2nd City Gas India Conference

5th & 6th Sept ‘07

Technical Aspects
of
City Gas Distribution
by
B.S.NEGI
 CONTENTS
City Gas Distribution Concept

System Design

Applicable Standards

Material & Equipment

Construction

Operation & Maintenance

Health, Safety & Environment

Specific technical issues

Emergencies & complaints

 CITY GAS DISTRIBUTION CONCEPT

 Development of Pipeline Network in a pre defined

geographical spread
Maintaining Different Levels of Gas Pressure to meet
the Demand of various segments of gas users -
Domestic, Commercial, Industrial and Automobiles.
Designing high pressure and medium pressure
network such that supply to any consumer is possible
from either side.
 CITY GAS DISTRIBUTION CONCEPT
Contd….

Design gas storage for maximum survival period

Consider safety at all stages

Balance growth of all consumer sectors, specially

those cross subsidizing each other.
PNG SUPPLY SYSTEM
NATURAL GAS DISTRIBUTION PLAN

MAIN TRANSMISSION PIPELINE

CITY LIMITS
CITY GATE EXECUTION & OPERATIONS
BY
Battery

GAS DISTRIBUTION COMPANY

Limits
CITY GAS DISTRIBUTION (CGD) - Overview

 COMPRESSED NATURAL GAS (CNG)

- AUTOMOBILES

 PIPED NATURAL GAS (PNG)

- DOMESTIC

- COMMERCIAL

- INDUSTRIAL
CGD - Infrastructure
Major Constituents of CGD are
 City Gate station

 Pipelines

 Steel Pipelines

 Poly Ethylene Pipelines

 GI / Cu Pipes

 Regulating Stations

 CNG Stations
 CITY GATE STATION (CGS)

 CGS is the location of Custody Transfer from Transmission

Company to Distribution Company.

 CGS has following facilities with a stand by mode :

 Filteration

 Pressure Reduction

 Metering

 Odorization
 NETWORK PRESSURE
 HIGH PRESSURE - Steel Pipeline MAOP
Class 150 # : 19 Kg/Cm2
Class 300 # : 49 Kg/Cm2
 MEDIUM PRESSURE - PE Pipeline
PE 80 / PE 100
Pressure Range 4 Bar
LOW PRESSURE - GI & Copper
75 Mbar & 21 Mbar
NG Transportation & Distribution System

MDPE
CGD Applicable Codes Standards

 SteelGrid …ASME B 31.8 / OISD -226

 PE Grid …… IGTD-2
 PE Network hydraulics ……synergy
software, Gasnet software
 Safety…OISD-226 / OISD GDN- 192
 CNG Mother Station …. OISD -179
 CNG RO …...OISD -179
 Applicable Codes Standards Contd..
STEEL PIPELINE GRID

 Steel Pipe Selection : As per API 5L

 Pipeline Execution : ASME B 31.8
 Steel Fittings Selection Standards:
 Ball Valves : As per API 6D
 Fittings : As per ASME A 234
 Flanges : As per API 105
STEEL PIPELINE GRID – Execution Criteria
(High Pressure - 150# & 300#)

 Grid to have Main line and Spur line.

 Main line to form a loop in the city.

 Steel Pipe Sizes (Typical) : 12” , 8”, 6”, 4” & 2” (for CNG station)

 Enhanced Wall Thickness As per Class-IV Location.

 Stringent Weld Joint Acceptance Criteria Over API 1104.

 Valves installation at every 2 km’s.

 Route selection considering ease of laying & O&M.

 Applicable Codes Standards Contd..
STEEL PIPELINE GRID – Execution Criteria
 Steel Pipeline conforms to ASME B 31.8

 Pipelines are Coated with three layer Polyethylene

 100% Radiography of Weld Joints

 Hydrostatic testing of Pipeline carried out at 1.5 times MAOP

 Cathodic Protection is provided – TCP or PCP

 Pipeline is laid with minimum 1.0 Mtr cover

 Warning mats are provided at 300 mm from top of Pipe

 Warning Markers are provided at close intervals

Applicable Codes Standards Contd..
PE PIPELINE GRID

 MDPE Pipe Selection Standard : As per IS-14885

BG PSL-II

 MDPE Fittings Selection Standards : As per ISO-4437

 Standard MDPE Pipe Sizes in mm :

Main Lines : 180 MM, 125 MM, 110 MM,
90 MM & 63 MM

Service Lines : 32 MM & 20 MM.

Applicable Codes Standards Contd..
PE PIPELINE GRID

 PE Network originates from District Regulating Station

(DRS) which is connected to High Pressure Grid.

 Based on load requirement the network is simulated for

specific geographic area to work out the Pipe Size and

Length.

 PE Network Looping is formed between two Regulating

Stations.
PE PIPELINE GRID – Execution Criteria
(Medium Pressure – 4 Bar)

 The Pipeline is tested at 6 Bar Pneumatic pressure, which

is 1.5 times MAOP

 Method of jointing- Electrofusion

 Warning tape with cautionary sign provided above the

pipeline

 Isolation valves are provided at strategic locations

Applicable Codes Standards Contd..
GI / Cu PIPE – SELECTION
(Low Pressure – 75 & 21 Mbar)

 GI Pipe Standard : As per IS-1239

 GI Fittings Standards : As per IS-1879
 Cu Pipe Standard : As per BS EN 1057
 Standard GI / Cu Pipe Sizes in mm : GI : ½” & ¾”
Cu : 12 MM
Metering Domestic diaphragm type : Domestic BIS 14439
EN 1359, OIML 31R
GB/T 6968
 GI / Cu PIPE – Execution Criteria
(Low Pressure – 75 Mbar or 4 Mbar)

 GI Pipe is installed on the walls of building and is

connected to Medium Pressure Grid of PE Network by

transition fitting

 Main risers are of higher size and the pipe size is reduced

inside the kitchen and option of Copper Pipe installation

is also available

 GI Pipes are routed considering safety and economics so

as to cater all the customer

Typical Piped Natural Gas Distribution Network
 PIPED NATURAL GAS SUPPLY MECHANISM
(THREE STAGE)
12” / 8” / 6” / 4” STEEL PIPELINE AT 17 - 32 BAR

4” STEEL PIPELINE

FIELD 4 BAR 180 / 125 / 63 / 32 MM MDPE DISTRIBUTION MAIN

REGULATING UNDERGROUND PIPELINE
STATION
RESIDENTIAL PREMISES B / W

• INLET – 17-
17-32 BAR
• OUTLET – 4 BAR
METER REGUATOR APPLAINCE VALVE
• FILTER 100 Mbar to 21 mBAR
• TWIN STREAM
REGULATION WITH
SLAMSHUT-
SLAMSHUT-OFF
• PRESSURE RELEIF GI RISER FLEXIBLE RUBBER
• METER • 100 MBAR X 21 mBAR HOSE
• HIGH / LOW
PRESSURE SLAM SHUT
CUT OFF METER
• RELIEF VALVE
ISOLATION
SERVICE REGULATOR VALVE

PE / GI TRANSITION FITTING BURNER

GROUND LEVEL

KITCHEN B / W

20 MM MDPE PIPELINE
 PIPED NATURAL GAS SUPPLY MECHANISM
(TWO STAGE)
12” / 8” / 6” / 4” STEEL PIPELINE AT 17 - 32 BAR

4” STEEL PIPELINE
FIELD 4 BAR 180 / 125 / 63 / 32 MM MDPE DISTRIBUTION
REGULATING MAIN UNDERGROUND PIPELINE
STATION
RESIDENTIAL PREMISES B / W
• INLET – 17-
17-32 BAR
• OUTLET – 4 BAR DOMESTIC APPLAINCE VALVE
• FILTER REGULATOR GI RISER
• TWIN STREAM • 4 BAR X 21MBAR
REGULATION WITH • HIGH / LOW FLEXIBLE RUBBER
SLAMSHUT-
SLAMSHUT-OFF PRESSURE SLAM HOSE
SHUT CUT OFF
• PRESSURE RELEIF
• RELIEF VALVE METER
• METER
ISOLATION
VALVE

PE / GI TRANSITION FITTING BURNER

GROUND LEVEL
KITCHEN B / W

20 MM MDPE PIPELINE
MAJOR EQUIPMENT / COMPONENTS USED
FOR PNG DISTRIBUTION

 FIELD REGULATING STATION

 REGULATOR

 METERS

 METER REGULATING STATIONS

FIELD REGULATING STATION
FEATURES
 TYPE- TWIN STREAM ACTIVE- MONITOR
REGULATORS WITH SLAMSHUT OF
VALVES AND METER

 INLET PRESSURE – 17 to 32 BAR

 OUT LET PRESSURE – 4 BAR
 DESIGN PRESSURE- 49 BAR
 MAX. FLOW- 5000 / 10000 SCMH

 SAFETY FEATURES-
 ACTIVE- MONITOR
REGULATION
 OVER PRESSURE SHUT- OFF
 UNDER PRESSURE SHUT-OFF
 PRESSURE RELIEF VALVE

 METER TYPE- TURBINE / RPD WITH

FLOW COMPUTER
REGULATOR AND METER
DOMESTIC REGULATORS
 TYPE- DIRECT ACTING
 INLET PRESSURE – 1.0 to 4 BAR
 OUT LET PRESSURE – 21 Mbar
 MAX. FLOW- 6.5 Cu.M/Hr.
 SAFETY FEATURES-
OVER PRESSURE SHUT- OFF
UNDER PRESSURE SHUT-OFF
RELIEF VALVE

DOMESTIC METER
• TYPE – G-1.6
• MAX. FLOW - 2.5 Cu.M/Hr.
• MIN. FLOW – 0.016 Cu.M/Hr.
• MOP- 300 mBAR
• ACCURACY –
Q max TO 0.2 Q max + 2%
0.2 Q max TO Q min + 3%
METERING REGULATING STATION INSTALLED
AT COMMERCIAL`S
FEATURES
 CUSTOMISED
 TYPE- TWIN / SINGLE STREAM
REGULATORS WITH SLAMSHUT OF
VALVES AND METER

 INLET PRESSURE – 19 / 4 BAR

 OUT LET PRESSURE – AS REQUIRED
 DESIGN PRESSURE - AS REQUIRED
 MAX. FLOW - AS REQUIRED

SAFETY FEATURES -
 OVER PRESSURE SHUT- OFF
 UNDER PRESSURE SHUT-OFF
 PRESSURE RELIEF VALVE

 METER TYPE- TURBINE / RPD WITH

FLOW COMPUTER
 PRESSURE GAUGES
 MDPE PIPES AND FITTINGS
 STANDARD PIPE SIZES BEING USED OD IN MM
- 180, 125, 90, 63, 32, 20
 ASSOCIATED FITTINGS
a. Coupler
b. Elbow
c. Tee
d. Reducer
e. Valve
f. Transition Fittings
g. Tapping Saddles
h. End Caps
 CATEGORIES OF PE FITTINGS
 ELECTRO FUSION FITTINGS

Injected moulded polyethylene

accessories equipped with a
heated element designed to
transform electrical energy
into heat to create self-
welding

 SPIGOT FITTINGS

PE fittings having smooth

ends which requires electro
fusion accessories to weld to
other pipe / fittings
 TYPES OF PE FITTINGS

 PE PIPE COUPLERS

FOR JOINING PIPE TO PIPE

AND PIPE TO FITTING

 TAPPING SADDLE

FOR TAKING TAP-OOFS FROM

LIVE LINES

 PE SHUT-OFF VALVES

FOR ISOLATING PE GAS

PIPELINES

 REDUCERS

FOR CONNECTING PIPES OF

DIFFERENT DIAMETER.
 TYPES OF PE FITTINGS (Contd…)
 PE ELBOWS
FOR JOINING PIPES IN
DIFFERENT ANGLE

 TRANSITION FITTINGS
ADAPTORS FOR PE TO STEEL /
GI.

 EQUAL TEE
FOR BRANCHING OF PIPELINE
NET WORK

 END CAPS
INSTALLED AT THE END OF THE
PIPELINE
 Specific technical issues

 Steel Pipeline #150, # 300, # 600

• # 600 more suitable for CNG supply

• Power saving in compression

• More line pack available to meet

emergency

• Cost saving in steel grid

• What should be reasonable & how?

Specific technical issues -contd…

 MDPE V/S HDPE

• Molecules widely scattered in MDPE
make it more suitable for squeezing,
HDPE may crack
• ESCR property of MDPE superior to
HDPE
• Wide range of MDPE fittings
available
• Electrofusion property
Specific technical issues -contd…

 PE pipe pressure – 4 bar v/s 8 bar

• Safety consideration
• Saving of material in 8 bar system
• More line pack in 8 bar system
• India implemented UK 4 bar PE
system
• PE application 8 bar in France
Specific technical issues -contd…
 PE grade- P 80/P100
• Material saving in P 100 grade
• Fittings to match the PE grade
 PE pipe testing
• Testing of the raw material- Density, MFI, Colour
and Structure
• Manufactured pipe testing –Tensile strength,
grain structure/ inclusion, hardness, indentation,
hydro test (normal, elevated temperature), ESCR
test (long duration)
Specific technical issues contd…
 CNG compressor suction pressure
variation
• Capacity constraint in steel grid –
Mother compressor, On line
compressor
• Improper design of steel garland /
belting
• Daughter booster compressor to
have variable suction pressure –
Idromechanica type hydraulic
compressor
Specific technical issues contd…

 CNG vehicle- range enhancement

• 230 bar seamless cylinder volume to
weight ratio 1:5 more than(sm3:Kg)
• Consider fiber reinforced Aluminum
cylinder (high pressure), Charcoal field
cylinder (low pressure adsorption)
• Alternatively have wider steel grid in city
and highway CNG re-filling stations
Specific technical issues contd…
 CNG Vehicles Queuing
• Compression Capacity available
• Vehicle filling time
• Vehicle maneuvering
• Billing & collection
• Vehicle rate of Conversion to CNG and
addition of new CNG vehicles
• Infrastructure to precede the conversions
Specific technical issues contd..
 CNG Cylinder Safety- Gas Cylinder Rules
• Responsibility of refueling person
• Spurious cylinder- Great Risk
• Initial testing, every five year testing
• RFID Tags- Mounted on cylinder, easy
solution
• Remote reading with hand held devices
• Smart cheep Inc (SCI) provide economic
and dependable solution
Specific technical issues contd..

 Safety Aspects of CGD

• Design stage safety –Mandate codes, standards
and best practices for CGD (regulators
intervention)
• Safety in construction –Material selection,
welding (both for steel and PE), check listing for
stage/ group/system completion
• Pre-commissioning and commissioning tests
• Operation Safety –Knowledge of all isolation
valve location, DRS location and safety gadgets
Specific technical issues -contd…

 Kitchen leakage –The small is big

(flame extinguishing due to boiling
milk, damage to hose pipe, damage
burner knob)
 Use kitchen safety valve like
Gasbangwoori brand safety valve
which stops gas supply to burner in
excess flow condition
Specific technical issues contd…
 Gas metering / billing / collection
• Manual meters need frequent visit reading
• Billing and collection costs money to
utility company
• Meter reading, Payment is hassle for gas
users
• Smart card based metering is the solution
Specific technical issues contd…
SMART CARD BASED DOMESTIC METER
Specific technical issues contd…

 Accreditation by third party

• Mandating National Standards
• Certification by different entity
 Reticulation systems
• Common code,Systems
 EMERGENCY, COMPLAINTS & REQUESTS
GENERAL EMERGENCY

COOKING APPLIANCE RELATED MAJOR

 N G CONVERSION  EMERGENCY CALL (Major Leakage MDPE)
 FLAME PROBLEM  PIPELINE DAMAGE BY THIRD PARTY

 NEW STOVE CONVERSION

 CONVERSION TO LPG

GI INSTALLATION RELATED MINOR

 NO GAS SUPPLY
 TEMPORARY DISCONNECTION( Defaulter)
 TEMPORARY DISCONNECTION (Personal Reason)
 TEMPORARY DISCONNECTION (Renovation)
 GI MODIFICATION
 RE-INSTALLATION (GI Modification)
 EMERGENCY CALL (Minor Leakage)
 EMERGENCY CALL (Minor Leakage from
rubber tube)
 LEAK FROM TRANSITION FITTING, FLEXIBLE
HOSE, FITTINGS ,JOINTS ETC.

MDPE PIPELINE RELATED

 PE MODIFICATION

 PE PLUGGING
 2nd City Gas India Conference

Thanks

Lets Begin the projects