3. Main Report

CITY GAS DISTRIBUTION

GSPC GAS The Pathway GSPC Gas Company Ltd., a group company of the Gujarat State Petroleum Corporation has been established to complete the presence of GSPC in the Energy Value Chain. GSPC Gas always works towards a principal aim to supply natural gas to retail customers, i.e. Domestic, Commercial/Non-Commercial, Industrial and CNG. GSPC Gas is playing a vital role to cater to the natural gas demand up to the last mile of the retail network. GSPC Gas is envisioned to be complementary to Gujarat State Petronet Ltd. (GSPL), which is evident from the presence of GSPC Gas retail network starting at every point and location that the GSPL network ends.

Core Philosophy The GSPC Group's foray into Gas Distribution in a big way bears testimony to the core philosophy of being 'A Complete Energy Company'.

Main Segments (Status on 31st May 2014) GSPC Gas is supplying natural gas to more than 4, 96,138 domestic households, 1,918 commercial and non-commercial segments and 1,897 industrial customers. GSPC Gas also supplies natural gas in the form of Compressed Natural Gas (CNG) through 159 CNG stations across the state that caters to more than 89,000 vehicles per day.

PNG Domestic

PNG Industrial

PNG Commercial

Figure 1 - Main Sectors where Natural Gas is provided by GSPC Gas 1

City Gas Distribution by Sarthak Kishore| GSPC GAS

CNG

Chapter 1 – Natural Gas and its Applications Naturally gas is composed primarily of Methane with minor quantities of Ethane, Propane, Carbon Dioxide, Nitrogen and Traces of Higher Hydrocarbon and Oxygen. It is a vital component of the world's supply of energy. It is one of the cleanest, safest, and most useful of all energy sources. It is a Non- Poisonous, Non- Toxic, Colorless, tasteless combustible source of Energy. It has no odor of its own; however, for City Gas Distribution Ethyl Mercaptan is added for distinct color so that layman can identify the leak if any nearby and report to the authorities for necessary corrective option.

Table 1 - Composition of Natural Gas

Component

Chemical Formulae

Percentage

Methane Ethane Propane Butane Carbon Dioxide Oxygen Nitrogen Hydrogen Sulphide Rare Gases

CH4 C2H6 C3H8 C4H10 C02 02 N2 H2S He, Ne, Ar, Xe

70%-90% 0%-20% 0%-8% 0%-0.2% 0%-5% 0%-5% Traces

Table 2 - Properties of Natural Gas Specific Gravity (Air 1.0)

0.56% to 0.67%

Boiling Point

-161°C

Melting Point

-182°C

Flash Point

-161°C

Auto Ignition Temperature

560°C

Flammable Limit

5% to 15% by volume in air

Critical Pressure

45.99 Bar

Critical Temperature

-82.59°C

Natural Gas Applications

I.

Domestic Usage: Most commonly known use of Natural Gas. It can be used for cooking, water warming, heating and air conditioning. Domestic appliances are increasingly improved in order to use natural gas more economically and safely. Operating cost of natural gas equipment is generally lower than those of other energy sources.

II.

Industrial Usage: It is used to treat waste material, for incineration, drying, dehumidification, heating and cooling, and cogeneration. It is used as an input to manufacture pulp and paper, metals, chemicals, clay, glass and to process certain foods.

III.

Commercial Purpose: Main commercial centers which use natural gas are Hotels, healthcare facilities and office buildings for cooking, cooling and heating purposes.

IV.

Natural Gas Vehicles (NGVs): It can be used as a motor vehicle fuel – as CNG (Compressed Natural Gas) and as LPG (Liquefied Natural Gas). Natural gas vehicles fleet accounts for about one and a half million vehicles worldwide. Concerns about air quality in most parts of the world are increasing the interest in using natural gas as a fuel for vehicles. Cars using natural gas are estimated to emit 20% less greenhouse gases than gasoline or diesel cars. In many countries NGVs are introduced to replace buses, taxis and other public vehicle fleets. Natural gas in vehicles is inexpensive and convenient.

Figure 2 - Natural Gas Consumption In India (Sector wise), 2011

Chapter 2 - what is CNG and PNG? 2.1. CNG (Compressed Natural Gas)



CNG (compressed natural gas) is natural gas mainly containing methane which is compressed up to 250 bars and used as vehicular fuel in vehicles running on CNG kits.



It has a Research Octane Number in excess of 120. The excellent knock resisting property of CNG allows for use of a higher compression ratio resulting in an increased power output and greater fuel economy when compared to petrol.



CNG can be used in engines with a compression ratio as high as 12:1 compared to normal gasoline (7.5:1 to 10:1). At this high compression ratio, natural gas-fuelled engines have higher thermal efficiencies than those fuelled by gasoline. The fuel efficiency of CNG driven engines is about 10-20% better than diesel engines.

The following are the benefits of using CNG:

1. Green Fuel Commonly referred to as the green fuel because of its lead and Sulphur free character, CNG reduces harmful emissions. Being non-corrosive, it enhances the longevity of spark plugs. Due to the absence of any lead or benzene content in CNG, the lead fouling of spark plugs and lead or benzene pollution are eliminated.

2. Increased life of Oil CNG does not contaminate and dilute the crankcase oil.

3. Mixes evenly in Air Being a gaseous fuel CNG mixes in the air easily and evenly.

4. Safety CNG is less likely to auto-ignite on hot surfaces, since it has a high auto-ignition temperature (540°C) and a narrow range (5%-15%) of inflammability. It means that if CNG concentration in the air is below 5% or above 15%, it will not burn.

5. Low Operational Cost At the prevailing price of fuel in Gujarat, operational cost of CNG vehicles is 68% lower than petrol and 36% lower than diesel.

2.2. Piped Natural Gas (PNG) Natural gas which is maintained at low pressure less than 4 bar and carried by poly ethylene pipeline mainly used for cooking in houses and various industrial purposes. The ratio of carbon to hydrogen is least in methane and hence it burns almost completely making it the cleanest fuel. It is procured from the oil / gas wells and transported through a network of pipelines across the country. The following are the benefits of using PNG:

1. Uninterrupted Supply PNG offers the convenience of ensuring continuous and adequate supply of NG through pipeline, without any storage of gas in cylinders.

2. Unmatched Convenience The domestic consumers have to take upon themselves the tiresome task of booking an LPG cylinder; refill time and again start the wait for the deliveryman to deliver the cylinder. Switching over to PNG renders this entire exercise unnecessary. PNG also eliminates the tedious routine of checking LPG refill cylinder for any suspected leakage, or it being underweight, at the time of delivery. Precious space, occupied by LPG cylinders is also saved.

3. Safety The combustible mixture of natural gas and air does not ignite if the mixture is leaner than 5% and richer than 15% of the air-fuel ratio required for ignition. This narrow inflammability range makes NG one of the safest fuels in the world. Natural gas is lighter than air. Therefore, in case of a leakage, it just rises and disperses into thin air given adequate ventilation. But LPG being heavier will settle at the bottom near the floor surface. A large quantity of LPG is stored in liquefied form in a cylinder. With PNG, it is safer since PNG installation inside your premises contains only a limited quantity of natural gas at low pressure i.e. 21 millibar. On leakage, LPG expands 250 times, which is not the case with PNG. Supply in PNG can be switched off through appliance valve and isolation valve, which fully cuts off the gas supply.

4. Billing The user is charged only for the amount of PNG used, and no pilferage is possible with PNG as the billing is done according to the meter. A unique feature is that the user gets to pay only after consumption of gas. The domestic consumer pays the PNG bill only once in two months. Moreover, there are no minimum consumption charges i.e., if there hasn’t been any consumption, there shall not be any bill. The user pays the gas consumption charges based on the exact consumption reading provided by the meter installed at his premises. The bill is delivered at the user’s doorstep.

5. Customer Support Round-the-clock customer support is assured through 24 hours toll free number backed by control rooms, which are manned by engineers and trained technicians. Thus complaints, if any, are promptly redressed.

6. A Versatile Fuel Natural gas is being used predominantly as a versatile fuel in many major cities catering to domestic and commercial applications, as a cooking fuel, for water heating, space heating, air conditioning, etc.

7. Environment Friendly Natural gas is one of the cleanest burning fossil fuels, and helps improve the quality of air, especially when used in place of other more polluting energy sources. Its combustion results in virtually no atmospheric emissions of Sulphur dioxide (SO 2), and far lower emissions of carbon monoxide (CO), reactive hydrocarbons and carbon dioxide, than combustion of other fossil fuels.

8. No Daily Liasioning The consumer is spared the task of liasioning with oil companies and co-coordinating with them for ensuring the daily supply of fuel, because PNG is supplied directly through pipes. The daily bills, settlements and reconciliation are also avoided as the consumer is billed once a month, and that too as per the meter reading.

Chapter 3 – Overview of CGD Business

A City gas distribution means a distribution system in which CNG & PNG sold to various segments by interconnecting gas pipeline & related equipments. Currently the CGD segment constitutes 10 percent of the total gas consumption in India. It is worth noting that this has been achieved in the past five years itself. It is expected to reach a share of 20 percent by FY20. The supply of natural gas for CGD is around 13 mmscmd in FY11 against the demand of 15.83 mmscmd in the country. Increasing demand from commercial and small industrial customers within the city limits, in addition to the automotive and residential demand, are the key drivers of growth in this segment. Much of the demand in future will continue to be as a result of customers finding natural gas to be more competitive than other fuels coupled with ease of handling and lower pollution. On the supply side expectation of large volumes of gas being made available within the next few years, though both new domestic finds and imports, has created greater compulsions for developing the CGD market. With an estimated demand of 100 mmscmd by FY 20, CGD market is expected to grow by leaps and bounds.

3.1. CGD Players in India Table 3

S. No.

Name of the CGD Network

Area Covered

1 2 3 4 5 6

Sonipat CGD Network Meerut CGD Network Kakinada CGD Network Dewas CGD Network Kota CGD Network Mathura CGD Network

Sonipat Meerut Kakinada Dewas Kota Mathura

7 8 9 10 11 12 13

Chandigarh CGD Network Allahabad CGD Network Jalandhar CGD Network Jhansi CGD Network Bhavnagar CGD Network Jamnagar CGD Network Firozabad Geographical Area

14 15

Agra CGD Network Hyderabad CGD Network

Chandigarh Allahabad Jalandhar Jhansi Bhavnagar Jamnagar Firozabad Geographical Area (U.P.) Agra Hyderabad

Entity Authorized Gail Gas Limited Gail Gas Limited Bhagyanagar Gas Limited Gail Gas Limited Gail Gas Limited JV of M/s DSM Infratech Pvt. Ltd. & M/s Saumya Mining Pvt. Ltd. M/s IOCL-AGL M/s IOCL-AGL M/s Jay Madhok Energy Pvt. Ltd. M/s Central UP Gas Ltd. M/s Gujarat Gas Company Ltd. GSPC Gas Company Limited GAIL Gas Ltd.

Green Gas Ltd. Bhagyanagar Gas Ltd.

16

Indore CGD Network

17 18

Gwalior CGD Network Gandhinagar, Mehsana, Sabarkantha CGD Network

19

20 21 22

Indore including Avantika Gas Ltd. Ujjain

Gwalior Gandhinagar, Mehsana, Sabarkantha Pune City including Pimpri, Pune City Chichwad CGD Network INCLUDING Pimpri, Chichwad Kanpur CGD Network Kanpur GA Bareilly CGD Network Bareilly GA Delhi CGD Network National Capital Territory of Delhi

Avantika Gas Ltd. Sabarmati Gas Ltd.

Maharashtra Natural Gas Ltd.

Central U.P. Gas Ltd. Central U.P. Gas Ltd. Indraprastha Gas Ltd.

23

Mumbai CGD Network

Mumbai and Mahanagar Gas Ltd. Greater Mumbai

24 25

Vijaywada CGD Network Mumbai CGD Network

Vijaywada GA Thane City and Adjoining areas

Bhagyanagar Gas Ltd. Mahanagar Gas Ltd.

26

Rajkot

GSPC Gas Company Limited

27

Surendranagar

28

Navsari

29

Nadiad

30

Khurja

31

Moradabad

31

Surat-Bharuch-Ankleshwar

Rajkot Geographical Area Surendranagar Geographical Area Navsari Geographical Area Nadiad Geographical Area Khurja Geographical Area Moradabad Geographical Area Surat-BharuchAnkleshwar Geographical




Adani Gas Limited

Siti Energy Limited

Gujarat Gas Company Limited

Area

Chapter 4 - Applicable Codes and Practices Table 4 - EUROPEAN STANDARD (EU) S. NO.

STANDARD NO.

DESCRIPTION

1.

EN 12186

2.

EN 12279

3.

EN 1776

Gas supply systems – Gas pressure regulating stations for transmission and distribution functional requirements Gas pressure regulating – installations on service lines Gas supply systems – Natural gas measuring stations – Functional Requirements

4.

EN 1594

Gas supply systems – Pipeline for maximum operating pressure over 16 bar-Functional Requirements

Table 5 - AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) S. NO.

STANDARD NO.

DESCRIPTION

1.

ASME B16.11

2.

ASME B31.3

Forged steel fittings, socket-welding and threaded Process piping

3.

ASME B31.8

4.

ASME B16.5

5.

ASME B16.9

6.

ASME – Boiler and Pressure Vessel Code

Gas transmission and distribution piping systems Pipeline flanges and flanged fittings Factory – Made wrought steel butt welding fittings Section 9- Qualification standard for welding and brazing procedures, welders, brazers, and welding and razing operations

7.

ASME – Boiler and Pressure Vessel Code – 2

Part C – Specifications for welding rods, electrodes, and filler metals

8.


Section 5, Non-destructive examination

9.


Section 2 Materials Part A-ferrous Material Specifications

Table 6 - OIL INDUSTRY SAFETY DIRECTORATE (OISD STANDARDS) S. NO.

STANDARD NO.

DESCRIPTION

1.

OISD-226

2.

OISD-GDN-115

3. 4.

FIRE PROTECTION MANUAL – TAC OISD – STANDARD – 141

5.

OISD STANDARD - 118

Natural gas transmission pipelines and city gas distribution network Guidelines for firefighting, equipment and appliances in Petroleum Industry Fire Engines, Trailer Pumps and Hydrant Systems Design and construction requirement for cross country hydrocarbon pipelines Layout for oil and gas Installations

Table 7 - AMERICAN GAS ASSOCIATION (AGA) S. NO.

STANDARD NO.

DESCRIPTION

1.

AGA

Purging Principles and Practices

2.

IGE/T/1

3.

AGA: REPORT NO. 7

Steel pipelines for high pressure gas transmission Measurement of gas by turbine meters

4.

AGA: REPORT NO. 8

5.

AGA: REPORT NO. 3

Orifice metering of natural gas and other related HC fluids Compressibility factors of natural gas and other related HC gases

Table 8 - AMERICAN PETROLEUM INSTITUTE (API)

S. NO.

STANDARD NO.

DESCRIPTION

1.

API STANDARD 1104

Welding of pipelines and related material

2.

API SPECIFICATION 5L

Specification for line pipe

3.

API SPEC. 6D

Specification for Pipeline Valves

4.

API STANDARD 1102

Specification for Steel pipeline crossing and highways

Table 9 - BS/DIN/ISO AND OTHER STANDARDS S. NO.

STANDARD NO.

1.

ISO-15590-1

2.

BS 6755:PART 2

3.

DIN 30672, PART 1

4.

DIN 30670

DESCRIPTION International standard for Petroleum and natural gas industries – Induction bends, fittings and flanges for pipeline transportation systems Testing of Valves Coatings of corrosion protection tapes and heat-shrinking products for pipelines for operational temperatures up to 50°C Polyethylene Coatings for Steel Pipelines and Fittings

Table 10 - T4S – TECHNICAL STANDARDS AND SPECIFICATIONS INCLUDING SAFETY STANDARDS FOR CITY OR LOCAL NATURAL GAS DISTRIBUTION NETWORK S. NO.

STANDARD

DESCRIPTION

1.

SCHEDULE 1A

Materials and Equipment

2.

SCHEDULE 1B

Welding

3.

SCHEDULE 1C

4.

SCHEDULE 1D

Piping Systems Components and Fabrication Details Design, Installation and Testing

5.

SCHEDULE 1E

Operating and Maintenances Procedures

6.

SCHEDULE 1F

Corrosion Control

7.

SCHEDULE 1G

Miscellaneous


Chapter 5 - City Gas Distribution Network -

The selection of design for CGD Network is based on the gas properties, required flow rates, operating pressures and the environment.

-

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

1.) City Gas Station (CGS) 2.) Pipeline Network – Steel Pipeline, Polyethylene Pipelines, GI/Cu Pipes 3.) Regulating Stations – District Regulating Stations (DRS), Service Regulators, Domestic/ Commercial/ Industrial Regulators 4.) Metering Stations/ Metering & Regulating Stations (MRS) 5.) CNG Stations

Fi gure 3 – Basic System Flow Diagram (Schematic)

13



5.1. City Gas Station (CGS) It is established at a tap-off point of high pressure transmission pipeline; from where we get gas inside the city via pipelines. The gas delivered at this point is at higher pressure i.e. greater than 40 bar. Once gas enters to CGS unit its pressure is reduced to in between 25-30 bar.

Figure 4 – City Gas Station (CGS) The main Components of City Gas Station and their function is as follows –

5.1.1. Filtration Skid: Dust particle and liquid coming with the gas stream are separated by high efficient filters in KOD. Gas is maintaining same pressure from the inlet to the filtration skid. After the filtration two streams are dividing from the main line using a header. Line which is in function is known as active line where another one is called passive line.

Figure 5 – Filtration Skid at CGS 14



5.1.2. Pressure Reduction Unit: A pressure reduction valve is installed for the reduction of the gas stream pressure from 40-45 bars to 25-30 bars. Creep relief valve and Slam Shut off valve is being installed in this skid for the safety purpose.

Figure 6 – Pressure Reduction Unit

5.1.3. Metering Skid: Metering skid is installed for the gas flow measurement. Orifice meter is used in this metering skid; because of the large pressure drop requirement. The various parameters such as temperature in the various sections of the line pressure at the inlet & outlet joints, flow inlet & outlet are monitor by the SCADA systems in the control room.

Figure 7 – Custody Transfer Meter at CGS 15



5.1.4. Odorization Unit: An Odorization unit is installed for addition of ethyl Mercaptan in the gas stream. The dozing unit of the ethyl Mercaptan should be of 9 mg/m3. This unit consists of mainly two cylinders of capacity of 160 kg, pneumatic panel, level indicator and a filter. This unit is directly connected to the main line after the metering skid.

Figure 8 – Odorization Unit

5.2. Steel Pipeline – It is the Primary Network in the form of Transmission Pipeline (Up to CGS) and Distribution Pipeline (CGS Downstream, Ring).

Figure 9 – Steel Pipeline Site 16



5.2.1. Design / Hydraulics / Simulation 

Simulation for Network Hydraulics is done in the SYNERGEE software.



This is basically required to derive diameter of pipeline in such a way that required pressure at all locations can be achieved and future load projections can be ascertained.



Formulae used for hydraulics: Colebrook White / Fundamental pipe equation with flow dependent friction factor.



Efficiency factor: 0.85 – 1



Velocity: Max. Allowable velocity of the gas in the steel pipeline Section of CGD network shall be 30 m/s.



STP: Standard Pressure: 1.01325 Bar, Standard Temperature: 15.5°C



Design Life: Steel Pipeline: 30 Years, PE Pipeline: 50 Years

Table 11 - Location Class Considerations

Location Class

Description

Design Factor

Class 1

10 or fewer buildings in 1mile section

0.72

Class 2

10 – 46 buildings

0.60

Class 3

46 or more buildings

0.50

Class 4

areas where multistoried buildings and heavy underground utilities

0.40

Wall Thickness Calculation for Steel Pipeline

P = 2St FET/D Where, P = Design Pressure S = Specified minimum yield strength D = Nominal OD of pipe t = Nominal wall thickness F = Design Factor E = Longitudinal joint factor T = Temperature de-rating factor 17



5.2.2. Line Pipe – Selection/Specification and Coating 5.2.2.1. Type: I. II. III. IV.

ERW (Electric Resistance Welded) HSAW (Helical Submerged Arc Welded Pipe) LSAW (Longitudinal Submerged Arc Welded Pipe) Seamless Pipes

5.2.2.2. Coating – To protect them from corrosion. I. II. III.

Coal Tar Enamel Coating (BS 4164, AWWA C203) 3 Layer PE/ PP Coating (DIN 30670) Fusion Bonded Epoxy Coating (CSA Z245.20)

5.2.3. Fittings, Valves and Welding 5.2.3.1. Fittings: ASTM A234 and ANSI B 16.5 & 16.11 1. 2. 3. 4.

Elbows & Bends Flow Tees & Fasteners Insulating Joints Flanges & Gaskets

5.2.3.2. Valves: API 6D 1. Sectional Valves and Tap Off Valves (future provisions) 2. Ball Valve, Gate Valve, Plug Valve, Check Valve, SRV, NRV

5.2.3.3. Welding: 1.) Fillet weld: A weld of approximately triangular cross section joining two surfaces approximately at right angles to each other in a lap joint, tee joint, or corner joint. 2.) Butt weld: It is used to connect the parts which are nearly linear and does not overlap. 3.) Girth weld: It is a complete circumferential butt weld joining pipe or components. 4.) Seam weld: The longitudinal or helical seam in pipe, made in the pipe mill for the purpose of making a complete circular cross-section.

18



5.2.4. Cathodic Protection - There are two main types of cathodic protection systems: galvanic and impressed current.

5.2.4.1. Galvanic system: Makes use of the corrosive potentials for different metals. Without CP, one area of structure exists at a more negative potential than another, and corrosion results. If, however, a much less inert object (that is, with much more negative potential, such as a magnesium anode) is placed adjacent to the structure to be protected, such as a pipeline, and a metallic connection (insulated wire) is installed between the object and the structure, the object will become the anode and the entire structure will become the cathode. That is, the new object corrodes sacrificially to protect the structure. Galvanic anodes are usually made of either magnesium or zinc because these metals have higher potential compared to steel structures.

5.2.4.2. Impressed current systems: Use same elements structure and is protected by applying a current to it from an anode. The anode and the structure are connected by an insulated wire and current flows from the anode through the electrolyte onto the structure, just as in the galvanic system. The main difference between both systems is that the galvanic system relies on the difference in potential between the anode and structure, whereas the impressed current system uses an external power source to drive the current. The external power source is usually a rectifier that changes input A.C. power to the proper D.C. power. Impressed current cathodic protection system anodes typically are high-silicon cast iron or graphite.

5.3.5. Construction Stages Table 12 – Pre-Construction Activities

19



Table 13

Table 14

20



5.3. District Regulating Station DRS are the device used to reduce the pressure from 25 bars to 4 bars. It is the interface between the steel grid network and medium pressure network. It is located at various demand centers for domestic /commercial users and typically consists of: 1.) Gas Filter 2.) Heater, if required 3.) Pressure reduction (active / monitor combination) skid with minimum 50% redundancy including slam shut valve for over pressure protection. 4.) Inlet and outlet isolation valves.

The flow capacity of DRS is in range of 5000-10000 SCMH. The inlet line of DRS is steel pipeline and outlet is polyethylene pipeline carrying a pressure of 4 bars.

21



Figure 10 – Inside view of DRS

5.3.1. Pressure Reduction Valve The pilot (2-stage) reduces the inlet pressure Pe in two stages and provides constant motorization pressure Pm to operate the main regulator. In the absence of pressure the plug 5 remains in the closed position by the spring 16, and soft seating Disc4 rests on the seat 3. The upstream pressure, even if variable, does not change this position as the plug is balanced and is therefore subject to equal pressures, even if the sections are different. The upstream pressure is passed through the hole in plug rod 18 to other chamber of plug, equalizing the pressure on both sides. The plug movement is controlled by the diaphragm 10 by the following forces acting on it: 1.) Downwards: the force of spring 16, the thrust deriving from the regulated pressure Pa in the top diaphragm chamber and the weight of the diaphragm assembly; 2.) Upwards: the thrust deriving from the motorization pressure Pm in the bottom diaphragm chamber, supplied by the pilot.

22



Figure 11 – Functioning of a PRV  The motorization pressure is obtained by drawing gas from regulator at the u/s pressure.  Filter 41 filters gas and is subjected to initial reduction in the first stage pilot, composed essentially of a plug 37, a spring 28 and a diaphragm 34A to a value, which depends on the pressure set point of the regulator.  The pressure then passes to second stage pilot that controls pressure by plug 35, a main spring 28 and a diaphragm 34B to the motorization pressure Pm, which is supplied to bottom diaphragm chamber of the main regulator.  The regulation of Pm is obtained by the comparison of the force exerted by setting spring 28B of the pilot and the action of the regulated pressure Pa, acting in the chamber below the diaphragm 34B.

5.3.2. SSV/SDV (Slam Shut Valve/Shut down Valve) 23



 The control mechanism (Pilot 1) has a latching arrangement holding main valve stem in open position. The sensing element is pilot regulator (Pilot 2) continuously monitors the line pressure to be safeguarded.  This pilot spring diaphragm type valve, in case of over pressurization gives signal pressure to control mechanism which in turn trips off main valve.  In normal condition the Pilot-2 remains in close position. The main valve remains in open position by holding the plug rod 14 by rack 21 through ball catch arrangement in Pilot-1.  Whenever the pressure monitoring by Pilot-2 exceeds above its set intervention value the diaphragm 48 moves upward displacing the plug 47.  Thus the pressure passes to Pilot-1 diaphragm 27 pressing it along with push rod 25, pressing the ball 41.  The rack 21 latched by the ball gets released resulting in downward movement of plug 7 and plug rod 14 closing the valve. The visual indicator 32 will indicate the position as CLOSE.  The valve can also be shut off manually by pressing knob 33 on pilot-2.

24



Figure 12 – Functioning of a Slam Shut Valve (SSV)

5.3.3. CRV (Creep Relief Valve) The controlled pressure is generally set to a pre-determined designed value using adjusting screw. This is the maximum pressure which pressure-gauge (installed on upstream side of control valve) indicates when the fluid is not flowing through the valve. Any accumulation of the gas results in increase in controlled pressure. This result in increase in the compensation force, which balances the controlling force, hence valve opens. This releases the rise/build up in the upstream pressure. Thus, it is clear that the pressure will not be the same during no-flow and during flowpassing through valve. Hence rise in the controlled pressure, during operation/flow through the valve, is to be accepted in principle and one should not try to re-set the valve/pressure because of the draw of fluid. The controlled pressure is expected to rise to allow for discharge to the downstream side of the valve.

25



Figure 13 – Functioning of CRV

5.3.4. Non Return valve (NRV) - It is also known as check valve. It maintains unidirectional flow and restricts reverse flow. It operates by itself by application of pressure present in line, minimum pressure range is required to operate this valve. Its functioning would be discussed later.

5.4. Secondary Network – MDPE Pipeline A. The distribution pipe is with standard dimension ratio (SDR 9) for 20 mm, (SDR 11) from 32 mm upto 63 mm and (SDR 17.6) for above 63 mm. The term SDR is defined as the normal outside diameter (DN) divided by the minimal wall thickness. B. It is standard practice in India to have a minimum 1 m cover. All MDPE Pipe back filled with sand around it to protect the plastic material.

26



Figure 14 – MDPE Pipeline

5.4.1. Specifications    

Tech. Spec.: IS 14885:2001 & ISO 4437 Material Grade & Color: Internationally approved resins of PE 100 grade of Orange color Minimum Required Strength (MRS) of PE 100 Grade pipe: 10 MPa Operating Pressure: 4 Bar, Operating Temperature Range: -10°C to +40°C

5.4.2. Advantages of MDPE Pipelines  High Performance (Globally proven leak free system), more flexibility, coil ability, ductility, high elasticity.  Low Density (low weight, high strength to weight ratio).  High resistance to corrosion and Low Heat Conductivity (low thermal loss).  Smooth surfaces (low pressure losses due to low pipe friction)  Reduced number of joints, hence safer and leak free system.  Less time is consumed to repair PE Damages as compared to steel damages, Avoidance of NDT techniques in building premises, which is very critical.  Size of trench is less in case of laying of PE Pipe as compared to steel.

5.4.3. MDPE Fittings 27



Figure 15 – Stem extension type valves and MDPE Fittings    

Tech Spec. : ISO 8085-3 or EN 1555-3 Material Grade: PE 100, Color: Black Terminal Pin Size: 4 or 4.7 mm Voltage: 39-40 Volts.

5.4.4. PE Stop Off Valves         

28

Standard: ASME B16.40, EN 1555.4 Pressure Class: SDR 11 Design Pressure: 5.5 Bar Design Temperature: 45°C Operating temperature: 10°C to 45°C End Connections: PE Material Stem Extension: Min. 690 mm from top of the pipe. Valve Design: One piece Construction Ball Position Indicator: Open/Close limits required.



5.5. PE Laying ‒MP Network 1. The MP PE network starts from downstream of DRS/CPRS and distributes the Natural Gas till the different Service Regulator located nearby a cluster of domestic customers or a main commercial customer or Industrial Customers upto MRS/IMS. 2. The PE mains are subdivided into sections by means of adequately located manually operated valves (Note: As per PNGRB in MP network minimum one at every 1 Km).

‒LP Network 1. The LP Network in PE starts from the downstream of Service Regulator (SR) and brings the natural Gas to domestic customers.

5.5.1. PE Laying Process for Open Cut Excavation: 1. Preliminary route survey as per GSPC GAS planning drawing. 2. Line marking before excavation work. 3. Trench depth to maintain 1.0 meter. Cover. 4. To check underground utilities with a minimum clearance of 25cm. from PE pipe. If not maintain min clearance distance to cover pipe by using RCC half round / PVC sheet. 5. When two PE pipeline (MP & LP) to be laid in same trench then min. 300mm distance to be maintained between two pipes. Also MP pipeline is to be laid at Road side and LP pipeline to be laid at extreme side of the road. 6. Pipe laying at the center of the trench for proper sand padding surrounding PE pipes. 7. 75mm sand bedding below pipe in case of normal soil and 150mm in case of rocky terrain and 75mm sand padding above pipe. 8. Stone free soil backfilling above sand padding upto 0.5 mtr. Of PE pipes. 9. Laying of Warning tape at 0.5 mtr. Depth from ground level 10. Backfilling entire Trench, Watering and Compaction, Excess soil scrapping.

29



Figure 16 - Trench Dimension for PE Pipeline: Size – 32mm. Similar for other Pipe Sizes

Figure 17 - Safe distance for Excavated soils storage/ Barricades

5.5.2. PE Laying Process for Crossing of River/Water Canal/ National Highway / Four-lane state Highway and Railway: i.

No EF joints shall be allowed in PE pipes in major crossings as mentioned above. If the pipe dia. requirement is higher than 90mm then steel pipeline shall be used in major crossings by providing Transition Fittings at both ends.

ii.

90 mm dia. PE pipes can be used without any EF joint in between if the crossing length is less than 100 mtr. 30



5.5.3. Electrofusion Jointing I.

The pipes ends to be welded must be cut at right angle by using proper pipe cutters.

II.

Visually check that the pipe/fitting surface is free of defects such as cuts, abrasion etc.

III.

Avoid using excessive ovalized pipes. Remove Ovality by using Re-round tool. Clean the pipe ends from dust, grease, dirt etc.

IV.

Mark the scraping area with an indelible marker pen. The scraping area must be 10mm larger than the insertion depth of the fittings.

V.

Remove the oxidized surface from the pipe, by scraping it. Remove an uniform surface for a depth of approximately 0.1mm for pipe diameter upto 63mm and 0.2 mm for pipe diameter higher 63mm.

VI.

AVOID ABSOLUTELY other scraping equipment such as abrasive paper, rasp, emery wheels, saw blades, etc. other than Mechanical/Manual scrapper.

VII.

Before inserting the fitting on the pipe, clean the scraped surface using isopropyl alcohol.

VIII.

Clean with the same chemical the inner surface of the fitting, which has to be removed from its protective wrapping only at the moment of use.

IX.

Do not touch with hands the just cleaned surfaces.

X.

The aligning clamp must be used for all diameters to be welded which, Protects, during the electro-fusion and the subsequent cooling, mechanical stresses on the jointing.

XI.

Allows revising possible off-centering between both ends to be welded and to recover the out-of-round of parts, it ovalized.

XII.

In case of EF coupler welding, sign a mark using an indelible pen on the two ends to be welded corresponding to the depth of insertion, equal to half length of the coupler.

XIII.

Insert the coupler up to the location mark and fasten the pipe into the aligning clamp.

XIV.

Connect the plugs of the control unit to the terminals on the fittings and proceed with the set-up of the welding parameters, strictly following the instructions of the welding unit.

XV.

When the fusion cycle is completed, verify the fusion indicators coming out. The fusion indicators are located near the terminal connection of the fitting.

XVI.

Cooling, in order to avoid possible stresses on the jointing, strictly respect the cooling time indicated on the bar-code and do not remove aligning clamp of the fittings. 31



5.6. Service Regulator These are installed before tertiary PE lines, generally located at customer premises for maintaining supply pressure and designed to maintain safe condition even in the event of rupture in the regulating downstream section. It reduces the pressure from 4 bars to 110 mbar to the service device. Table 15

5.6.1. Selection of Location for Installation of SR 1.) Private premises: If possible, immediately after entering and adjacent to boundary wall of private premises. The best suitable place is Foot-Path, if available nearby. 2.) Min. Distance to be maintained - 10.0 Mtr. from any turning / junction of the road, 15.0 Mtr. from Bus stand or public gathering spot, 15.0 Mtr. from any above ground electrical installations i.e. Transformer, Junction box, Pole etc. 3.) Water logged area, In front of Entry / Exit of building / Shop/Garbage collection area is avoided.

5.6.2. Installation of SR A. Installation of Service regulator module shall be done as per the foundation drawing /specification. B. 90 degree EF elbow shall be used for hook-up of the Service Regulator for 63mm and above size pipeline. 32


CITY GAS DISTRIBUTION C. Installation of Service Regulator should be in such a position that Flow direction of Service Regulator and gas flow in pipeline is in the same direction. D. Golden yellow color shall be applied on foundation of Service Regulator.

Figure 18 – Service Regulator.

5.6.3. Testing of SR I.

Pre-commissioning testing for performance of safety devices i.e. UPSO, OPSO, and Relief valve, which is integral part of Service Regulator, shall be done.

II.

The set pressure of Service Regulator for different features are as per the below: –Set Pressure: 100 – 110 mbar –UPSO: 50 mbar –OPSO: 150 mbar - All electro-fusion joints (SR Hook up joints) shall be checked with soap solution before commissioning of Service Regulator.

5.6.4. Commissioning of SR A. Ensure all installation and pre-commissioning activities are completed. Inlet and Outlet valves shall be kept in closed position. B. Gas in upto inlet valve of Service Regulator by opening of Valve/squeeze tool.

33



C. Leak test shall be carried out upto upstream of inlet valve. If no leakages found, open inlet valve of Service Regulator and ensure no leakages upto outlet isolation valve. D. Monitor Outlet pressure of Service Regulator for 5 min. before opening outlet valve. E. Ensure positive lock-up pressure (to confirm no leakages or open end during commissioning) in downstream network before opening outlet valve. F. Ensure that not a single domestic connection has been connected through downstream of the network which is to be commissioned. G. Release lock up pressure before opening outlet valve of SR and by keeping inlet valve closed. H. Slowly open inlet valve first and subsequently outlet valve of Service regulator to allow Gas – in the downstream network.

5.6.5. Installation of PE Valve A. Isolation valve to be installed at every 1.0 km on 90mm dia. and above PE pipeline Medium Pressure network. Where tapping of 90mm and above on Medium Pressure PE network, PE isolation valve to be provided immediate after tapping. B. Isolation valve to be installed before 2.0 meter of end cap for 125mm and higher dia. Medium Pressure PE pipeline. C. The valve shall be supported on a bed of firmly compacted by using fine sand. D. Ensure proper installation/alignment of PE valve. Ensure proper PCC prior to installation of Pre-cast chamber of Valve. E. Isolation valves shall be provided in PE pipe line at both ends of major crossing carried out with Steel pipeline.

5.6.6. PE Testing 5.6.6.1 MP Network Testing: The MP Network will be tested at 7.0 bars for A. PE distribution mains of length greater than 1 Km for at least 24 hours. B. PE distribution mains of length shorter than 1 Km at least 6 hours after pressure stabilization and the pressure gauge must measure an unchanged pressure during test duration. The test medium shall be air or nitrogen. 34


CITY GAS DISTRIBUTION C. Suitable Relief Valve set at 5% higher than i.e. 7.9bar test pressure shall be fitted at the test to avoid over pressurization during testing. D. The DRS/CPRS, Service Regulator and service line must be disconnected during testing. The section to be tested must be completely isolated.

5.6.6.2 LP Network Testing: The operating pressure of LP network is 110 mbar. The procedure to follow the pneumatic testing and flushing of a LP network is similar to the procedure for the MP network. Except for the following: A. The LP network also must be tested at 7.0 bars for 6 hour. B. The Contractor will test network by section starting from the Service Regulator till all the sections of the concerned area have been tested satisfactorily.

5.6.7. PE Pipeline Marker A. Pipe line marker shall be installed at every 200 mtr. distance on sizes of 63mm and above PE pipelines. Also pipe line marker shall be installed at both sides of Main road crossing, river crossing, railway crossing and any other locations as specified by GSPC GAS. B. Marker installation shall be done as per GSPC GAS approved diagram. Ensure marking on Pipeline Marker is as per approved drawing of GSPC Gas. Installation of Pipeline route marker as per approved drawing of GSPC Gas.

5.6.8. Commissioning A. To check the hot work permit. B. As laid PE Network drawing / schematic of the section to be commissioned and existing end cap showing vent point. C. Ensure pneumatic test report. Check and assure that the positive pressure in the pipeline stayed equal as the pressure measure after testing. D. Calibrated pressure gauge is used. E. Ensure that EF welding machine with ELCB (Earth leak circuit breaker). F. Ensure availability of additional Squeeze tools for emergency. G. The gas should be vent continuously by crack opening of valve until two reading confirm a concentration of gas by methane detector.

35



5.7. Industrial Metering Station (IMS)/MRS A. They are used to measure the gas supplies to Industrial customers. The main components in IMS is filter, Isolation Valves, RPD Meters, Regulators (if low pressure requirement) and Non Return Valve. B. Inlet Pressure Range – 1.5 Bar to 4 Bar, Outlet Pressure – As required by customer.

Figure 19 – Industrial Metering Station

Main Components of IMS  Filter - It is also a cartridge type filter with pore size of 5 microns.  Gas meter - Volumetric gas meter is used here.  NRV - It allows one way flow as discussed above.  CRV - It is used here to relief excess pressure in line in case of over pressure.  PRV in customer premises - Same as PRV in CGS skid and CPRS skid it reduces pressure as required. It operates without pilot valve. 36



Chapter 6 – PNG Installation 6.1. Domestic and Commercial / Non-Commercial PNG Connection - The connection between consumer meter set assembly and gas appliance may be made by GI Pipes or Copper Tubing or Steel Rubber Hose. - Commercial Connection has same components as domestic connection but some customers may have larger diameter GI Pipeline and higher pressure meter. - The quantity of gas consumed by an average domestic consumer will remain almost same for all customers. Basic data sheet is prepared based on practical assumption & past experience of similar gas distribution industries. For estimating/calculating the peak demand of domestic consumer we consider following assumptions.

6.1.1. Design of vertical risers:  Apartment connections can be classified into the following category: - Single connection (kitchen) per riser on each floor. - Two connections (kitchens) per riser on each floor. - ½‟‟GI pipe riser up to 7 floors for one connection on each floor. - ½” GI pipe riser up to 3 floors for two connections on each floor.  1” GI pipe riser for connecting more than seven floors and up to sixteenth floor from single riser & single connection on each floor.

6.1.2. For Horizontal common approach pipeline  ½” GI pipe common approach, maximum five connections to be connected.  1” GI pipe common approach, more than five up to twelve connections to be connected.

6.1.3. Route Selection  Pipe shall not be installed on un-plastered wall or in the house under construction or in an unventilated void space.  Route shall be selected that maximum length of the pipeline shall be installed outside. Route of the pipeline shall be planned for the shortest possible length.  The gas pipeline and meter shall be away (minimum distance of 300mm) from the electrical line and heat source. There shall be minimum change of directions and minimum no of threaded joints. 37



 Maximum two Point in the single kitchen for gas stove only.  Compound gate or doors and windows inside the house shall not hit the Gas pipeline, if no alternative route found installs proper pipe protection guard.

6.1.4. Positioning of Valves, Regulator & Meter:  Riser Isolation Valve: For apartments, one riser isolation valve shall be provided at a height of 2 meter from the ground level.  Customer wise individual main isolation valve shall be installed. Brass made Regulator and Meter adaptor shall be used.  Regulator shall be installed in such a way that it reduces the length of H.P. Line (Max. pressure 0.1 Bar) to minimum possible. Wherever possible meter Regulator shall always be installed outside residence and at a convenient height.  It is advisable to install Gas Meter shall in such a way that it shall be protected from direct rain or waterfall on the meter. Location of the Gas meter shall be decided during the route selection.

6.1.5. Appliance Valve:  The position of the appliance valve shall be convenient to operate and it shall keep the rubber tube at a safe distance from the heat source.  The orientation and distance from cooking platform/ground shall be maintained in such a way that the Bending Radius of the Rubber Tube shall be more than 100mm.  Appliance valve shall be installed in ventilated space and the lever of appliance valve shall not foul with the wall during the on-off operation.

6.1.6. GI Pipe cutting & Threading:  After site and route clearance, the measurements for pipe cutting shall be taken and pipes shall be cut accurately as per the required lengths.  Installed piping threaded connections / joints shall be tightened in such a way that all the joints shall be free from heavy stresses and misalignments due to incorrect pipe length. Cutting fluids (oils) shall be used while thread cutting.

38


CITY GAS DISTRIBUTION  The condition of thread die and pipe vice jaws shall be checked regularly and shall be free from defects. BSP taper thread dies to be used for threading and shall be checked with “GO” and “NOGO” gauge.  Threaded pipes shall be handled carefully so that the threaded oily portion shall be free from dust, mud, water and any damage due to impact of any object.  Cutting burrs on the pipe shall be removed from the edges. The edges shall be straight and free from Knife-edge formation.

6.1.7. G.I. Pipe Installation & Clamping:  Teflon tapes of approved make shall be wrapped on threaded portion of the pipe with minimum three overlaps.  The pipeline portion containing the Regulator and Meter, either horizontal or vertical, shall have clamps on both side of the regulator and meter. Clamps shall be fitted in such a way that they do not create misalignment of pipes.  The clamp shall be installed by drilling 6 mm hole in plastered wall and screwed using rowel plug. The clamps should be fixed properly on the walls and grip pipe in position.  Distance between two clamps shall not be more than 1.0 meter. Clamps shall be installed in a straight line and shall be parallel to each other.  Self-adhesive anti-corrosive tape shall be wrapped on the pipe with 50% overlap. Casing sleeve shall be installed in wall for wall crossing.  Wherever compound gate, house door or window may hits the G.I. pipe, protection clamp shall be installed to protect the pipe. Concealed piping shall not be done.  All the pipes shall run on walls with clamps. Pipe should not be overhung and shall not be installed without pipe clamp.  PE to GI (transition fitting) threaded joint shall be provided above ground. PE pipe length should be 1.5 meter of transition fitting.

39



Figure 20 – GI Clamps to Pipe on Wall

6.1.8. Testing of Installed Piping Connection:  Before carrying out the pneumatic test of the whole installation; testing assembly, air foot pump with pressure gauge / manometer shall be checked its calibration and proper functioning.  Before pneumatic testing of the installed connection spacing between two clamps, tightening of the clamps thread joints, alignments of the whole piping shall be checked. Valve shall be kept in open position and the appliance valve shall be kept in close position.  Calibrated pressure gauge shall be used having the range of 0 – 1 Bar. Position of the pointer of the pressure gauge shall not be marked with the marker pen on the glass. It should be recorded in the test records. Table - 16 S. No.

Type of Testing

Test Pressure

Duration

1.

Pneumatic Pressure Testing (PPT) MMT Riser Testing

3.5 Kg/Cm2

30 minutes

Gas Pressure 3.5 Kg/Cm2

15 minutes 1 Hour

2. 3.

 After pressurization of the whole piping section shall be checked for the leakage with the help of soap solution.  During the testing, air should reach up to the appliance valve. After completion of testing, pressurized air shall be released from appliance valve only.

6.1.9. Conversion of Burner 40


CITY GAS DISTRIBUTION  All the appliance valve and riser isolation valve shall be kept in closed position. Ensure that meter and regulator adaptor shall be leak proof.  Open the burner knob and remove the plug from the hot plate.  Clean the simmer hole. Make the simmer hole of 0.6 mm with the help of simmer drill.  At the time of drilling the hole, ensure that it should not be inclined. Remove the dust from plug.  After greasing, plug and knob should be properly positioned at their original position.  Remove the burner from hot plate and clean it. Open the existing jet (LPG) and replace it by 125 no jet if it is big burner or 110 no jet if it is small burner.  Place the burner on its original position and connect the nozzle with appliance valve using flexible and braided SURAKSHA rubber hose.  The length of rubber hose shall not exceed 1.0 mtr. Both the ends of the rubber hose shall be clamped by metallic clamps on the nozzle.  Check all the joints with soap solution and ensure that the flame color should be blue.

6.1.13. Meter Job Card Meter Job card to be prepared duly signed by Contractor, Customer & Third Party Inspector and to be submitted to GSPC Gas immediately on completion of conversion.

41



Figure 21 – Schematic Diagram of a Domestic PNG Connection

6.2. Industrial Connection:  Natural Gas Requirement identification: A format consisting of equipment details and fuel consumption pattern to be furnished by customers to finalize the size and type of MRS and for the agreement with customers.

6.2.1. Scope of work of GSPC Gas Co. Ltd.: I.

Finalize the location of Industrial Metering Skid as per safe installation distance: Table - 17

Reference Location

Distance of IMS Installation

Electrical Transformer Open flame or furnace/ any gas fired

12 meter 15 meter

42


CITY GAS DISTRIBUTION equipments Boundary wall Bore well or sock pit/underground septic tank

2 meter 6 meter

- Battery limit of GSPC Gas and Industrial customer is as follows:

Figure 22 – Scope of Work of GSPC Gas for Industrial Customer.

6.2.2. Scope of work of Industrial Customer: 6.2.2.1. Skid Location/layout: I.

Appropriate location and space for installation of IMS to be provided by customer.

II.

Preparation of foundation to be done as per Foundation drawing.

III.

Installation of mounting pole to be done by customer within 3 to 5 meter from IMS.

IV.

Installation of brick Chamber near hook up portion of skid and filling with fine sand to protect PE pipe as per GSPC Gas requirement.

V.

Chain link fencing to be done surrounding the Industrial Metering skid for restricted unauthorized entry. Minimum distance to be maintained 1.5 meter from the foundation.

6.2.2.2. Internal piping and accessories: I.

Installation of above ground Piping downstream of the Industrial Metering skid by customer as per GSPC Gas specifications.

II.

Supply and Installation of Regulators, Isolation valves, pipe fittings, fasteners and consumables shall be done by the customer as per individual equipment flow and pressure requirement. 43


CITY GAS DISTRIBUTION III.

Supply and installation of Gas train with safety interlocks, Gas Burner and equipment conversion. Pneumatic testing of Internal Piping.

6.2.2.3. Electrical: I.

Un-interrupted AC power supply for Metering purpose and two separate earthing for IMS to be provided and done by customer.

6.2.3. Installation of Internal Piping: I.

Internal piping installation shall be done through competent steel pipeline contractor.

II.

Underground steel pipeline shall not be allowed inside the premises.

III.

Jointing of Internal piping shall be done through welding method only. No threaded joints shall be allowed for internal piping installations. Welding spatter should be removed by grinding.

IV.

Pipe should not be routed through heated zone like bhatthis / tandoor / furnace etc. For wall crossing the pipe should be protected with anti-corrosive wrapping tape.

V.

All pipe work should be horizontally and vertically aligned.

VI.

Pipe support should be firmly fixed on wall and Pipe should be firmly tightened on support with U bolt or to be installed on proper fabricated structure on ground.

VII.

Pipeline shall not rest on support directly. Rubber sheet piece to be kept between pipe and support to avoid erosion and leakage.

VIII.

A safe gap of minimum 1" should be maintained between pipe and wall. Pipe support should not be provided on temporary wall/shed/trees etc.

IX.

Main Isolation Valve to be provided immediately after entering into industrial premise and branch Isolation ball valve at each tapping from main header.

6.2.4. Testing: I.

Pipeline should be flushed with air or nitrogen to remove dust, dirt, welding spatter etc. Meter and regulator should be removed before flushing. Flushing should be done from each tapping.

II.

Once flushing is completed entire pipeline shall be tested at min. of 1.5 x design pressure (MOP) or 7 bar whichever is higher with air or nitrogen for 06 Hrs. Testing shall be done with all isolation valves semi open. Pressure should not drop during testing hours.

44


CITY GAS DISTRIBUTION III.

Once testing is found OK, pressure should be vented out till pipeline pressure becomes 0.5 bars. Positive pressure shall be kept hold till pipeline commissioning.

IV.

Once testing is OK a testing certificate to be submitted by customer to GSPC Gas.

6.2.5. Painting: I.

Selection of proper paints to be made depending on the environment conditions.

II.

Entire pipe should be cleaned with wire brush. It should be free of welding spatter, dust, dirt, rust and moisture.

III.

Painting should be done only after testing is found O.K.

IV.

Primer and finished coat shall be done as per paint manufacturer recommendations. Final coat shall be “Golden Yellow” color for gas pipeline identification.

V.

Direction of gas flow should be marked along the pipeline at the interval of 2 meters.

6.2.6. Safety Requirements: I.

Location of Industrial Metering Skid as per safe installation distance with various references.

II.

Portable Fire Extinguisher of ABC type -10 kg. (ISI marked) to be placed nearby Industrial Metering skid by customer before commissioning of Internal Piping.

III.

“NO SMOKING”, Safety Instruction Board and other safety signage near Industrial metering Skid. Customer internal piping with electrical bonding at joints.

IV. V.

Any modification/alteration after commissioning of internal piping shall be done only after prior intimation to GSPC Gas.

VI.

Intimation to GSPC Gas in case of plant shutdown/ No usage of NG for long time.

6.2.7. Pre-Commissioning of Industrial Metering Skid: I.

GSPC Gas engineer shall ensure undertaking from customer for successfully testing of internal pipeline on their letterhead.

II.

GSPC Gas representative need not to certify testing of customer premises internal piping.

III.

Pre-commissioning check list shall be filled before IMS commissioning.

6.2.8. Commissioning of Industrial Metering Skid: 45



I.

GSPC Gas engineer shall ensure undertaking from customer for successfully internal pipeline testing on their letterhead.

II.

Tool-Box talk shall be conducted in presence of Industrial customer covering Do’s and Dont’s.

III.

Ensure positive lock pressure in internal piping before opening of Industrial Metering Skid outlet valve to industrial customer.

IV.

Ensure internal piping of Industrial metering skid up to equipment connected before commissioning of metering skid, and no inter connection with other fuel system.

V.

Ensure oil level in case of RPD meter before Industrial metering skid commissioning.

VI.

Ensure all required accessories of meter are installed prior to commissioning.

VII.

Ensure GSPC Gas engineer presence during commissioning of internal piping.

VIII.

Industrial Metering skid commissioning report shall be prepared after commissioning.

Chapter 7 – Gas Metering We are only going to discuss about the major category of Gas Meters used by GSPC Gas in different Segments, i.e., Domestic, Commercial and Industrial.

7.1. Diaphragm Gas Meter (Domestic & Commercial) It is having four measuring chambers separated by synthetic diaphragms. These chambers are filled and emptied periodically and the movement of the diaphragm is transferred via a gear to crankshaft. And thus shaft moves the valves that measure the volumetric gas flow. Rotations of the gear are transferred to the index via a magnet coupling, ensuring proper sealing. Ex. Elster, Raychem etc.

Table -18 Specification 46

Domestic Meter


Commercial Meter

CITY GAS DISTRIBUTION Tech. Spec

EN 1359

EN 1359

Capacity

2.5 m3/hr.

10,25, 40, 65 scmh

Range ability or TD Ratio

1:150 or better

1:150 or better

Nominal Working Pressure

21 mBar

100 mBar

Domestic Meter: End Connection: ¾” as per BS 746, Center to Center Distance: 110 mm between Inlet and Outlet Connection. Commercial Meter: Pressure Rating: Suitable to withstand Max. Working Pressure of 200 mBar

Figure 23 – Domestic and Commercial Diaphragm Meter

7.2. Rotary Positive Displacement Meters (RPD) It is having a two 8-shaped impeller. These impellers rotate due to pressure difference created by the gas entering the meter from one end. Timing Gear is present to synchronize the two impellers to rotate in opposite direction. The gear trains are used to move counter in turn to generate LF/HF Pulse.

Specifications: I.

Tech. Spec.: EN 12480

II.

Volumetric Meter, Large Measuring range, Needs lubrication

III.

Appropriate for Medium Size Load

IV.

Typical Turndown 35:1 to 50:1

V.

Accuracy +1%

VI.

Not sensitive against Disturbances, Not sensitive against fast changes against flow rates 47



Figure 24 – RPD Meter

Chapter 8 – Valves Types and Features The three basic functions of valves are: 1. to stop flow, 2. to keep a constant direction of flow, and 3. to regulate the flow rate and pressure. There are various types of Valves used in CGD Industry. GSPC Gas equipments are mostly consisting of Ball Valves.

8.1. Ball Valves  They are suitable for gas, compressed air, liquid and slurry device. They are commonlu used for Isolation services.  A ball valve shall have a spherical closure member which rotates about an axis which is perpendicular to the direction of flow. It is easier to obtain a tighter seal with a sphere than with other shapes.  The valve shown has flanges end parts, which connect to the piping and are held to the main body by bolting arrangement. The valve is operated by turning the spherical plug (ball) a quarter turn in the clockwise (for closing) or anti-clockwise direction (for opening). 48



Figure 25 – Flanged End Ball Valves

8.2. Check Valve (Non Return Valve)  A check valve shall have a closure member(s) (as ball or a flapper) permit fluid to flow in one direction only. Lift-check and swing-check are the two major types of valves used in process work.  The lift-check, or ball-check, is most often used in 2- inch and smaller sizes. It has a ball or guided plug which is lifted by fluid pressure and does not have a tendency to slam - as the swing-check type does. For this reason, the lift-check valve is preferable for services having irregular or frequent reversals of flow.

49



Figure 26 – Lift Check Valve  For sizes larger than 2-inch, the swing-check valve is most often used.

Figure 27 – Swing Check Valve

Chapter 9 – PNG O&M (Operation and Maintenance) The major assets, associated activities and their frequencies as per Operation and Maintenance Plan (O&M) are as under – Table - 19

Sr. No. 1.

Description PNG Connection

50


Frequency

Responsi bility

CITY GAS DISTRIBUTION 1.1 1.2

Inspection/ Maintenance of Domestic Connection Replacement of Flexible Rubber Hose for all points (No cost for Customer for Single Kitchen Point) GI Riser Maintenance Inspection/ Maintenance of Commercial Connection

Annual Once in 5 Years

1.5

Replacement of Flexible Rubber Hose for all points (Chargeable to Customer)

Once in 5 Years

2.

CGS/CPRS/DRS/Let Down Skid upto CNG Station

2.1 2.2 2.3 2.4

Monitoring of Pressure/Flow Leak Check of all points Valve Operation & Greasing Stream Changes & Functional Test of PRV/SSV & CRV Maintenance of Filters/KOD Calibration of SRV/CRV Testing of Gas Detection System Calibration of Gas Detection System Checking of Earth Pit and Earthing Electrodes Painting/Touch up of A/G Piping Hydro testing of Filters/KOD

1.3 1.4

2.5 2.6 2.7 2.8 2.9 2.10 2.11

2.12

Calibration of Meter other than Custody Transfer Meter (PT,TT)

2.13 2.14 2.15 2.16

Calibration of all Pressure Gauge Environmental Monitoring (Air Pollution Check) Noise Level Monitoring Maintenance of Power System and Power Back – Up

2.17

Maintenance of TR Unit, Anode Bed, Reference Cell

3. 3.1 3.2 3.3 3.4

Odorant System

3.5

Monitoring of Odorant Level/Smell Odorant transfer from Barrel to Tank Monitoring/Inspection of Odorant Storage area Leak Check of all joints and at the time of every odorant filling Pneumatic Test of Odorant Tank

3.6

Calibration of Pressure Gauge

51


Once in 2 Years Annual

PE/PNG O&M Team

Daily

Half Yearly

Yearly Half Yearly Yearly Yearly Need Base Variation in wall thickness Half Yearly

Yearly

PE/PNG O&M Team

Steel Pipeline Engineer Metering Engineer Steel Pipeline Engineer

Half Yearly

Daily When required Half Yearly If Wall thickness varies Yearly

PE/PNG O&M Team


4.

Steel Distribution Network

4.1 4.2 4.3 4.4 4.5 4.6

Patrolling within City/Town area crossing Patrolling Intra City/Town LPT Survey of Steel Network LDT within City LDT outside City Preventive Maintenance of Valve Chamber

4.7 4.8 4.9 4.10

Pest Control at Valve Chamber Operation and Greasing of Valves Repair of Valve Chamber Emergency Patrolling & Third party Coordination if work is going on near gas pipeline route

4.11 4.12

Maintenance of all type of Markers Repair of Pipeline Coating

Daily Monthly Quarterly Quarterly Yearly Pre and Post Monsoon Need Basis Half Yearly As & When required

5.

Cathodic Protection System (TCP, ICCP)

5.1

Monitoring of TR

Daily

5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10

Preventive Maintenance of TR Unit PSP Monitoring Monitoring of Insulating Joints Preventive Maintenance of TLPs Painting of TLP,AJB,CJB On-Off Potential Measurement Calibration of Voltage & Ampere Meter Maintenance of Battery Tank Monitoring of Anode Ground Bed (AGB) and Reference Cell

Half Yearly Half Yearly Monthly Yearly When Required Yearly Yearly Half Yearly Half Yearly

6.

Statutory Compliance Monitoring

6.1 6.1.1 6.1.2

Factory Act Requirement Factory License Audit Finding Compliance post visit of Factory Inspector GPCB Compliance

6.2 52


PE/PNG O&M Team Steel Pipeline Engineer PE/PNG O&M Team Steel Pipeline Engineer PE/PNG O&M Team

NA NA

Steel Pipeline Engineer (Steel Pipeline CP Contractor )

Legal ZH/GA

CITY GAS DISTRIBUTION 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6

NOC Air Consent, Water Consent Authorization for Hazardous Waste Disposal Submission of Monthly Monitoring Reports to GPCB Submission of Annual Environment Reports to GPCB Annual Return of Hazardous waste dispatched during whole year

Once Half Yearly Half Yearly

HSE

Yearly

Figure 28 - Pressure Profile of CGD Network

Chapter 10 – CNG Distribution System I.

CNG Refueling Station is a facility set-up for supplying CNG mainly as a fuel to vehicles. The system receives odorized gas at certain pressure (3-19 Bar), through 53


CITY GAS DISTRIBUTION transmission line and supplies the same to the customers/vehicles after filtration, compression (upto 250 Bar) and check metering. II.

CNG is stored at compression stations which are directly connected with the gas pipeline. Here the gas is compressed to a required pressure and aids fuelling. CNG can also be transported to other retail outlets by cylinder trucks. These trucks carry a number of cylinders which provide CNG to fuel stations which are not connected by pipelines.

III.

The system has major assets like, Odoriser Unit, CNG Compressor, Storage facility, Dispenser, LCV/HCV Filing Point, Mobile cascade vehicle, Electrical Installations, DG set and Air Compressor. The size, rating and type of the major and sub assets are selected based on the pressure rating, capacity and other applicable criteria considered for refueling station for meeting the current and future customer potential, health and safety of employees, customers and public at large, environmental protection and complying the statutory, legal requirements, national and international technical and safety standards/ practices.

IV.

Various operation and maintenance activities, as per annual operation and maintenance plan are carried out for ensuring safe and uninterrupted gas supply.

Figure 29 – CNG Station

10.1. Types of CNG Refueling Stations

54



1. Mother Station: A CNG station provided with whole set up (compressors, dispensers, cascade etc.) along with a LCV filling point is known as a mother a CNG station.

2. Online Station: This CNG station has same set up as a mother station but LCV connection is not provided for filling.

3. Daughter Booster Station: Daughter station provided with the compressor (known as boosters) to compress the gas we are getting from the mother station are known as daughter booster station.

4. Daughter Station: Daughter stations are established in those areas where laying a pipeline is not possible. In that case gas is delivered from mother station to daughter station; via mobile cascade van. The gas from mother station is filled in mobile cascade by a LCV filling point.

Figure 30 – Types of CNG Station

10.2. Working of CNG Station: 55



10.2.1. CNG Compressor  Steel line of 2 inches dia. coming to compressor as a suction line (25 bars). Suction line is provided with isolation valve followed by a strainer for removing of foreign particles.  After strainer comes the suction filter of size 5 micron. From here the suction line is divided into two lines, one is inlet to 1st stage of compressor and another one is instrument line for operating actuator valves in the compressor.  Instrument line having a pressure of 25 bar it goes to a PRV which reduces pressure upto 6-8 bars for the SOV which provide functioning of actuator.  Now the main suction line goes in Non Returning Valve (NRV) which provides only forward movement of gas. From NRV it goes into Blow down Vessel. We have two interconnected Blow down vessels. In these, gas is stored which is mainly used during startup of compressor.  Now from NRV it comes to main PRV & then first Suction volume bottle. From here it enters to compressor.  Valve and Piston means in other compressors valve and piston are provided separately but here valve is provided in the piston so function of both is performed by piston only.  The first stage is double acting stage; here compression is affected from both the ends of the cylinder of the compressor. Then gas is sent to the intercooler for the cooling of the gas.  Now gas from intercooler enters to second stage for the compression and again same it goes to intercooler for air cooling of the compressed gas.  Finally it reaches to third stage for final compression from intercooler for the desired final pressure of gas. At every stage, the gas pressure and temperature is: Table -20

 After third stage compression from intercooler it comes in discharge line. 56


CITY GAS DISTRIBUTION  Lubrication oil is provided for piston and crank case separately. - Oil SS220 for lubrication - Oil SS150 for Crank Case  Final discharge line goes to separator first and then filter of size of 1 micron. Now gas enters to mass flow meter for measurement. Water cooling is provided for the cooling of the oil used in compressor. From mass flow meter gas comes to priority panel.

Figure 31 – CNG Compressor

Gas Compressor Specifications: The following codes and standards (version/revisions valid on the date of order) are referenced to & made part of specification API-11P (latest edition), API 661:1997, ASME VIII Div. 1999, API 618 BS 5514 - 1996. ISO 3046/1 NFPA-37, OISD 179 and NFPA-52: 1995 or equivalent. NFPA- 12, IS: 6382, Gas Cylinder Rule-2004 IS: 5571, IS: 5572, IS: 5580 Indian Electricity Rules, Indian Explosive Act Standard specifications of Bureau of Indian Standards Specification/Recommendations of IEC

10.2.2. Safety Units in Compressor 57


CITY GAS DISTRIBUTION     

Flame detectors and Gas detectors CO2 flooding system Vibration Switch FSLL(Flow Switch Low) SRV

10.2.3. Priority Panel  Discharge line coming out from the compressor is splitting into five lines in sequence as: 1. Direct line which is directly going to dispenser high pressure bank. 2. High pressure line directly going to cascade high pressure bank. 3. Followed by medium pressure line divided into two lines one goes to cascade and other to dispenser medium pressure bank. 4. Followed by low pressure line divided into two lines one goes to cascade and other to dispenser low pressure bank. 5. Last line is provided for the mobile cascade filling.  Each line is provided with Non returning valve and pressure transmitter respectively. Priority system having the following set points: - High Bank - 220 Bar - Medium Bank – 210 Bar - Low Bank – 200 Bar  Each Bank diverts comp. discharge to Lower side in sequence: 1. Auto Start 190 Bar at High Bank priority 2. Auto Stop at 245 Bar at all 3-Bank priority

10.2.4. Cascades  A bank of cylinders used for buffer stock of compressed natural gas is known as cascade. Stationary cascade is used to store the gas when vehicle is not there at the dispenser then the gas from compressor flows into a cascade.  Cylinders in a cascade are divided accordingly as: - High Pressure Cylinders (HP) - 5 cylinders - Medium Pressure Cylinders (MP) - 11 cylinders - Low Pressure Cylinders (LP) - 24 cylinders 58


CITY GAS DISTRIBUTION  The cascade having horizontal cylinders and sited parallel to other cascade, cylinder fittings should be arranged so that they do not face cylinder fittings of other cascade.  Cylinder installed horizontally in a cascade shall be separated from another cylinder in the cascade by a distance of not less than 30 mm.  Cascade with horizontal cylinders shall have the valves fitted on the same side within the cascade opposite to the refueling point and arranged in a manner that any gas leakage is discharged upwards.  Cascade/bulk units shall be installed on a firm, compacted, well-drained non-combustible foundation, in the form of a plinth with the raised edge at 2 M from the front and sides of the cascade. The cascade shall be securely anchored to prevent floating in case flooding is anticipated.  Gas storage facility shall be protected from the effects of the weather by a roof or canopy designed to facilitate the dispersion of free or escaped gas.  Adequate means shall be provided to prevent the flow or accumulation of flammable or combustible liquids under containers such as by grading, pads or diversion curbs.  Only dedicated trailer, truck or any other vehicle to be used for transportation of CNG storage units. These units should have lugs fitted for lifting and in no case magnetic device to be used for lifting purposes.  The vehicle with the cascade there own, shall be placed with easy access and egress on a low platform or hard compacted ground, which shall extend to at least another one meter on all sides and this platform or hard ground shall be under a light roof or canopy.  The trailers/ vehicle carrying CNG should be made immovable by application of brake and wheel choke prior initiation of filling or dispensing operation. We have two types of Cascades:

1. Stationary Cascade: These are fixed cascades established on CNG station for the storage of CNG. It has a direct inlet from compressor and outlet to line connected to dispenser.

2. Mobile Cascade: Cascade is mounted over an LCV and it carries CNG from Mother station to Daughter station or Daughter booster station as per the requirement.

59



Figure 32 – Cascade Unit

Codes and standards for Cascades: IS 7285 IS 3224 OISD-179 Gas Cylinder Rules-2004 Indian Explosive Act

10.2.5. Dispenser Main components of a dispenser: High, Medium, low bank lines Gas Filter SOV Actuator Mother Board Non Returning Valve (NRV), Ball Valve, Pressure Regulating Valve (PRV), SRV Mass flow meter, Pressure Transmitter Hose Pipe Three Way Valve Hex Nipple, Filling Probe O-Ring

Working of a Dispenser:  A dispenser has three banks connection namely:- Low pressure Bank (LP) - Medium pressure Bank (MP) 60


CITY GAS DISTRIBUTION - High pressure Bank (HP)  Gas from dispenser will dispense in the sequence: - low bank, medium bank and high bank.  A PRV is connected to main line coming to the dispenser which is reducing the pressure for the operation of Actuator.  For any maintenance work Emergency valves should remain closed.  It has filters (size of one micron) where oil and other foreign particles are removed.

Figure 33 – Dispenser Unit

61



Chapter 11 – CNG O&M (Operation and Maintenance) Table 21 – CNG Station asset, Major activities and their frequencies

Name of Major Asset

Major Activities Daily

Odorization Unit Suction Skid

CNG Compressor

CNG Cascade

Mobile Cascade Electrical Installation

Air 62

Patrolling

Leak Check & Oil top-Up & Drain Leak Checks

Leak Survey

Check List

Check & Replace parts as in Check-List

Leak Checks & Filter drain Leak Check

CNG Dispenser

DG Set

Fortnight Monthly Quarterly

House Keepin g Check Diesel, Coolant and Oil Level Leak


Half Yearly

Yearl y

Emergency

Valve Chambe r Preventi on Check & Replace parts

Check & Replac e parts

Damage or Leakage Part Repair

Damage or Leakage Part Repair Damage or Leakage Part Repair Damage or Leakage Part Repair Damage or Leakage Part Repair Damage or Leakage Part Repair


Compressor

Check and Check oil Level

Damage or Leakage Part Repair

Chapter 12 – GSPC Gas HSE Policy and Action Plan 12.1. Various Emergencies - Some of the common circumstances under which an emergency situation can arise. I.

A Natural Gas leakage without associated with fire from potential leakage sources e.g. flange and valves in the DRS, CNG stations (Cascade connections), Valve Chambers, MRS and customer premises.

II.

A leak from the main Steel pipeline section (15-25 bar pressure) could be well damaging and requires quick isolation of gas supply.

III.

Any fire in customer premises (not a very credible scenario because of very low pressure in the domestic section of pipeline) or a fire explosion in the gas/leak.

IV.

Third party Pipeline damage requiring system pressure reduction/isolation.

V.

Preventive shutdown action during any Natural calamities, e.g. flood, earthquake, epidemic, storm etc.

12.2. Why HSE Reporting is Necessary?  It enables data compilation and analysis.  To find out root cause of incident / accident – unsafe process/act/design.  Identify area of improvements  To know the reason behind the established Causes  To prevent Recurrences before they become Recordable or Serious  For the establishment of new corrective actions  Improve companies safety culture 63



 To develop Statistical safety data base  To learn from the mistakes

12.3. Classification of Emergencies Level 1 a) Emergency / incident can be effectively managed and contained at the location/installation by available resources. b) Has no impact outside the site.

Level 2 a) Emergency / incident cannot be effectively managed and contained at the location. b) Additional support required. c) Have potential to effect beyond facilities where external support/ mutual aid required. d) Likely to be danger to life, environment and industrial assets.

Level 3 a) Emergency / incident with off-site impact, catastrophic. b) Likely to affect population, property and environment. c) Control is done by District Administration.

12.4. Various Emergency Plan On site emergency plan: A responsive plan to contain and minimize the effects due to emergency within the installations.

Crisis management plan: A well-coordinated comprehensive response plan to contain crisis that has a potential to cause loss of life, property, environment and provide speedy and effective recovery by making the most effective use of available resources.

Off-site emergency plan: A responsive plan to control/ mitigate the effects of catastrophic incidents. This is prepared by district management based on the data of the installation(s) given by all the owners.

12.5. Incident Controller 64



Site Incident Controller (SIC) or Incident Controller - means the person who

I.

goes to the scene of the emergency and supervises the actions necessary to overcome the emergency at the site of the accident. - The City Managers / technical in charges at respective locations will be the Incident Controller. II. Chief Incident Controller - means the person who assumes absolute control of the unit and determines the action necessary to control the emergency. - Respective Zonal Head of GSPC Gas is CIC for GSPC Gas Company Ltd.

Duty Manager - means the Manager nominated from time to time at corporate office

III.

of GSPC Gas at Gandhinagar, on duty, whose role is to provide incident management support during and outside working hours.

12.6. Actions taken by GSPC Gas to maintain HSE Standards I.

HSE Policy

II.

HSE Reporting

III.

HSE Manual

IV.

HSE requirement in Scope of work (Tender, Work Orders, Manuals)

V.

Permit to Work ( Hot Work, Cold Work, Working at Height, Boring, Electrical Isolation and Energization)

VI.

Mock Drills (Table Exercise, Functional Exercise, Full-Scale Exercise)

VII.

HIRA (Hazard Identification Risk Assessment), QRA (Quantitative Risk Analysis)

VIII.

Risk Register

IX.

Safety Competency Training (STC)

X.

Personal Protective Equipment (PPE) – Gloves, Safety shoes & glasses, Face Shields, etc.

XI.

Tool Box Talks, Life Guards (focus on High Risk Activities)

XII.

Site Safety Audits

XIII.

Periodic Review Meeting at Local/Zonal/Corporate Level

XIV.

Recognition & Penalty 65



XV.

ERDMP (Emergency Response & Disaster Management Plan) – Each Zone has its own.

XVI.

GPCB Clearance

12.7. ERDMP (Emergency Response Disaster Management Plan) 12.7.1. Objectives of ERDMP  To define and assess emergencies, including risk and environmental impact assessment.  To control and contain incidents and their effects within the shortest possible time.  To safeguard employees and people in vicinity and to minimize damage to property or/and the environment.  To inform employees, the general public and the authority about the hazards/risks assessed, safeguards provided, residual risk if any and the role to be played by them in the event of emergency.  To be ready for ‘’mutual aid’’ if need arises to help neighboring unit. Normal jurisdiction of an OEP is the own premises only, but looking to the time factor in arriving the external help or off-site plan agency; the jurisdiction must be extended outside to the extent possible in case of emergency occurring outside.

12.7.2. Essential Features of ERDMP as per PNGRB  Classification of Emergencies  Consequences of defaults or non- compliance  Pre-emergency planning and Emergency mitigation measures  Emergency preparedness and ER procedures  Emergency organization and responsibilities  Declaration of on-site and off-site emergencies  Infrastructure requirements and Demographic information  Medical facilities 66


CITY GAS DISTRIBUTION  Evacuation through developing Public relation and information to public.  Incident reporting  Emergency recovery procedures  Security threat plan and action plan to meet eventualities

Chapter 13 – CGD Regulations The Petroleum and Natural Gas Regulatory Board Bill, 2005 establishes the Petroleum and Natural Gas Regulatory Board (PNGRB) to regulate downstream activities in the petroleum and natural gas sector. It includes refining, processing, storage, transportation, distribution, marketing and sale of petroleum, petroleum products and natural gas excluding production of Crude Oil and Natural Gas.

13.1. Regulations for Access Code The Regulations for Access Code was passed in June 2007 by PNGRB for Natural Gas transmission Pipeline and City or Local Natural Gas Distribution Network. The main objectives of this access code are – 1.) Promote the development of a competitive gas market by establishing uniform principles for owners and users of gas pipelines to allow transport and non-discriminatory access to the gas pipelines and CGD Network. 2.) Prevent abuse of Monopoly Power 3.) Ensure that a Pipeline/CGD Owner provides minimum service of access to available capacity on a “Firm Service” basis and/or on “Interruptible Service” basis. 4.) Provide basis for resolution of disputes.

13.2. Regulations for Exclusivity Market Exclusivity The entity winning the right to set-up CGD Network in a city will have 5 year marketing exclusivity. After 5 years, the network will be thrown open to competition but a fresh entrant will not be allowed to lay a new pipeline. It will have to use the network for which it will have to pay a fee to the CGD Company. However, a company that has operated a CGD Company for 3 years or more prior to the appointment of PNGRB, i.e. 1st October, 2007 will have a marketing exclusivity for 3 years compared to 5 years. 67



Infrastructure Exclusivity The CGD Company will have a lifetime exclusivity of 25 years for the pipeline network.

Eligibility Criteria Those who want to obtain rights to set up a CGD network would need to meet the following eligibility criteria:  Body Corporate or Company registered under the Companies Act.  Should have a credible plan for sourcing of Natural Gas.  Should have experience of laying aggregate of over 300 Km of oil and gas pipelines or form a Joint Venture with a company which has that experience.  The entity should have experience of at least one year in operation and maintenance of a CGD Network or should have a Joint Venture with 11% holding with another entity having such experience.  Appropriate technical assistant agreement for at least one year with another party having experience of operating and maintenance of CGD Network for at least a period of one year. An entity interested in developing a particularly City gas project needs to submit “Expression of Interest” to PNGRB with Rs 8-12 Lakh as fee depending upon population of the city (NonRefundable), Geographical Area, market potential of CNG and PNG, business plan.

68



Chapter 14 – Challenges for Implementation of City Gas Projects  Need of creating vast CGD network with accelerated pace, commensurate to wide public Demand.  Developing CGD specific safety standards and developing & multiplying their monitoring by the third party  Developing & multiplying core competence of skilled manpower to handle the operations in cities after cities.  Meeting public expectations – I. II. III.

Cheaper fuel / competitive prices by multi operators. Easy availability anywhere Foolproof safety everywhere

 Expectations are to be met by the Government, by Regulator & by CGD operators. Proper understanding of regulatory act & mechanism to avoid contradictions for synergy. i. Logical clarity in the regulations to manage contradictions for win-win situation. ii. Common understanding of the act to be read as a whole to make it effective & workable for the public good. iii. Too much control not to dampen the spirit of free competition. Regulatory systems to have: i. Gas availability / allocation to all CGD entities, which are not gas producer or marketer. ii. Gas purchase pricing for CGD at affordable price for public good. 69


CITY GAS DISTRIBUTION iii. Single window clearance from various statutory bodies.  Sharing of resources like equipment, inventories at reasonable prices.

70


3. Main Report

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