TECHNICAL STANDARDS

AND SPECIFICATIONS
INCLUDING SAFETY
STANDARDS (T4S) for CGD
As per PNGRB Act, 2006
 Introduction
• In exercise of the power conferred by section 61 of
PNGRB Act, 2006 the PNGRB made regulations
(Technical standards and Specification including Safety
Standards for Natural Gas Pipelines) Regulation, 2009.

• It come into force from 11th November, 2009

• It covers the design, materials, fabrication, installation,

inspection and testing, commissioning, operation,
maintenance, modification and abandonment of CGD
network for domestic, commercial and industrial users.
 Introduction
• The CNG Station, CNG Mother Station, CNG On-Line
Station and CNG Daughter Station shall be designed,
operated and maintained in line with the requirements
of the Chief Controller of Explosive as detailed in the Gas
Cylinder Rules, 2004

• These regulation also cover safety aspects of operation

and maintenance of CGD network
 Common Definitions
City Gas Distribution Entity : An entity authorized by the Board to
lay, build, operate or expand the city or local natural gas
distribution network.
City Natural gas Distribution network : An interconnected
network of Gas pipelines and the associated equipments used for
transporting natural gas from a bulk supply high pressure
transmission main to the medium pressure distribution grid and
subsequently to the service pipes supplying natural gas to
domestic, industrial or commercial premises and CNG station
situated in a specified geographical area.
Consumer Meter : A meter that measures gas delivered to a
consumer at the consumer’s premises.
City Gate Station (CGS) : The point where custody transfer of
natural gas from natural gas pipeline to the CGD network takes
place.
District Regulating Station (DRS) : A station located within
authorized area for CGD network having isolation, pressure
regulating and overpressure protection devices.
 Common Definitions
Active Regulator : A regulator in Pressure Regulation Station (PRS) that
normally controls the outlet pressure.
Active and Monitor Regulator system : An arrangement of two
regulation devices in series, one (Active) normally to control the outlet
pressure and the other (Monitor) to assume control in the event of
failure of the active regulator.
Creep relief valve : A relief valve installed to relieve over pressure caused
by creep in the system and having maximum 1% flow capacity of such
a system.
Positive Isolation : The isolation with blind or spectacle blind , in case
of flanged joints or with welding the cap in case of welded joints.
Slam shut valve: A valve that is designed to close quickly in the event of
an abnormal pressure (whether excess or low) being detected at a
selected point in a gas pipeline system.
Electro Fusion Joints : A joint made in thermo plastic piping by passing
the current through he electrical coil provided in the fitting and
heating the parts sufficiently to permit adequate flow and fusion of the
materials between the two surfaces put in contact.
 Intent
• These regulations are applicable to all new and already existing
entities.
• If the entity has laid, built, constructed or expanded the CGD
infrastructure based on some other standards or is not meeting the
standards specified in these regulations, the entity needs to carry out
a detailed technical audit of its infrastructure through a board
authorized or approved third party agency by the board.
• The entity thereafter shall submit the recommendations made by the
third party along with its time based mitigation plan ad
implementation schedule to the Board for authorization within six
month from the date of notification of these regulation.
 Intent
The continuation of the operation of existing CGD network shall be
allowed only if meets the following requirements.
• The CGD system downstream of CGS shall have been tested
initially at the time of commissioning in accordance with ASME B
31.8 Chapter IV
– Minimum test pressure for steel network – 1.4 times of MAOP
– Minimum test pressure for PE network – 1.4 times of MAOP or 50 psig
(whichever is higher)
• The entity should have proper records of the same. Such record shall
have been valid for the current operation.
• If such a record is not available, the entity should produce in service
of the CGD network having tested at a pressure of 1.1 times of
MAOP as per ASME B 31.8
 Intent
• Provision of operational Leak Detection System
– Gas network – Odorisation based
– Enclosures – Gas leak detection based.
• Provision of Pressure relief valves
• Protection of the system against third party damage (steel pipe and
PE pipe both)
• The critical component of the system as identified by the Board for
such existing network shall be complied with these regulation within
a period specified at Appendix – 1 and the authorized entity shall
maintain the integrity of the existing system at all times.
 Schedule - 1
• Material and Equipment –( Schedule -1A)

• Welding (Schedule – 1B)

• Piping system components and fabrication (Schedule – 1C)

• Design, Installation and Testing (Schedule – 1D)

• Operating and Maintenance procedures (Schedule – 1E)

• Corrosion Control (Schedule – 1F)

• Miscellaneous ( Schedule – 1G)

 Default and Consequences
• Compliance of the provision of these regulation through conduct of
technical and safety audits during the construction, commissioning
and operation phase, as well as on an on-going basis as may be
specified from time to time.
• In case of any deviation or short fall, in achieving the targets for
implementing the specified standards, the entities shall be liable to
face following consequences.
– For critical activities at Appendix – 1, the entity shall be given a single notice
by the Board specifying the time limit to remove the specified shortcoming
and ensure the compliance
– If the entity fails to comply within in the specified time limit, immediate
suspension or termination, as deemed appropriate of the authorization shall be
done.
 APPENDIX – 1
List of Critical Activities in CGD Network
Sr No Critical Infrastructure / activity / processes Implementation Plan
1 Pressure reduction skid CGS (active / monitor Modification of CGS
combination) with a minimum 50% redundancy Skid
including slam shut valve for over pressure protection
and creep relief valves.
2 Online odorization equipment designed to minimize Automated
fugitive emission during loading, operation and odorisation system to
maintenance. be used
3 Height of the vent shall be minimum 3 meters above Increase height of
working level. vents
4 Gas detectors shall be installed at critical location Install gas detectors in
the CGS and DRS
5 Pressure reduction for DRS (active / monitor Modification /
combination) skid with minimum 50% redundancy replacement
including two safety devices at least on of them shall be
a slam shut for over pressure protection / under –
pressure and inlet and outlet isolation valves.
 APPENDIX – 1
List of Critical Activities in CGD Network
Sr Critical Infrastructure / activity / processes Implementation Plan
No
6 Steel reinforced rubber hose conforming to IS 9573 Type IV Replacement of all
rubber hoses

7 Pipeline test record and joint radiography and cover in the To be submitted in
form of pipe book stages
8 HSSE Management System To be implemented

9 Emergency Response Plan, Disaster Management Plan and To be implemented.

written emergency procedures. Also, provide for an
Emergency Control Room, manned round the clock and
equipped with effective communication system and
emergency vehicles fitted with communication facilities,
first aid equipment, fire extinguishers, gas detectors, repair
kits and tools, maps, plans, MSDS etc at its disposal.
 APPENDIX – 1 (as per 2009 Regl.)
List of Critical Activities in CGD Network
Sr Critical Infrastructure / activity / Implementation Plan
No processes
1 Test record for radiography, ultrasonic To be submitted
test or other applicable NDT methods
(as carried out before commissioning)
2 Hydro-test (as carried out before To be submitted
commissioning) Report
3 Pipeline cathodic protection record To be submitted

4 Pipeline As-built records To be submitted

5 Intelligent pigging shall be carried out
to detect metal loss for the pipelines of
size NPS of 12 inches and above the
length of 10 Km and above.
If the pigging has not been done for
more than 5 years for sour gas and 10
years for sweet gas pipelines, then the
intelligent pigging shall be carried out
within two years, otherwise relevant
records shall be submitted.
 APPENDIX – 1 (as per 2009 Regl.)
List of Critical Activities in CGD Network
Sr Critical Infrastructure / activity / Implementation Plan
No processes

6 HSE Management System (including To be implemented

fire protection system

7 Height of the vent shall be minimum Increased height of vent.

3 meters above working level.

8 Gas detectors shall be installed at Install gas detectors for SCADA backed
compressor station, gas receiving and up system, elsewhere hand held gas
delivery terminals. detector shall be provided.

9 Environmental friendly fire For control room, switch gear and battery
extinguishing flooding system for room etc (CO2 is acceptable only for
closed space. unmanned station)

10 HAZOP shall be done for all the HAZOP reports to be submitted along
pipeline facilities with mitigation plan
 Schedule – 1A
Materials and Equipment
1. Materials to be used in facilities exposed to low operating
temperatures shall have adequate impact properties to prevent
brittle fracture at low temperatures.
2. Defined Carbon Equivalent for steel pipelines.
3. Line pipes should be hydrostatically tested in pipe mill using test
pressure that produces a hoop stress equal to 95% of SMYS
irrespective of material grade.
4. For new pipelines, the test pressure shall be held for a minimum
period of 15 sec.
5. Use of ductile iron pipes is not permitted for natural gas pipelines.
6. Equipment used in natural gas pipelines manufactured to standards
listed in Annexure – II of this standard shall also be accepted.
 Schedule – 1B
Welding
1. Preparation for Welding
 Notches or lamination on pipe ends are not permitted and must be
removed by cutting the pipe as a cylinder and re-beveling of pipe
end or by grading prior to welding.
 Re-beveled ends shall be re-examined by Ultrasonic or magnetic
particle methods if cut section is more than previously examined
length
 As far as practical seal welding of threaded joints should be
avoided.
2. Qualification of Procedures and Welders.
• For welding of gas pipeline shall be qualified as per API 1104 and
shall include toughness testing requirements as applicable for the
material to be welded.
• For station piping shall qualified as per ASME Boiler and Pressure
Vessel (BPV) Code Section IX or API 1104.
 Schedule – 1B
Welding
3. Inspection of Welds
• All Non Destructive Testing (NDT) including radiographic
examination shall be performed in accordance with the
requirements of API 1104 except that no root crack shall be
permitted.
• Carbon steel butt welds in natural gas pipelines shall be subjected to
100% radiographic examination and / or ultrasonic testing.
• The weld joints in vent and drain piping open to atmospheric
pressure need not be radio graphed/ ultrasonically tested. Such
welds however shall be visually examined and root pass of at least
10% of such welds shall be examined by Liquid Penetration Testing.
• All butt welded golden joints shall be subjected to 100%
radiography as well as examination by ultrasonic techniques.
• Socket welded golden joints shall be tested by LPI method or wet
Magnetic Particle Inspection (MPI) method.
 Schedule – 1B
Welding
3. Repair or Removal of Defective in Piping:
• Welds having defects shall be removed or repaired in accordance
with API 1104.
• Repaired weld areas shall be subjected to additional radiography or
ultrasonic testing after repair.
 Schedule – 1C
Piping System Components and Fabrication Details
• Various components shall be in conformities to standards and
specifications mentioned under ASME B 31.8
• Valves having pressure containing components including body,
bonnet, cover, end flanges etc. made of case iron or ductile iron
shall not be used.
• Flanges made of cast iron, ductile iron and non-ferrous materials
(brass or bronze) shall not be used.
• Flanges and flanged components shall not be used in buried piping
unless entire flange assembly is encapsulated in water tight and
electrically insulating materials.
• All studs and nuts used in NG pipelines shall meet the design
conditions as per applicable ASTM standards. Cast iron, brass or
bronze materials are not permitted.
• Fittings made of cast iron and ductile iron shall not be used.
• Plain and compressed asbestos gasket shall not be used.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING
• Cross country pipeline of less than NPS 4 shall not be used.
• Necessary calculations shall be carried out to verify structural integrity
and stability of the pipeline for combined effect of pressure,
temperature, bending, soil / pipe interaction, external loads and other
environmental parameters as applicable.
• Such calculations shall include…
 Buoyancy control and stability analysis for pipeline section to be
installed in areas subjected to flooding / submergence.
 Crossing analysis of major rivers.
 Evaluation of potential for earthquake occurrence along pipeline
route and carrying out requisite seismic analysis to ensure safety
and integrity of the pipeline system.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING
STEEL PIPE:
Following factors shall be considered while selecting Nominal wall
Thickness for the Steel pipe
 Overburden loads
 Dynamic and seismic loads
 Cyclic and vibratory loads
 Internal pressure fluctuations
 Geo-technical loads (including slides, differential settlement of
pipeline, loss or support, and thermal effect of the pipeline on soil
properties).
• The minimum wall thickness for cross country pipeline of size NPS 4”
and above shall be 6.4 mm.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING
STEEL PIPE:
• Location and layout of pipeline installations.
• Originating, intermediate and terminal facilities of pipelines such as
Tap-off stations, metering and regulating stations and sectionalizing
valve stations etc. should be located considering following aspects.
 Functional and pipeline hydraulic requirements.
 Environmental consideration based of Environmental Impact
Assessment (EIA) and Risk Assessment (RA) study for the
pipeline and stations.
 The HAZOP and risk analysis.
 The availability of space for future augmentation or facilities.
 Approachability, water table and flood level and natural drainage.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING
Equipment Layout
Following aspects to be considered while establishing station layout.
• Station equipment and their sizes
• Utilities requirement.
• Flaring / cold vending requirements.
• Operation and maintenance philosophy of station equipment.
• Requirement of space and access around the compressor shed /
house and other equipment.
• High Tension (HT) pole structure, Transformers, Breakers and
Motor Control Centre (MCC) etc. shall be located in non
hazardous area.
• Over Head power lines shall not be allowed to pass directly above
the process piping / equipment area and building
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING
Piping Layout
• Station piping may be installed above ground or buried. Buried piping
inside the terminal area should have a minimum cover of 1.0 m from
top of pipe to finish ground level.
• At internal storm water drain a minimum cover of 300 mm with
additional concrete slab extending at least 500 mm on either side of
pipe edge shall be provided.
• Where buried pipe comes above ground, the anti-corrosion coating on
the buried pipe will continue for a length of at least 300 mm above
ground.
• Platforms and crossover shall be provided for ease of operation and
maintenance of above ground piping where required.
• All the above ground piping should be properly supported to withstand
operational safety requirements.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING
Protection of Facilities
• Proper.ly laid out roads around various facilities shall be provided
within the installation area for smooth access of fire tenders etc. in case
of emergency.
• Proper industry type boundary masonry wall at least three mtrs high
including 0.6 mtrs barbed wire on top shall be provided all around the
major installation such as Sectionalizing valve (SV) station .
• For other installations 3.0 m high chain link fencing including 0.6 m
barbed wire on top can also be provided.
• Emergency exit with proper gate shall be provided in the earmarked
zone at all compressor stations.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING
Pipeline system should be equipped with
• Supervised Control and Data Acquisition (SCDA) System.
• Leak Detection System with provision for identification / Location of leak and
isolation of affected section.
• Communication facilities
• Emergency Response and Disaster Management Plan (ERDMP).
SCADA & Telecom Requirements
Gas pipeline system should be monitored and controlled using SCADA or
equivalent monitoring and control system
Compressor stations, SVs with remote operation capabilities as well as Telecom
Repeater Station including voice communication facilities / CP stations should
have suitable field signals connectivity with the control system.
Provision shall be made for transmitting the Pressure, temperature, Flow
measurement & gas composition data etc. through SCADA system to Central
Gas Management System
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING
Pipeline System and Component
Valves shall be provided for isolating sections of pipeline/ station in order
to..
a. Limit the hazard and damage from accidental discharge from
pipeline / piping.
b. Facilitate repair and maintenance of pipeline / piping facilities
and critical equipments.
• Mainline / Sectionalizing valves shall be installed on the pipeline for
the O&M and control of emergencies. Spacing between mainline
valves / sectionalizing valve in various Location Class shall not exceed
values given in Specification.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING

• Overhead power lines shall not be allowed to cross directly over the process
area of the valve section facilities.
• Mainline / SV should preferably be installed below ground and be provided
with suitable stem extension for ease operation.
• As far as practical, all mainline isolation valves should be with butt weld ends.
• Flanged end valves shall not be used in buried piping except at the locations
where hot tapping operation is to be carried out for which buried valve with
flanged ends may be used to facilitate mounting of hot tapping machine.
• Sectionalizing valves station shall have blow down or vent line connection to
evacuate the isolated pipeline section in case of an emergency and / or repair.
The size of the connections for blowing down the mainline line shall be not be
less than 1/3rd of the mainline size.
• All joints between the mainline pipe and the first valve on the branch, including
the inlet to first valve, should be welded joints.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING

• Minimum radius of Cold / Hot Field Bends given.

• Insulating joints shall be provided to electrically isolate the buried pipeline from
the above ground pipeline and station piping.
• Branch connection of size below NPS 2 are not recommended in buried
section.
• All branch connection from mainline shall be provided with an isolation valve
located at a minimum possible distance from the main pipeline.
• Threaded joints shall not be used in underground sections of cross country
pipelines.
• Threaded joints may be permitted in above-ground stations / above ground
section of SV station, only if a welded isolation valve is provided before it.
• The flanged joint shall be made using wither spiral wound metallic gasket or
metallic type gasket. Plain asbestos sheet / reinforced gasket / CAF gasket
shall not be used.
 Schedule – 1D
DESIGN, INSTALLATION AND TESTING

• Appropriate type of meters shall be installed at all custody transfer points

meeting requirements of AGA standards as agreed mutually between buyer and
seller.
• Dry gas meters may be installed at the upstream of the meters if required by
the manufacturer of meters.
• All Electrical equipment operating above 250 volts shall have two separate and
distinct connections to earth grids. Separate earthing grid shall be provided for
instrument ad electrical power.
• A reliable and dedicated communication system to interact between various
stations including SVs, with remote operation capability, along the entire
pipeline shall be designed, installed and maintained.
Thank You