Basic Concepts of Design &

Construction of
Gas Distribution Network
GSPC Gas Company Limited
December, 2009
Gandhinagar
City Gas Distribution – An
Overview
WHAT IS CITY GAS
DISTRIBUTION?

CGD is the last component of the

Natural Gas value chain delivering
Natural Gas to end users in town
and cities to meet the demand for
a cleaner, more efficient,
economical and environmentally-
friendly energy source.
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.
Design gas storage / Gas sourcing for
maximum survival period
Consider Health, Safety & Environment at
all stages
Steps in the design of Gas
Distribution System
• Market demand estimated based on comprehensive
field survey of units covering domestic, commercial,
industrial and transport sectors.
• Demand forecast projection is carried out for 20-25
years.
• Peak hour consumption estimated for network design.
• The system is to be designed based on 20-25th year
projected demand at peak load in a phased manner.
• Reconnaissance Route Survey within the town to
identify suitable routes for laying pipelines, locations
for City Gate Station, District Regulating Station &
CNG Station
Steps in the design of Gas
Distribution System
• Network design and optimization with
available software
• Design of Mother Station and Daughter /
Daughter booster station for CNG supply to
automobiles
• National / International standards adopted
for design.
• Project implementation done subsequently.
 Battery Limits
Transmission Distribution
Transmission Line

Distribution Zone

City Gate Station

CGD SYSTEM BASIC
CONCEPT

HP Network

CITY GATE
MPB Network

CNG Mother Stations

DRS DRS DRS

MPA Network

Domestic and
Commercial
LP Network
Users
 CGD PRESSURE REGIMES
Outlet
Sr. No. Network Component Inlet from Inlet Pressure Outlet to
Pressure

1 CGS Transmission line 99 - 60 barg 26 barg Steel Grid

2 Steel pipeline CGS 26 barg 26 – 14 barg DRS / CNG

3 DRS Steel pipeline 26 – 14 barg 4 – 1 barg MP MDPE pipeline

4 Service Regulators (SR) MP MDPE Pipeline 4 – 1 Barg 110 mBarg LP MDPE Pipeline
Industrial MRS &
5 MP MDPE pipeline DRS 4 barg 4 – 1 barg Commercial
Connections
Regulator of Domestic /
6 LP MDPE Pipeline SR 110 mBarg 110 – 50 mBarg Commercial
Connections

1.5 barg or
MP MDPE pipeline 4 – 1.5 barg customer specific Industrial internal
7 Industrial MRS
Steel pipeline 26 – 14 barg pressure within pipeline
the supply range
Online / Mother CNG
8 Steel Pipeline 26 - 14 barg 250 Barg Vehicle at 200 Barg
Station

9 Domestic Connections LP MDPE Pipeline 110 – 50 mBarg 21 mBarg Meter & Gas Stove

75 mBarg or
LP MDPE Pipeline 110 – 75 mBarg customer specific
10 Commercial Connections Meter & Gas Stove
MP MDPE Pipeline 4 – 1 Barg pressure within
the supply range
City Gas Distribution –
Applicable Codes &
Standards
European Standard
S. No. STANDARD NO. DESCRIPTION

Gas supply systems - Gas Pressure Regulating Stations for

1 EN 12186
Transmission and Distribution. Functional Requirements

2 EN 12279 Gas pressure regulating - installations on service lines

Gas supply systems - Natural gas measuring stations - Functional

3 EN 1776
requirements

Gas supply systems- Pipeline for maximum operating pressure

4 EN 1594
over 16 bar- Functional requirements
AMERICAN SOCIETY OF
MECHANICAL ENGINEERS
(ASME)
S. No. STANDARD NO. DESCRIPTION

1 ASME B16.11 Forged Steel Fittings, Socket-Welding and Threaded

2 ASME B31.3 Process Piping

3 ASME B31.8 Gas Transmission and Distribution Piping Systems

4 ASME B16.5 Pipe line flanges and flanged fittings

5 ASME B16.9 Factory - Made Wrought Steel Butt welding Fittings

Section- IX- Qualification Standard for Welding and Brazing

ASME- Boiler and Pressure Vessel
6 Procedures, Welders, Brazers, and Welding and Brazing
Code
Operators

ASME Boiler and Pressure Vessel Part C- Specifications for welding Rods, Electrodes, and Filler
7
Code- II Metals

8 ASME Boiler & Pressure Vessel Code Section - V, Non-destructive Examination

ASME Boiler and Pressure Vessel

9 Section-II Materials Part A- Ferrous Material Specifications -
Code
BS/DIN/ISO AND OTHER
STANDARDS
S. No. STANDARD NO. DESCRIPTION

International Standard for Petroleum and natural gas industries - Induction

1 ISO- 15590-1
bends, fittings and flanges for pipeline transportation systems

3 BS 6755: Part 2 Testing of Valves

Coatings of corrosion protection tapes and heat-shrinking products for

4 DIN 30672, Part I
pipelines for operational temperatures upto 50oC

6 DIN 30670 Polyethylene coatings for steel pipes and fittings

OIL INDUSTRY SAFETY
DIRECTORATE (OISD
STANDARDS)
S. No. STANDARD NO. DESCRIPTION

1 OISD-226 Natural Gas Transmission Pipelines & City Gas Distribution Networks

2 OISD-GDN-115 Guidelines on Fire Fighting, Equipment and Appliances in Petroleum Industry

Fire Protection Manual-

3 Fire Engines, Trailer Pumps and Hydrant Systems
TAC

4 OISD- Standard- 141 Design and Construction requirements for cross country hydrocarbon pipelines

5 OISD-Std-118 Layouts for Oil and Gas Installations

AMERICAN PETROLEUM
INSTITUTE (API)
S. No. STANDARD NO. DESCRIPTION

1 API Standard 1104 Welding of Pipelines and Related Facilities

4 API Specification 5L Specification for Line pipe

Specification for Pipeline Valves ( Gate, Plug, Ball and

5 API Spec. 6D
Check Valves)

7 API Standard 1102 Specification for steel pipeline crossing & highways.
AMERICAN GAS ASSOCIATION
(AGA)

S. No. STANDARD NO. DESCRIPTION

1 AGA Purging Principles and Practices

2 IGE/TD/1 Steel Pipelines for High Pressure Gas Transmission

5 AGA: Report No. 7 Measurement of Gas by Turbine Meters

6 AGA Report No.3 Orifice metering of Natural Gas and other related Hydrocarbon fluids

Compressibility factors of Natural Gas and other related Hydrocarbon

7 AGA-Report No 8
gases
City Gas Distribution –
System Components
CGD - Infrastructure
Major Constituents of CGD are;
City Gate station
Pipeline Network
Steel Pipelines
Poly Ethylene Pipelines
GI / Cu Pipes
Regulating Stations
District Regulating Stations
Service Regulators
Domestic / Commercial / Industrial
Regulators
Metering Stations / Metering & Regulating
Stations
CNG Stations
CITY GATE STATION (CGS)
CGS is the location of Custody
Transfer from Transmission
Company to Distribution Company.
CITY GATE STATION (CGS)
 Inlet & Outlet isolation valves
 Knock Out Drum (KOD), If required
 Filter
 Metering Unit (Turbine / Orifice / Ultrasonic)
 Gas Chromatograph (GC), If required
 Pre-heater (if required)
 Pressure reduction skid comprising
 Active & monitor Regulators
 Stream discrimination arrangement
 Slam shut valve for over & under pressure
protection
 Creep relief valves.
 Odorising Unit
STEEL PIPELINE
 The Steel Grid pipeline sizes is 12”NB & 8”NB whereas,
spur lines shall be of 6”NB & 4”NB.
 Steel pipelines used in the distribution system is fully
coated. The coating is extruded polyethylene, with each
weld joint coated with either heat shrink sleeves or field
applied tape.
 Prior to the pipeline being put into service, the
distribution pipeline to be non-destructively tested by two
methods. Firstly, welds would be radio graphed and,
secondly, the completed pipeline extension would be
hydro-statically tested at a higher pressure than its
operating pressure.
 After hydrostatic testing, the pipeline to be dried, purged
and filled with natural gas. The testing and
commissioning procedures will be detailed during the
detailed design phase of the project.
STEEL PIPELINE
To protect the pipeline from corrosion, a cathodic
protection (CP) system of impressed current is
proposed. During the detailed design phase, the
CP capability of the existing transmission system
will be investigated to establish if it has the
capacity to provide CP to the extension. If it is
found that the existing system does not have the
capacity, additional CP facilities will be designed.
The steel grid is installed at a minimum depth of
1.0 meter cover, and in accordance with Indian
requirements.
MDPE PIPELINE
The distribution pipe is with Standard
Dimension Ratio (SDR 9) for 20 mm, (SDR) 11
from 32 mm up to 63 mm & (SDR) 17.6 for
above 63 mm. The term SDR is defined as the
normal outside diameter (DN) divided by the
minimum wall thickness.
It is standard practice in India to have a
minimum 1.0 meter cover. This additional depth
in a densely populated area would be
recommended.
All MDPE pipe back filled with sand around it to
protect the plastic material.
MDPE PIPELINE
 Medium Density PolyEthylene
(MDPE) Pipes
 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
 Pressure Class: SDR 9 (dia 20 mm), SDR 11 (dia 32 & 63 mm)
and SDR 17.6 (dia 90, 110, 125 and 160 mm).
 Operating pressure: 4 bar (g).
 Operating temperature range: - 10 0 C to + 40 0 C.
Advantages of PE pipes
 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
 Low heat conductivity (small thermal loss)
 Smooth surfaces (low pressure losses due to low
pipe friction)
 Easy to transport, handle and lay
 Longer life
Advantages of PE pipes
 Easier and speedier joining techniques to ensure
leak tight joints by employing electro fusion
techniques
 Higher productivity, i.e., reduction in installation
time (15 minutes in case of PE against 4 hours in
case of steel), thereby lesser inconvenience to
public
 Reduced number of joints, hence safer and leak free
system
 Less time is consumed to repair PE damages as
compared to steel damages
 Good squeeze off properties
Advantages of PE pipes
 Longer design life of PE pipes (50 years) as
compared to steel pipeline (30 years)
 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
MDPE Fittings
 Tech Spec: ISO 8085-3 or EN
1555-3
 Material Grade: PE 100
 Terminal pin size: 4 or 4.7
mm
 Voltage: 39 – 40 Volts.
 Color: Black.
 PE Stop Off Valves (Typical)
 Standard: ASME B 16.40, EN 1555-4
 Pressure Class: SDR 11.
 Design Pressure: 5.5 bar (g).
 Design Temperature: 45 0 C.
 Operating Temperature: 10 0 C to 45 0 C
 End Connections: PE Material (Spigot Type)
 Stem Extension: Integral stem extension
required (Minimum 690 mm from the Top
of Pipe)
 Valve Design: One piece construction.
 Ball position Indicator: Open / Close limits
required.
Crimping Fitting (Typical specification)

 Used to connect u/g PE pipes with a/g GI pipes

 Operating Pressure: up to 4 bar (g)
 Operating Temperature: 40 0 C
 Hydrostatic Test Pressure: Minimum hold Pressure
of 10 bar (g), for 1 hour duration
 Pneumatic Test Pressure: Minimum pressure of 6
bar (g), for 1 hour duration
 Pull out Test:
• Shall not fracture within the jointed assembly
• Shall withstand the Pneumatic pressure leak test
• Shall not leak
District Regulating Stations
District Regulating Station
District Regulating Station
Service Regulators
Typical requirements of Pressure
Regulators used for domestic and
small I&C customers

 Maximum Inlet Pressure: Maximum 4 bar (g)

 Nominal Outlet Pressure: 100 mbar (g)
 Flow capacities: 50, 150, 200, 250 scmh
 End connections: Threaded (& Tapered) as per BS 21
 Operating ambient temperature: up to 45 0C
 Lockup: Maximum pressure, under no-flow condition, up to 125
mbar (g)
 Creep relief valve: To protect against downstream over pressure
at low flows or in the event of valve seat malfunction, preset to
140 mbar (g)
 Over Pressure Shut Off (OPSO): Device to protect against
downstream over pressure, preset to 160 mbar (g)
 Under Pressure Shut Off (UPSO): Device to protect against
downstream under pressure with a pressure setting range 40
mbar (g) to 65 mbar (g)
Regulator Selection
Information required to select a regulator:

 Maximum and Minimum inlet pressure

 Required outlet pressure
 Maximum flow rate
 Tolerance on outlet pressure
 Size of pipework
 Type of gas
 Safety features required
 Size of orifice
 OPSS, UPSS & Relief settings
 Installation indoors of outdoors
 Orientation of regulator
Gas Meters
The most common types of meters used are:

Diaphragm
Rotary Positive Displacement (RPD)
Turbine
Diaphragm Gas Meters (Domestic)
 Tech Spec: EN 1359
 Capacity: 2.5 m3/hr
 Rangeability or TD ratio: 1:150 or
better
 Nominal Working Pressure: 21 mbar
(g)
 End Connections: ¾”, as per BS 746
(Male)
 Center to Center distance: 110 mm
between inlet and outlet connections
Diaphragm Gas Meters (Commercial)

 Tech Spec: EN 1359

 Capacity: 10, 25, 40, 65
scmh
 Rangeability or Turn Down
ratio (ratio of Qmax and Qmin):
1:150 or better
 Nominal working Pressure:
100 mbar (g)
 Pressure rating : Suitable to
withstand maximum working
pressure of 200 mbar (g)
 Rotary Positive Displacement (RPD)
meters
 Tech Spec: EN 12480
 Volumetric meter
 Appropriate for medium size
load
 Typical Turndown 35:1 to
50:1
 Accuracy ±1%
 Large measuring range
 Not sensitive against
disturbances
 Not sensitive against fast
changes in flow rate
 Needs lubrication
Rotary Positive Displacement (RPD)
meters
 Rotary Positive Displacement (RPD)
meters
Advantages Disadvantages

Good flow turndown Filtration essential (50 microns or

finer)
Tolerance to installation effects Requires lubrication
and load behaviour
Accuracy ±1% Physical size at large capacities

Much smaller than a diaphragm Can create pressure fluctuations

meter on on/off loads
Very long life Can cut off gas supply when it fails

Expensive
 Industrial Metering Station (IMS)
 IMS are used to measure gas supplied to
Industrial consumers
 Main component in IMS is filter, Isolation
Valves, RPD Meters with EVC & Modem,
Regulators (If low pressure requirement) and
Non return Valve
 Inlet pressure range – 1.5 Barg to 4 Barg
 Outlet pressure – As required by customer
 MRS components
 Inlet & Outlet
isolation valves
 Filter
 Pressure regulator
with a built in slam –
shut device
 Relief valve
 Strainer
 Flow Meter (RPD,
Turbine, etc.)
GI ERW Pipes

 Tech Spec: IS 1239 (Part 1)

 Types used: Medium Class and Heavy Class
 Material: IS 1387
 Pipes shall be screwed with Taper threads
 Threads: Tapered and conforming to BS 21
 Galvanizing: IS 4736
• Coating requirements: Mass of coating is 400 gms /
m2
 Test Pressure: 5 MPa
 Powder Coating:
• Powder Material: Pure Polyester
• Application: Electrostatic spraying (40 – 90 KV,
Manual / Automatic)
GI Fittings (Malleable Cast Iron)
 Tech Spec: IS 1879
 Material: IS 2108 Grade BM 290
 Dimensions: IS 1879
 Threads: IS 554
• All Internal & External Threads shall be
tapered
• Chamfer shall have included angle of 900
+/- 50 for Internal threads & 700 +/- 100
for external threads
 Galvanizing: IS 4759
• Coating requirements: Mass of coating is
700 gms / m2.
Forged Fittings (Wrought
Steel Iron)
 Tech Spec: IS 1239 Part 2
 Material: IS 1387
 Dimensions & Tolerances: IS 1239 Part 2
 Threads: IS 554
• All Internal & External Threads shall be tapered
• Chamfer shall have included angle of 90 0 +/- 50 for
Internal threads & 700 +/- 100 for external threads
 Galvanizing: IS 4759
• Coating requirements: Mass of coating is 700 gms /
m2.
Brass Valves
(Meter Control Valves, Riser Isolation
Valves & Appliance Valves)
 Tech Spec: EN 331
 Pipe Nominal Diameter :- ¼” to 2” NB.
 Operating Pressure: 4 bar (g).
 Operating Temperature: 10 – 60 0 C.
 Material: Nickel Plated Forged Brass.
 Pattern: Full Bore, Quarter Turn Ball
Valve.
 Handle: Suitable Metallic Handle,
Lever / Knob / Cap Type with yellow
coating (Powder / Plastic) on Surface
marked as “GAS”
 End connection: Screwed, As per BS
EN 10226-1, Tapered Threaded,
Female
Meter Regulator
 Gas flow rate: 2.5 m3/h
 Nominal Inlet Pressure: 100 mbar (g)
 Maximum Inlet Pressure: 160 mbar (g)
 Nominal Outlet pressure: 21 mbar (g)
 Lock-up pressure: Shall not exceed 30 mbar (g)
 Low pressure Cut-Off: at inlet pressure of 11.5 mbar to 15 mbar
(g).
• Re-pressurization safety device is fitted which prevents the
regulator from re-opening when the inlet pressure is restored
unless there is a downstream backpressure, i.e., all connected
appliances have been turned off.
 End connections: Right angled inlet and outlet connections of
¾”x ¾” BSPT (Female)
Rubber Hose (flexible and
steel wire braided)
 Used to connect the appliance,
inside the house of domestic
customer
 Tech Spec: Type IV of IS 9573
 Size: 8 mm NB
 Material: It consists of
A. Lining: Synthetic rubber like
Nitrile Butadiene Rubber (NBR) or
Chloroprene Rubber (CR)
B. Reinforcement: Wire reinforced in
braided form in between the
lining and the cover
C. Cover: Consolidated by wrapping,
and uniformly vulcanized to give
good adhesion
Rubber Hose (flexible and
steel wire braided)
 Mechanical Properties:
• Tensile strength: Minimum 10 MPa for lining and cover
• Elongation at break: Minimum 200% for lining and 250%
for cover
 Salient features:
• Strong (Steel wire reinforced) hence rats can't bite
through steel wire Flame resistant
• Abrasion, ozone and weather resistant, hence no cracks
• Low temperature flexibility
• Minimum burst pressure of 0.5 MPa
• Long life (5 years)
• Grip strength (to nozzle of appliance)
City Gas Distribution –
Network Design
System Basics
 System of units
 The International System of Units (SI), also known as
the "Metric System" to be used. The International
Gas Union (IGU) has also recommended to
generalize the use of the SI system in all matters
relating to Gas and Gas facilities. The SI system shall
be in compliance with ISO 1 000. The SI system shall
be of general use with exception to the following:
 Gas Volumes and Flow,
 Pressure,
 Temperature,
 Heating Value
 Pipeline and Piping Nominal Diameters shall be
expressed under either one or both systems
where "Common Practice" of Pipeline and Piping
Engineers so suggests;
System Basics
Data relating to equipment shall use that
system of unit that is most common in the
relations with suppliers.
Where advisable for good understanding,
the corresponding value in the other System
of Units shall be mentioned between
brackets.
Results of technical calculation and related
figures issued from specific software shall
remain expressed in that system of units
that is used by the relevant software.
Steel Pipelines
Steel mains
 Notwithstanding the major advantages of
polyethylene (PE), steel pipelines remain necessary
as follows;
High-Pressure Mains
 Location class: the design of High pressure mains
shall consider requirements as for Location Class 4
(ASME 31.8) to allow timelessness should the
environment change in the future.
 Wall thickness: according to ASME B31.8 – Section
841.11 with Design factor of 0.4. In addition, wall
thickness shall, in no way, be lower than the values
below in function of Nominal Diameter (ND)
Steel Pipelines
 4 in. and below - 3.9 mm
 6 in. - 4.5 mm
 8 in. - 5.0 mm
 10 in. - 5.6 mm
 20 in. - 6.3 mm
GSPC Gas is using 6.4 MM Wall thickness.
Steel Grade: The Design Concept considers
API Grade X 52 Steel quality to offer maximum
flexibility for line pipes procurement.
Bend Radius: to allow pigging under special
circumstances
Steel Pipelines
Steel Pipes
 API 5 L - Line Pipes
 ASTM A 106 - Seamless Pipes
 ASTM A 333 - Seamless & Welded Pipes for low
temperature services
Location Class
 Location Class I - 10 or fewer buildings in 1 mile section
 Location Class I I - 10 – 46 buildings in 1 mile section
 Location Class III - 46 or more buildings in 1 mile section
 Location Class IV - Areas where multi story building & heavy
traffic plus other underground utilities
Steel Pipe Design Formulae
P = (2 St/D) * FET – As per ASME B 31.8, 841.11 (a)

t = PD / 20fs
Steel Pipelines
Above Ground Mains
Polyethylene being forbidden for above
ground crossings, if any, steel mains sections
are needed at the crossing with PE/steel
transition fitting to be buried with the
adjacent PE mains.
Steel Pipelines
Process Design
Wey-mouth Formulae
Q = 0.0813 * (d)2.6667 * {(p12-p22)1/2 /
(S * L)1/2 }

Velocity
V = Q / A
Velocity for filtered gas to be 40 m/s
& unfiltered gas to be 20 m/s
maximum.
Example

1 2
Example
 Q = 2,00,000 SCMD i.e. 9,166.66 SCMH
 Using Wey Mouth Formulae: Q = 0.0813 * (d) 2.6667 * {(p12-
p22)1/2 / (S * L)1/2}
 9166.66 = 0.0816 x (d)2.6667 * {(16.0132-10.0132)1/2/(S* L)1/2}
 d = 198.52 mm : Calculated Diameter.
 We have to select diameter from the available range e.g.
200.1 mm from API 5 L
 Now, P1V1 = P2V2
 1.013 * 9,166.66 = (9.32+1.013) * V 2
 V2 = 898.8 M3 / Hr = 0.2497 M3 / Sec.
 Now, for Velocity, Q = A * v
 0.2497 = (3.14/4) * (200.1 * 10 -3)2 * v
 V = 7.94 m/s
 Now, for Wall Thickness, t = (P*D) / 20fs
 t= (16.013 * 219.1) / (20 * 0.29 * 241)
 t = 2.5099 mm
Example

1 2 3

2
1
Polyethylene Pipelines
 MRS (Minimum Required Strength)
 The MRS value represents the long-term
circumferential stress in the pipe under which the
break may occur after 50 years at the earliest.
 Stress = MRS / C, where C is overall service coefficient
 The minimum value of C for the material to be used
for Gas application is 2.
 MAOP (Max. allowable Operating Pressure)
 MAOP = (20 * MRS) / [C * (SDR-1)].
 Standard Dimension Ratio
 SDR = Dn / En
 SDR used in GSPC Gas is SDR 9, SDR 11 & SDR 17.6
 Standard followed by GSPC Gas
 IS 14885: 2001
Polyethylene Pipelines
Base resin
 The PE resins of “Third Generation” (PE 100 or MRS
10) in full compliance with detailed specification is
being used. First Generation is PE 63, second PE 80
& Third generation is PE 100.
Wall thickness
 The MDPE network designed and qualified for a MOP
of 4 bar.
 The “Network analysis” and resulting structure and
behaviors are based on such design. PE line pipes
wall thickness shall be in accordance with the
following SDR
 Gas mains (ND ≥ 90 mm): SDR 17.6
 Gas mains and Service lines (ND ≤ 90 mm): SDR 11.
 Service lines (ND = 20 mm): SDR 9
Polyethylene Pipelines
 Different Material used for PE Pipes
The following materials have been approved to date:
 Solvay Eltex TUB 121(Black) or Eltex TUB 125(Orange) PE
100
 Borealis HE 2490 PE 100
 Fina Finathene XS 10 B PE 100
 Dow BG 10050 PE 100
 Elenac Hostalen CRP 100 PE 100
Codes:
 Manufacturer Commercial Brand Name Code(*)
 SOLVAY ELTEX TUB 121/125 E3
 BOREALIS HE 2490 N3
 FINA FINATHENE XS 10 B F3
 DOW BG 10050 D3
 ELENAC HOSTALEN CRP 100 H7
Polyethylene Pipelines
Process Design
 Wey-mouth Formulae
 Q = 0.11672 * (d)2.664 * {(p12-p22)0.544 / (S *
L)1/2}
 Velocity
V = Q / A
 Velocity for filtered gas to be 40 m/s &
unfiltered gas to be 20 m/s.
 Being a complex network, required
specialized tools for Planning & Designing
the network. GSPC Gas use SynerGEE
software for designing the PE Network.
PNG Domestic & Commercial
Connection
Process Design
Polyflow Formulae
Q = 1.522786 * 10-3 * (d)2.623 * {(h/L)0.541}
Peak Gas flow is assumed @ 0.5 SCMH
for one house
Being a standard PNG Connection, we
have standardize the design of PNG
Network as follows;
 ½” GI pipes up to G + 4 apartments OR 5 connections
in case of raw house.
 1” GI Pipe above 5th Floor apartment OR above five
connections in raw house.
PNG Domestic & Commercial
Connection
Route Selection for GI / Copper Pipe Installation
 Route selection for GI pipe installation shall be carried out as per
the guideline given below;
 Pipe shall not be installed on un-plastered wall or in the house under
construction.
 Pipe shall not be installed 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 shall be away (minimum distance of 200mm) from
the electrical line.
 There shall be minimum change of directions and minimum no of
threaded joints.
 Maximum two Point in the kitchen for gas stove only.
 Compound gate or doors and windows inside the house shall not hit
the Gas pipeline.
 Copper installation should be a minimum 300mm away from heat
source and Electrical installations. If it is not possible for copper
installation then suitable protection should be given.
 If the copper pipe installation is carried out inside cupboards, there
should be a provision for adequate ventilation like louvers/holes in
cupboard doors.
PNG Domestic & Commercial
Connection
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 and individual meter control valve shall be
installed for each connection.
 The riser isolation valve shall be installed at a convenient
height so that it is easy to operate the valve in emergency.
 Meter Regulator:
 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.
PNG Domestic & Commercial
Connection
 Gas Meter:
 Gas Meter shall be installed 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.
 Meter shall be installed at convenient height so that it is easy
for the meter reader to take correct readings.
 The meter shall never be positioned very near to Electric
Line. A minimum distance of 200 mm shall be maintained.
 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.
Clamping
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.
 If the length of pipes is not correct, the threaded joints come
under heavy stresses, which may ultimately cause gas leakage.
 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.
 The condition of thread die and pipe vice jaws shall be checked
regularly and shall be free from defects.
 Cutting fluids (oils) shall be used while thread cutting.
 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.
G.I. Pipe Installation &
Clamping
 Teflon tapes shall be wrapped on threaded portion of the pipe with
minimum three overlaps. The Teflon tap should be of approved make
and gauge.
 The no of clamps shall be adequate. 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.
 Distance between two clamps shall not be more than 2 meter; the
gap between riser and wall shall be minimum 25 mm.
 Clamps shall be installed in a straight line and shall be parallel to
each other.
 The clamps shall be fixed properly on the walls and should grip pipe
in position.
 For wall crossing, drill the hole with the help of electrical drilling
machine in such a way that plaster and tiles shall not be damaged. It
shall be ensured that there is no concealed wiring or any other fitting
on the opposite side of the wall for a particular location of drilling.
G.I. Pipe Installation &
Clamping
 Self-adhesive anticorrosive tape shall be wrapped on the
pipe with 50% overlap.
 Casing sleeve shall be installed in wall for wall crossing.
 Alignment of the pipeline shall be maintained.
 Whenever compound gate, house door or window 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.
 Wherever powder coating is peeled off during fitting and
tightening of the pipe, touch up shall be done after the
installation is completed by two coats of approved paint.
 Prior to installation all pipes and fittings shall be checked
internally to ensure that they are free from any obstruction.
 PE to GI (transition fitting) joint shall be provided above
ground.
Installation of Valves,
Regulator & Meter
 Union and testing T shall be installed before riser
isolation valve.
 Meter control valves, Meter regulator and Gas meter
shall be protected from the over tightening of the thread.
 Valves, Meter regulator and Gas meter shall be installed
with the clamps on both sides. As far as possible hex
nipple shall not be used for connecting. Both side
threaded 3” to 8” long pipe nipple shall be used.
 Gas meter, regulator and installed piping shall be aligned
properly.
 Flow direction of the gas meter shall be checked before
installation.
 Flat rubber washer shall be checked and ensure at inlet
and out let of the adaptor joint to the meter.
 Pipe nipple shall be installed between elbow and
regulator to avoid direct load of line or riser on regulator
and a clamp must be provided on the pipe nipple.
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. Pneumatic testing pressure shall be kept 1.5 times of the
working pressure and should be maintained for 30 minutes.
 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.
Conversion of Burner
 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 rubber hose.
 The length of rubber hose shall not exceed 1.5 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.
All the Best