Rajasthan, U.P., Delhi and Haryana.
Major gas producing fields:
Petronet LNG
Dahej
Kochi
Shell Hazira
Ratnagiri Gas Dabhol
GSPC LNG
Total(in MMT)
Total( in MMSCMD)
15 | P a g e
those who own the pipeline (today, GAIL is the biggest, followed by Reliance)
And those who distribute the gas (Indraprastha Gas, Gujarat Gas and GSPC etc.).
Bidding procedure
There's a step-wise competitive bidding process for the licences. To start with, companies
submit an expression of interest (EOI) to PNGRB for the cities they are interested in. If
there's sufficient interest in a city, PNGRB calls for bids. Bidders have to meet financial (net
worth-related) and technical (experience) parameters to submit bids.
PNGRB is targeting CGD bidding in 200 cities by 2012. For most cities, it will be a head to
head contest between Reliance and GAIL. Currently CGD networks are operative in multiple
cities including Delhi, Mumbai, Indore, Pune, Vijayawada, Vadodara, Surat, Ankleshwar,
Ahmadabad and Kanpur.
significant investment
lengthy gestation period
provision of tax incentives to companies interested in setting up these networks by
the government Currently, the domestic tax law provides a 10 year tax holiday for
laying and operating 'cross country' natural gas distribution network, including
pipelines and storage facilities.
GAIL was the first company in India to pioneer city gas distribution project. In addition to
marketing Natural Gas through Trunk and Regional Transmission systems, GAIL has formed
joint venture companies to supply gas to households, commercial users and the transport
sector. The backbone of this pipeline system is a national grid that circumnavigates and crisscrosses the country, and whose size is increasing by the day. GAIL has completed 7,000 km
and is aiming for 13,000 km by 2012; Reliance has 1,400 km and is waiting for government
clearance for another 3,000 km.
Demand build-up.
Supply
Infrastructure required
Technological challenges
17 | P a g e
With the growing concern about environmental aspect, GOI started CNG distribution in
cities. Various organizations like GAIL, IOCL, BPCL, GGCL etc. entered into this sector by
forming JVs with other players and provided this sector the necessary thrust. The CGD
network caters to the supply of PNG to domestic households and small commercial/industrial
establishments and CNG to automobile sector. With the introduction of PSUs the Indian gas
chain has become more structured and organized. Currently major oil PSUs like IOCL,
BPCL and HPCL are providing substantial support in all parts of the gas chain with the
formation of JVs like Green Gas Limited in Lucknow &Agra; IGL in Delhi-NCR etc.
COMPANY PROFILE
SITI ENERGY LIMITED
Siti Energy Limited (SEL) is a .Company was incorporated in 2006 and was given work for
implementation of City Gas Projects for supply of Piped Natural Gas (PNG) to domestic,
commercial and industrial customers and Compressed Natural Gas(CNG ) to automobile
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consumers in the cities Agra and Lucknow. Now GGL is the only player in PNG & CNG
distribution field of above cities.
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FUTURE PLANS
Siti Energy Ltd. has vigorous expansion plans for the implementation of City Gas
Distribution (CGD) projects in its authorized areas. Simultaneously, SEL is striving hard to
explore business opportunities in other parts of the country as well.SEL is looking forward to
provide the complete energy solution by moving beyond the CNG and PNG applications
currently in existence which would enable it to enhance value for the stakeholders including
customers, shareholders and employees. The company is committed to be a customeroriented organization by adopting world class operational practices. Recognizing the fact that
vehicle owners will not convert their vehicles to CNG until and unless CNG has been made
available in adequate quantity and at many locations across the city, SEL has decided to make
CNG available at multiple places and to ramp up the availability of CNG both in terms of
quantity and geographical spread.
20 | P a g e
Technical Standards: In city gas distribution, some of the widely used standards referred
for establishing the gas network and ensuring the safety of customers include:
PNGRB Norms
ASME B31.8
OISD Standards
GAS CYLINDER RULES, 2004
21 | P a g e
1. PNGRB-Petroleum and Natural Gas Regulatory Board (PNGRB) Act came into force on
April 03, 2006 to protect the interest of consumers and is engaged in specified activities
to ensure uninterrupted and adequate supply of petroleum, petroleum products and natural
gas in all parts of the country and promote competitive markets in Oil and Gas sector of
India. This document lays down certain standards which need to be followed during setup
of a CGD network in comparison with other standards as well. Some of the important
aspects discussed in this document include: material and equipment (Schedule1A),
welding (Schedule1B), piping system components and fabrication (Schedule 1C),
design, installation and testing (Schedule1D), operating and maintenance procedures
(Schedule1E), corrosion control (Schedule1F) and miscellaneous (Schedule1G).
2. Oil Industry Safety Directorate The Oil Industry Safety Directorate (OISD) is an organization supported by all
petroleum companies of India, like IOCL, ONGC, BPCL, HPCL, OIL etc. OISD has
basically framed rules and guidelines for Safe Distances to be observed for various
Facilities in an oil/gas installation.
Eg: OISD-179: This standard lays down the minimum safety requirements at installations
handling Natural Gas for dispensing into vehicles and minimum checks required in the
vehicles by refueling stations. (For more details refer OISD-179 norms)
3. Gas cylinder rules: It is a draft published under explosives act 1884, and states following
4. ASME B31.8: This document lays down codes and procedures for designing, operation
and maintenance of gas transmission & distribution piping systems. (for more details
refer ASME B31.8 norms)
22 | P a g e
23 | P a g e
(air =1)
CNG
No
No
0.55(lighter)
Natural gas
Petrol
Moderate
Moderate
3.4
Petroleum
Diesel
Moderate
Moderate
4
Petroleum
The fundamental purpose of a CNG station is to dispense natural gas to vehicles. Where,
practical CNG stations have been located close to a transmission pipeline. At these stations
natural gas is tapped from pipeline and connected to the suction side of a compressor. The
natural gas is then compressed and transferred to storage cylinders (cascades) and held until a
vehicle is connected. When it has not been possible to locate a dispensing station close a
transmission pipeline; mother-daughter concept has been used whereupon a mother station
compresses the gas into cascades which are then transported by a road vehicle to daughter
dispensing outlet. In some cases mother station also acts as a dispensing station.
Mother station
Online station
Daughter station
Daughter /Booster Station
24 | P a g e
25 | P a g e
26 | P a g e
These stations are generally not economical for the operating company as the pressure in the
mobile cascades goes down very rapidly as a result of which the residual gas content left is
more which remains unutilized.
CNG Daughter Booster Station:
Hydraulic Booster Compressor operated electrically is provided in CNG Daughter Booster
Station, which is used to supplement the pressure energy of the residual gas in the cascade
cylinders.
Compressors
Cascades
Dispensers
LCVs
1. COMPRESSOR:
Compressors are used to compress incoming natural gas for converting into CNG.
Compressors are used for increasing the suction pressure (from 17-19 bar to 250 bar). Air
Actuated Valves starts the engine of the compressor. Air coming from air compressors at
pressure of 7-8 kg/cm2 is stored in a vertical vessel which provides storage of compressed air
at constant pressure for pneumatic startup of the gas compressor. During pneumatic startup
firing takes place and the compressor engine then continues to operate.
27 | P a g e
Chicago Pneumatic
DR( Dresser Rand)-used by GGL
Safe
Delta
Sulzer
Knox western
BPCL
28 | P a g e
29 | P a g e
TABLE 8: GAS ANALYSIS AND ADDITIONAL OPERATING DATA OF DRESSER RANDCOMPRESSOR USED BY SEL
GAS COMPOSITION
Nitrogen
Cabon di oxide
Hydrogen sulfide
Hydrogen
Methane
Ethane
Propane
Iso butane
Normal butane
Iso pentane
Normal pentane
Ethane plus components
Ethylene
Propylene
Water vapour
MOLECULAR WEIGHT
28
44
34
2
16
30
44
58
58
72
72
28
42
18
Total %
WT%
0.057
3.068
86.1
7.27
2.34
0.52
0.64
0.0053
100
CNG
1
CYLINDER 1
4
2
CYLINDER 2
3.125
3
CYLINDER 3
3.125-2.25
DIA(in.)
STROKE(in.)
CYLINDER TYPE
MATERIAL
7
DA
C.I
7
SAHE
F.S
7
SACE
F.S
STAGE(ONE)
INLET
KSCG
CYLINDER 1
16.31
CYLINDER 2
52.1
CYLINDER 3
115.08
PRESSURE
INLET TEMP.
DISCHARGE
0C
KSCG
30
53.2
55
117
55
255
PRESSURE
DISCHARGE
0C
120
116.11
123.33
30 | P a g e
TEMP.
BHP
HP
SPEED
RPM
CAPACITY AT SCMH
203
685
1200
203
685
1200
203
685
1200
INLET
C.I.- Cast Iron
F.S.- Forged Steel
KSCG- kg/cm2
SACE- Single Acting Frame End
DA- Double Acting
SAHE- Single Acting Outer End
Engine driven by DR
Make- Chicago Pneumatic
Model- NG 1200M
KW-200
RPM- 1485
Belt drive- V-belt drive
2. PROIRITY PANEL: It is situated inside the compressor house .The flow of the compressed
gas from the compressor to the various equipments is decided by the priority panel & priority
is given by programming.
31 | P a g e
32 | P a g e
Functions
33 | P a g e
Safety valve: it is used to prevent excess pressure which can be there under abnormal
conditions. The valve is set in way that whenever pressure in dispenser reaches above
atmosphere.
Some common dispensers used in CNG station are:
- Compaq
- SAFE
- FTI
- TGT
- Nuovo Pignone
The compressed gas from the priority panel goes to the dispenser through three pipes
flow meter where the amount of gas flowing into the dispenser is measured.
There is a safety valve besides the mass flow meter to release high pressure gas
34 | P a g e
known for their robust build quality. They also have a higher working, test and burst
pressure parameters than CNG cylinders used in vehicles. The cascades are filled in
three modes viz. low, medium, high. The cascades are filled at a pressure of 250 bars.
The gas is withdrawn from a cascade in the reverse mode i.e. high, medium and then
low.
Cascades are primarily of two types:
Features :
35 | P a g e
Mobile cascade
Features:-
36 | P a g e
11. All electrical fittings and equipment such as compressors, motors, switches, starters, etc.,
installed in the premises used for compressing and filling of CNG shall be of flameproof
construction conforming to IS:2148 or such other specification as approved by the CCOE.
12. No alterations or additions shall be carried out to the premises without prior approval of
the licensing authority.
TABLE 10: INTER DISTANCES From buildings and outer boundaries to gas storage units
Total capacity of gas storage cascade units (in Minimum distance from buildings
liters)
Up to 4500
4500 to 10000
10000 to 100000
TABLE 11: Inter distances between various facilities in the CNG fuelling station
Sl.
Distance from
CNG
CNG
Storage
Outer
MS/HSD
Vent of MS/HSD
Filling
No.
(in meters)
Compressor
dispensing
cascade
boundary
Dispenser
point
Unit
wall/
MS/HSD
CLF*
1
CNG compressor
T-1
CNG dispensing
(Min-3)
-do-
Unit
3
Storage cascade
T-1
T-1
T-1
-do-
Outer boundary
T-1
(Min-6)
6
(Min-4)
4
-do-
wall/CLF*
5
MS/HSD
T-1
-do-
Dispenser
Vent of MS/HSD
(Min-6)
T-1
(Min-4)
Filling point of
T-1
MS/HSD
(Min-3)
of
38 | P a g e
ii) Distances shown as -shall be any distance necessary for operational convenience.
iii) A suitable curbing platform shall be provided at the base of the dispensing unit to prevent
vehicles from coming too near the unit.
iv) A CNG cascade having cylinders of total water capacity not exceeding 4500 liters can be
mounted on top of the compressor super structure.
13. Smoking, naked lights, lamps, source of fire, mobile phones or any other implements
capable of igniting flammable vapour or gas shall not be allowed inside the premises.
14. Every person managing or employed on or in connection with the licensed premises shall
abstain from any act whatsoever which tends to cause fire or explosion and which is not
reasonably necessary and to the best of his ability, shall prevent any other person from doing
such act.
15. The operators and attendants shall be fully conversant and trained with all the facets of
the dispensing activities including operations, procedures, maintenance and hazards of CNG
and the risk associated with the handling of the product.
16. The emergency telephone numbers of local fire service, police and the principal
marketing company and emergency instructions shall be conspicuously displayed in the
licensed premises.
TABLE 12: Economics of CNG usage (cost in Rs/km)
Fuel
Petrol
Diesel
CNG
Car
3.07
2.20
1.33
Bus
9.43
8.75
Auto
1.84
1.32
0.70
39 | P a g e
40 | P a g e
After conversion, the vehicle should be turned on gas at workshop after 1000 km
to 1500 km.
During normal servicing, nothing special is required for CNG kit except for
41 | P a g e
PNG System: PNG implies Piped Natural Gas i.e. natural gas which is supplied through
pipes to homes and establishments.PNG is continuously supplied through the Hazira
Vijaypur - Jagdishpur (HVJ) pipeline of GAIL.
Characteristics and advantages over LPG system
Pollution free
Uninterrupted supply at all times
Less storage area occupied as compared to LPG cylinders
Gives a cost benefit of 10% to the user as compared to LPG.
Can be used for multiple purposes like A/C, geysers, lanterns etc.
System design is temper proof
Environmental friendly and clean source of fuel: Its combustion results in virtually
no atmospheric emissions of sulphur di oxide (SO2), and far lower emissions of
carbon monoxide (CO), reactive hydrocarbons and carbon dioxide, than
combustion of other fossil fuels. In fact, when natural gas burns completely, it
Characteristics
Composition
LPG
Mixture
Relative density
Auto ignition temperature
Calorific value
Physical property
butane
b/w 1.4- 2.1
b/w 410- 470 deg C
10900 kcal/kg
Liquefied at high pressure
of
propane
PNG
& Primarily methane
0.65( hence lighter than air)
570 deg C
13570 kcal/kg
Remains in gaseous form
gas in cylinders
and pressure
Through LPG cylinders
Through pipeline
Refineries and fractionizing From gas sources
Safety
plants
processing plants
In gaseous state, it is twice In the eventuality of any
via
reduced.
Moreover
the
safety
ensures
Convenience
Requires
booking
system
that
tripping
of
Coal
3-4 kg
Furnace oil
2 kg
LPG
0.9 kg
Electricity
11.4kwh
Gas filter
Pressure reduction skid comprising active and monitor combination with minimum
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).
43 | P a g e
44 | P a g e
3. MRS
be provided.
Metering facilities may or may not be part of this station.
Filtration facilities not provided
Copper tubing
MDPE pipeline
45 | P a g e
Copper fittings
Plastic fittings
Split tees
Consideration shall also be given to loading due to following while selecting nominal
47 | P a g e
Where
D
P
t
S
=
=
=
=
permitted
Use of thermoplastic piping in above ground piping is not permitted unless the piping
degree centigrade).
Test medium shall be air or nitrogen for test pressure up to 100 psig. For test pressure
greater than 1 km and minimum 4 hours for length shorter than 1 km.
Use of automatic shut-off device (slam shut valves) as a means of accidental over-
as per IS 9573. 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.
LAYING OF PIPELINE COMPLIANCE
Road signs, warning lamps and barrier systems shall be
provided on highway or
objects, stones etc. The trench should be padded with soft soil / sand to minimum of
100 mm below the pipe.
At identified locations pipelines shall be provided with impact protection from
excavating machinery as indicated in the figure below where h shall not be less than 500
mm,250 mm.
49 | P a g e
2
5
0
m
m
Where it is necessary to cross or run close to any other utility, a minimum of 250 mm
clearance shall be maintained. In case the clearance is less, appropriate protection measures
shall be taken. The relative position of PNG pipeline with respect to other underground
utilities shall be as shown along side:
Provision shall be made for locating the buried PE pipe by installation of electrical
conductive trace wire or plastic coated metallic tape or any alternate proven locating method.
50 | P a g e
PIPELINE MARKERS:
Further, warning signs shall be displayed on the service line to consumer premises.
A marker shall be marked in easily readable local language with at least the following:
-
Location code
-
CGS.
Pressure reduction skid with 50%
redundancy reduces the pressure from
47 bar to 19 bar and odorises the gas
bar.
Piping system downstream of DRS consists of MDPE pipeline whose grade, nominal
outside diameter, wall thickness, tensile strength and other parameters are calculated
Principle
Diaphragm expands
contracts,
liver
Advantages
and These are positive
converts displacement
Diagram
type
are
highly
produce
volumes
and
52 | P a g e
pressures
Turbine
than
diaphragm meters
A small internal turbine Turbine gas meters
measures the speed of the infer gas volume by
gas, which is transmitted determining
mechanically
mechanical
Orifice
to
or
the
counter
meter.
A type of differential meter They
are
well
by
measuring
and
the understood
in
they
are
since
easy
field-service
have
Ultrasonic flow
no
to
and
moving
parts.
Ultrasonic meters measure Inexpensive varieties
the speed of gas movement of ultrasonic meters
by measuring the speed at are available, which
which sound travels in the can
be
used
to
53 | P a g e
METER MIN.
FLOW
MAX. FLOW
TYPE
(/100) SCMH
(*1.6) SCMH
G1.6
G2.5
G4
G6.5
G10
G16
G25
G40
G60
G100
G160
G250
G400
G650
G1000
0.016
0.025
0.040
0.065
0.10
0.16
0.25
0.40
0.60
1.00
1.60
2.50
4.00
6.50
10.00
2.5
4
6
10
16
25
40
60
100
160
250
400
650
1000
1600
MOP (BAR)
0.5
0.5
0.5
1
1
1
54 | P a g e
Regulating System: A pressure regulator is a valve that automatically cuts off the flow of a
liquid or gas at a certain pressure. Regulators are used to allow high-pressure fluid supply
lines or tanks to be reduced to safe and/or usable pressures for various applications.
A regulator includes a restricting element, a loading element, and a measuring element:
The restricting element is a type of valve. It can be a globe valve, butterfly valve,
poppet valve, or any other type of valve that is capable of operating as a variable
restriction to the flow.
The loading element applies the needed force to the restricting element. It can be any
number of things such as a weight, a spring, a piston actuator, or more commonly the
diaphragm actuator in combination with a spring.
The measuring element determines when the inlet flow is equal to the outlet flow. The
diaphragm is often used as a measuring element because it can also serve as a loading
element.
In the single-stage regulator shown below, a diaphragm is used with a poppet valve to
regulate pressure. As pressure in the upper chamber increases, the diaphragm is pushed
upward, causing the poppet to reduce flow, bringing the pressure back down. By adjusting the
top screw, the downward pressure on the diaphragm can be increased, requiring more
pressure in the upper chamber to maintain equilibrium. In this way, the outlet pressure of the
regulator is controlled.
55 | P a g e
Natural gas
Direct acting spring control pressure regulator
with in-built pressure regulating valve type
balance regulating unit to ensure a constant
outlet pressure having insufficient downstream
Installation
Installation position
Capacity
Inlet pressure
Design pressure
Outlet pressure set point
years.
Horizontal/vertical
2.5 m3/hr (actual)
100 mbar(g)/(100-300 mbar(g)
6 bar
21 mbar(g)(factory set point)(spring range 18-
30 mbar)
15 mbar(g)
0-40 deg C, Design 65 deg C
Casing and body of die cast aluminium / steel
conforming to ASTM A216 WCB and water
weather proof/corrosion resistant for outdoor
Fire resistance
Diaphragm
Internals
installation.
As applicable
Synthetic rubber
Stainless steel, brass seal of nitrile rubber or
aluminium
Essential(inbuilt)
Closed
Auto/manual (vendor to confirm)
Filter
Failure position
Type of reset
Note: The domestic regulators are mainly of diaphragm type and are designed on various operating capacity,
pressure and temperature depending on the requirements of the customer.
57 | P a g e
The pipe is softer and more susceptible to damage during transport, installation and
future third party activities in the vicinity of the installed pipe.
Because of its thermoplastic nature PE is weaker at higher temperatures. At full
design pressure it should not operate at temperatures above 40C. Its use is therefore
restricted to underground only.
Because of its thermoplastic expansion (10 times greater than steel) temperature
changes need to be taken into account during construction.
It has a tendency to cold flow or creep under load. An internal stiffener is required to
prevent cold flow whenever a mechanical joint is employed.
Pipeline System
Pipeline network consists of steel pipeline, polyethylene pipeline, galvanized iron pipeline
and finally copper pipeline. A typical CGD network should consist of the following
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 DRS. The
maximum velocity in the pipeline network should be limited to 100 ft / sec (30 m/sec)
immediately after pressure regulating instrument.
Secondary Network: A low pressure distribution system comprising of gas mains or
distribution Mains usually constructed using thermoplastic piping (MDPE) and connects DRS
58 | P a g e
to various service regulators at commercial, industrial, and domestic consumers. The network
should be sized for maximum flow velocity of 100 ft / sec (30 m/sec).
Tertiary Network: A service pressure distribution system comprising of service lines,
service regulators and customer /consumer meter set assemblies constructed using a
combination of thermoplastic (MDPE) piping and GI /copper tubing components. Tubing /
Hose pipe for connecting consumer meter set assembly and consumer appliance: The
connection between consumer meter set assembly and gas appliance (provided by consumer)
may be made by GI pipes or copper tubing or steel reinforced rubber hose. Steel reinforced
rubber hose shall conform to IS: 9573
59 | P a g e
laid in conformity with the levels depths, slopes, curves, dimensions and instructions shown
on drawings, specifications. It is done under the direction of the company.
Trail holes refers to the small pits which are generally dug before the actual excavation
process for determining the pipe route and locate other underground plant or investigate
possible obstruction if any e.g. telephone wires, cables, water lines, pipelines belonging to
other companies.
The trial holes are normally preplanned i.e. the location of between the trial holes is
normally at a distance of 25m. They are excavated to a depth of pipe and an addition of
250mm. These holes are not closed immediately. They are protected and fenced. The trial
holes are planned in such a way that there are no abandoned trenches and also to avoid
insufficient trial holes. The excavated trench is maintained on stacked centre line as per the
sheets approved and also taking into account of the curves of the pipelines. Proper care is
taken while trenching to ensure all underground structures and utilities are disturbed to the
minimum. The crossings wherever necessary is provided and maintained for the general
public property owners or tenants to cross and also to move any stock from one side of the
trench to another.
Trenching is made in sufficient slopes on sides in order to minimize collapsing of the
trench. In places, where there is any danger of landslides the pipeline trench is maintained
open for time required to lay the line i.e. the work in that area is completed in less time and
covered. The soil stability is analyzed in areas like drainage, ditch etc.
The bottom of the trench is normally maintained in the square form to the maximum extent
with the equipments so as to avoid the hand grading at the bottom of the trench. The bottom
of the trench is made free of loose rocks, pebbles and trim protruding routes from the sides of
the trench wall. A stretch of 12m is allowed to remain excavated before joining or back
filling.
Any kind of rock which cannot be drilled using sledge hammer, chisel is considered as hard
rock. Any other Plain cement concrete (PCC) or Reinforced cement concrete (RCC)
encountered during excavation are removed in supervision of authorities as the cost of
removing those type of obstructions is high.
PE Trenching
Trenching refers to the making of holes i.e. opening the ground wide apart. It is classified into
2 types,
Open Cut.
60 | P a g e
Boring.
Red boring.
Red boring refers to the boring of ground without opening the ground wide apart using the
normal tools i.e. by hand.
Machine Boring.
When the boring is not possible by red boring, machine boring is made use of. This happens
when hard obstructions are encountered.
The design of the depth of the trench varies for different locations as follows,
For distribution main 1.5m
Minor water crossing or canal 1.5m
Uncased or cased road crossing 1.5m
Rail or road cased crossing 1.5m
Normal areas 1.2m
The above mentioned depths may vary depending on the locality. In case of any difficulties
in maintaining the required depth due to unavoidable factors the new depth shall be decided
and put in to effect in the particular area only.
The width of the trench is maintained in wide enough to provide bedding around the pipe
and to prevent damage to the pipe inside the trench. The distance between the ground and the
bottom edge of the pipe is 50 mm for 63mm diameter pipelines and 100 mm for pipes larges
than 63 mm which included the 90 and 125 mm pipes.
The following clearances are provided between the external wall of the gas pipe and the
external surface of the other underground assets in the locality.
150 mm where the gas pipe crosses other assets, other than electric cables where the
clearance is 300mm.And 300 where the gas pipe to be laid is on a similar alignment to the
other assets.
In places where this clearance cannot be maintained due to various reasons, suitable barrier
protections are installed between the pipe and the service line like the electric cable. RCC
half round hume pipe is constructed along the trench.
61 | P a g e
All the works in the municipal or public roads are required to be executed as per there codes
and conduct with a view to cause minimum inconvenience to pedestrian and vehicular traffic.
All the trenching works are carried out with proper caution. E.g. before commencing of the
excavation the caution board & information board as per the standard size, shape and
color are installed at the site. The crown of the backfilled earth is maintained between 50mm
and 100mm and is free from sharp edged stones & boulders. The site is maintained neat and
clean without causing any nuisance to the public until the completion of the work.
In case of rain dewatering is done prior to back filling. This is maintained strictly for the
protection of the gas pipeline. While back filling the mud or the soil is cautiously done such
that there is no extraneous material or hard lumps of soil near the laid pipeline which could
damage the line or the coating or leave void spaces in between the fillings. The surplus
material is neatly crowned over the trench and adjacent excavated areas on both sides of the
trench. Little extra allowance of mud is put over the trench such that it comes to the normal
level during settling.
In cases where rock, gravel, lumps of hard soil or materials are encountered at the time of
trench excavation, sufficient sand is placed around and over the pipe to form a protective
cushion extending at least to a height of 100 mm above the top of the pipe. Thorough and
proper compaction is done where in places where the trench is dug like, the drive or road
ways. Special compaction methods are adopted.
Trench excavated in dikes which belonging to the property of railways or which are the part
of the main roads are graded and backfilled in their original profile and condition. The
backfill materials if required are supplied.
PE warning grid or mat are placed on the distribution main and on service lines inside
premises after backfill of the trench up to a height of 300mm after the sand bedding. The
warning mat is unrolled centrally over the pipe section and thereafter the backfilling is done.
All the excavated material which will be required for backfilling are kept separately and
properly. In areas of roads or pedestrian places the refilling are done immediately to avoid
inconvenience to the public.
The back filling is assumed to be complete after the joining of pipes are complete. During
the backfilling of the trenches in private society premises, municipal premises and panchayat
premises, watering and ramming or mechanical compaction are carried out. Excess soil in the
area is cleared off the site and is dumped at suitable location.
Experienced supervisor is always present at the site to decide on various factors in the
required situations. A third party officer is also made to be always available on the site. A
prior information of excavation is given to the people in the area where the work is to
commence in advance for their prior arrangements.
62 | P a g e
Turf is replaced in highly developed grass area. In lesser grassed area top soil are replaced
during the restoration process. In areas where the restoration works cannot be completed
immediately, alternate arrangements are done temporarily for the traffic and the pedestrians.
Boring
In some areas where the normal trenching cannot be carried out, trenchless technology is
carried out which is known as the boring. This is mainly done while the crossing of the roads.
The boring is carried as per the requirement. The survey of the underground utilities are done
before the boring process so that the other pipelines are not damaged. The cost of boring is
costly i.e. 5 times the normal trenching. Hence, the boring is done in required areas only.
In areas like road junction, front of the society main gates, crossings are done in phases
during the night times due to the traffic problems. The works are done so as to finish the work
in night itself. If in case any area is left uncovered or not completed by night, steel plates are
provided are for the movement of traffic in day time.
PE laying
The laying of the MDPE pipelines commence only after the ensuring of the proper
dimensions and clean surface of the trench. The trench bottom is made to be free from the
presence of cuts, stones, roots, debris, stakes and rock projections up to 150 mm below the
underside of the pipe and any other material which could make perforations or tearing of the
pipe wall. After ensuring of all the above factors, the MDPE coil is uncoiled
smoothly inside through proper process and care inside the trench ensuring no damage to
pipe coil during laying.
It is ensured that the pipe caps are provided before the lowering of the pipeline. The trench
after this is released for backfilling leaving adequate lengths open to the ends for joining.
Before lowering of the pipeline a sand bedding of fine soil is done at the trench bottom.
Similarly after lowering of the pipe the trench is filled with sand around and up to 100mm
from the top of the pipe.
Proper inspections of pipes and fittings are done before the releasing of the latter from the
store and the defects are reported to store authorities.
Proper care is taken for PE pipe and fittings after issued from the store till the transporting
storing sheltering the pipe near the trench, uncoiling of the pipe by proper process and
sufficient man power, lowering of pipe in the trench or pulling of the pipe through the trench
such that no external damage is caused to the pipe.
Electro fusion jointing
63 | P a g e
Jointing of the pipes is normally carried out by the electro fusion process based on the
requirements. Proper care is taken during the EF jointing such that there is no failure of the
joint.
Electro fusion
Electro fusion is a simple method of joining PE pipes in circumstances where butt fusion is
not practicable, such as where valves, elbows, and tees must be added. Prefabricated fittings
are used, incorporating an electrical heating coil which melts the plastic of both the fitting
and the pipe, causing them to fuse together.
The characteristics of the fitting to be welded, such as the fusion time, are registered via a
barcode on the fitting. On swiping the sensor over the bar code the required setting time and
temperature are set and on click of start the process starts. An electro fusion control unit
(ECU) supplies the electrical energy necessary to heat the coil. When the coil is energized,
the material adjacent to it melts and forms an expanding pool which comes into contact with
the surface of the pipe. The continued introduction of heat energy causes the pipe surface to
melt and a mixing of pipe melt and fitting melt takes place, this is vital to produce a good
weld. Following the termination of the heat cycle, the fitting and the pipe are left to cool and
the melted material solidifies to form a sound joint.
Hot and cold zones, sometimes called melt and freeze zones, are formed after energizing the
coil. The length of these zones is particularly important. Each zone ensures that fusion is
controlled to a precise length of the socket of the fitting and that the melt pressure is also
controlled throughout the entire jointing process. The precisely controlled pitch and
positioning of the coil in relation to the inner surface of the socket ensures uniform heat
distribution.
The basic fusion parameters: temperature, pressure and time, are controlled by the ECU
which is programmed to establish these parameters from the barcode read from the fitting
itself. The ECU also provides a permanent record of the procedure followed.
Compact ECUs are now available that allow in-trench electro fusion welding to be carried out
safely by just one man.
The effectiveness of electro fusion depends on attention to preparation of the jointing surfaces
and ensuring that the surfaces to be welded have satisfactory contact during the welding and
cooling cycles. The pipe surfaces to be fused need to be scraped to remove the surface
oxidation layer prior to fusion. Pipe clamps or other approved methods of restraining,
aligning and re-rounding the pipes during the fusion cycle should be used. To prepare the
jointing surfaces the pipe surface must be scraped with an appropriate pipe scraper, as
64 | P a g e
recommended by the pipe or fitting manufacturer, to remove the entire surface of the pipe
over the area indicated, to a depth of approximately 0.3mm. Metal files, rasps, emery paper
etc are not suitable end preparation tools. Following scraping the scraped surface must be
wiped with an authorized Isopropanol impregnated pipe wipe, as recommended by the pipe or
fitting manufacturer, to remove any dust residue. Methylated spirits, acetone, methyl ethyl
ketone (MEK) or other solvents are not recommended for wiping the scraped surface. The
prepared surfaces must completely dry before proceeding. The resulting joint, when properly
made, is as strong as the original pipe and can withstand all the loads applied during routine
installation and operation. All the fittings related to electro fusion are according to the design
standards.
The pipeline is normally flushed with air to remove dust, water mud etc which would have
entered the pipe during the laying process. Before jointing the packing sand is placed under
the pipes on both the sides of the joint to keep the pipes in line and correct during the jointing
process. The alignment clamps with correct size are used whenever necessary to align the
pipe during the electro fusion jointing cycle. It is a usual practice to make a joint of electro
fusion fitting on the same day of laying.
The electro fusion joint is inspected before the restoration of the trench so as to ensure the
leakage. In case of leakage the joint is redone with a separate coupler to prevent future
damages to line.
The time of electro fusion for the normal 90mm MDPE is around 42secs and a temperature
of 48 deg C is to be maintained. This reading is noted from the meter. The various types of
the joints which are used in the coupling or jointing of the MDPE pipes are normally 3 types
I. Coupler
II. Tee
III. Elbow
65 | P a g e
The testing carried out during the commissioning process includes the testing of the charged
line for the composition of the gas. The methane content in the gas is tested using the
specified meters. The oxygen content in the line is also checked up. The maximum allowable
range of oxygen in the line is 0-2%. Normally the oxygen content in the line is 0.2%.
The testing is done with all necessary regulators, hoses and connections, which are in good
condition and working order.
A record of all the purging plan before the commencing of the purging work is kept as a
reference drawing. The plan includes the provision of the following materials and
equipments.
Fire extinguisher.
Purging adaptor
Purge stack with flame trap and gas sampling point.
Gas sampling equipment
Squeeze off tool.
The design of PE pipe networks should follow conventional network practices with the
installation of valves at convenient or critical locations. The valves can then be operated to
isolate sections of the pipe network for maintenance.
Additionally however PE pipe networks have the advantage that more localized isolation can
be implemented by the use of pipe squeeze-off. Squeeze-off is used in routine and
emergency situations to stop or nearly stop flow in PE pipe by flattening the pipe between
parallel bars.
PE pipe squeeze-off utilizes the ductility of PE by allowing the pipe to be squeezed together
using relatively simple but specially designed squeeze-off tools thus preventing the flow of
fluid and isolating the pipe section. It is important that only specifically designed tools are
used and that the squeeze-off controls are set for the specific diameter and SDR of the pipe in
order to control the degree of compression of the PE pipe and prevent any damage.
The squeeze off tools are generally mechanically operated up to about 125mm diameter and
hydraulically operated for larger diameters. However squeeze-off equipment is not readily
available for the largest diameters of PE pipe. It is important to follow the manufacturers
instructions when using these tools and to use tools appropriate for the pipe diameter and
SDR. Also the tools need to be capable of resisting the operating pressure of the pipe, and
there are limits to the pressures that they can sustain.
67 | P a g e
Properly implemented squeeze-off, using the correct tools, is not expected to cause damage
to the PE pipe, which regains its circular cross-section after the tool is released. However
squeeze-off is not recommended to be done more than once at any location. If repeated flow
control is required a valve or an appropriate flow control device should be installed in the
system.
Squeeze-off is not intended as a means to throttle or partially restrict flow. Complete flow
stoppage may not occur in all cases. When squeezing larger pipes, particularly at higher
pressures, some seepage is likely. When seepage is not acceptable, it may be necessary to
vent the pipe in-between two squeezes-offs. Any work performed must be downstream of the
second squeeze-off.
Inflatable bag flow stopping equipment can also be used for PE pipes. A saddle fitting needs
to be fixed to the pipe, through which the inflatable bags are inserted. It is important that the
correct saddle fitting is used compatible with the equipment being used. Reference should be
made to the manufacturers instructions.
Adequate and sufficient trench is provided for commissioning process or providing tap off.
The reopening of any trench might be required during the commissioning process. . The
maximum trench dimensions which might be required during the commissioning is 2.5m by
1m.
PE Route Marker
The route marker can be defined similar to a milestone. The PE route marker shows the
route of the laid pipeline. This is for the easy reference for finding the route. The Route
marking process is to be completed before the commissioning process.
The route marker is normally laid for lines in which the pressure of the line is greater than
110mbarg. The distance between each route marker is approximately 300m.
The precast of RCC mix of 1:1.5:3 is required for the route marker stone. The route marker
stone is casted as per the design requirements. For easy understanding of the route marker in
the diagrams it is represented by the yellow color.
A 6mm smooth thick cement plastering work is to be done over the projected route marker
including scaffoldings, curing etc.
Tap of from charged gas mains
The taping process from the charged gas line is a tedious and time taking work. This is done
in case of emergency purposes. The number of live connections from the charged lines can be
minimized by proper planning and synchronizing medium pressure network charging for a
particular area.
The flow stopping devices are used such as squeezers. These are used only on the MDPE
lines as they have their property of regaining their after squeezing.
The method to be used for each connection, the number and type of flow stop devices to be
used is to be determined by the company.
68 | P a g e
Records to be maintained
The various records which is maintained to ensure the proper laying of the line and also the
cost of laying is as follows,
Daily progress report.
Approval for technical deviation if any.
Material reconciliation report as in the designed format.
The testing report of the PE network with reference drawings as per the desired codes
Employees presence registers on site during the PE laying.
Other specific documents wherever necessary.
Organizational chart before the starting of the work.
Details of tools resources and tackles before start.
69 | P a g e
CONCLUSION
On Demand / Supply Terms
GIS/GPS/MMI/SCADA systems.
Pipeline laying activity involves great risk and responsibility as the engineers need to
with
the
help
incorporate maximum design factors, safety factors and rugged material specifications
time.
The operating company are emphasizing on the connection of their dispensing
stations directly to their pipelines rather than opting for DBS.
On human grounds: Team work and feeling of collective responsibility are the only mantras
to ensure success story of an industry.
Employee retention and talent pool conservation are also important factors to consider
70 | P a g e
REFRENCES
-
http://www.angiinternational.com
http://www.petroleum.nic.in
http://www.kgbasin.in
http://www.gglonline.net
http://www.gailonline.com
http://www.wikipedia.com
http://www.mahanagargas.com
http://www.adanigas.com
http://www.iglonline.net
ANNEXURE 1
71 | P a g e
By
25.4
0.454
3.785
0.746
1055
0.556 (f-32)
0.0703
6.895
0.069
0.0283
3.785
To obtain
Mm
Kg
L
kW
J
Deg C
kg/cm2
Kpa
Bar
m3/min
L/min
72 | P a g e