Module :

CGS / CPRS-DRS / Steel Pipeline

CGS
CGS is the location of Custody Transfer from Transmission Company to
Distribution Company
Basic Function of CGS is to
Filteration

Pressure Reduction
Custody Transfer metering
Odorization
Preheating of NG if required

CGS Design Criteria

Upstream Pressure
Downstream pressure requirement

Downstream flow requirements including peak flow rates

Future projections of volume growth / flow-rate
Future expansion
Consider safety at all stages
Reference Standards : IGE/TD/13

Major Elements of CGS

Suitable Land
Below facilities with a hot stand by mode :

Filtration (Knockout drum, Filter Cum Separator)

Let Down Skid (PCV or PRV, SSV, CRV/SRV, Pressure Gauges)
Metering (Turbine / Ultrasonic / Orifice)
Odorization

Pre-heating
Ball Valves
Station Piping & Supports
Electrical Work
Instrumentation work (SCADA / Control Panels)

Typical City Gate Station

Typical City Gate Station

Pipeline

Type of Pipelines:
Steel Pipeline
Transmission Pipeline (Up to CGS)
Distribution Pipeline (CGS Downstream, Ring)
Poly Ethylene Pipeline
Medium Pressure (4 Bar)
Low Pressure (110 mBar)

Requirement / Considerations for Steel Pipeline

Delivering Natural Gas at required pressure to :
CNG Stations
CPRS
DRS

Covering entire City / Town by forming a RING in the periphery of the

city/town, to cater existing and forecasted demands

Consideration of future load of outskirts areas / developing areas

Future need of Looping / Interconnections

Steel Pipeline Reference Standards

Standard / Code

Title

PNGRB T4S

Technical Standards and Specifications including Safety Standards - CGD

ASME B 31.8

Gas Transportation and Distribution Piping Systems

ASME B 31.4

Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids

OISD-141

Design & Construction Requirements for Cross-Country Hydrocarbon Pipelines

OISD-214

Cross-Country LPG Pipelines

OISD-226

Natural Gas Transmission Pipelines and City Gas Distribution Networks

API 5L / ISO 3183

Specification for Line Pipe

API RP1102

Recommended practice for Rail and Highway crossings

API 1104

Standard for welding pipeline and related facilities

API 6D / ISO 14313

Pipeline Valves

DNV OS-F101

Submarine pipeline systems

Other References

Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN

Stages of Steel Pipeline Project

Conceptualization
Market surveys for deriving basic assumptions on demand
Study Alternatives
Initiation of Feasibility Study for Commercial / Technical viability
Feasibility Report
Route Selection & Surveys
Hydraulics / Simulations
Estimation of Project Cost
Market Demand Assessment
Project Approval
Engineering & Planning
Design & Sizing
Specifications & Tender Document preparation
Material Procurement / Release of Word Orders & Contracts
Acquire RoU / Permissions
Project Execution & Commissioning
Operation & Maintenance
As per AOMP

Route Selection / Surveys

Considerations / Detailing Required
Pipeline Length
Type of Terrain
No of Crossings / Type of Crossings
No of Valves (Section/Tap off/Future Extension)
Obstructions / Limitations
Identification of Authorities for permissions
Type of Surveys
Topographical
Geo-Technical
Population Density Index (Location Class)
Soil Resistivity
Cadastral

Design / Hydraulics / Simulation

Process
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
Roughness:
Type of Material

Roughness (microns)

Steel new pipe (</= 10 Yrs old)

With internal coating 10 15
Without internal coating 35 40
Steel old pipe (> 10 Yrs old)

With internal coating 15 20

Without internal coating 40 45

Design / Hydraulics / Simulation

Process
Efficiency factor: 0.85 1, factor shall be determined by duly
calibrating actual field data in the approved flow equation
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 (a)
Standard Temperature : 15.5 Deg C
Design Life:
Steel pipeline : 30 Years
PE Pipeline : 50 Years

Design / Hydraulics / Simulation

Location Class:
Class I
10 or fewer buildings in 1mile section
Class II
10 46 buildings
Class III
46 or more buildings
Class IV
areas where multistoried buildings and heavy
underground utilities
Basic Design Factor:
Location Class

F (design factor)

Class I

0.72

Class II

0.60

Class III

0.50

Class IV

0.40

Design / Hydraulics / Simulation

Location Class:
Class I
10 or fewer buildings in 1mile section
Class II
10 46 buildings
Class III
46 or more buildings
Class IV
areas where multistoried buildings and heavy underground
utilities
Wall Thickness calculation for steel pipeline
P = 2St FET
D
where
P
S
D
t
F
E
T

Design pressure
Specified minimum yield strength
Nominal OD of pipe
Nominal wall thickness
Design factor
Longitudinal joint factor
Temperature de-rating factor

Line Pipes Selection / Specifications

Type
ERW
Seamless
LSAW
HSAW

Material Grade
Nominal Diameter and Wall Thickness
Length (single random / double random)

Coating
Coal Tar Enamel Coating (BS 4164, AWWA C203)
Primer
Two layers of coal tar enamel & glass fiber Inner wrap
One layer of coal tar impregnated outer wrap
Coating thickness 4.7mm
3 Layer PE/ PP Coating (DIN 30670)

First layer of Fusion bonded epoxy

Second layer of extruded adhesive
Third layer of extruded PE/ PP
Coating thickness 2.0 to 3.7 mm
Fusion Bonded Epoxy Coating (CSA Z245.20)
350-500 micron thick single layer coating
600-800 micron thick dual layer coating

Fittings & Components in Pipeline

Fittings:
Elbows & Bends
Flow Tees
Insulating Joints
Weldolet / Sockolet
Flanges
Gaskets
Fasteners
Valves:
Sectional Valves
Tap Off Valves (future
provisions)

ASTM A 234
ANSI B 16.5 & 16.11

API 6D

Construction Stages

Pre-constructional Activities

Construction Activities

Testing and Commissioning

Handover to Operations

Construction Stages
Pre-constructional Activities
Activity

Description / Steps

Planning

Resource & Equipments

Scheduling

Scheduling of activities & milestones

Material Ordering / Delivery schedule

Mobilization

Mobilization of Manpower & Equipment

Procedures /
Qualifications

Approval of procedures for various activities

Welding Preparedness (WPS/PQT, EQT, Welders Qualification)
Insulators qualification

Training

Safety Trainings
Site Briefing

Readiness to Start
Construction

Kick off Meeting

Construction Stages

Construction Activities

Activity

Description / Steps

Grading

RoU clearance, Marking and cleaning

Trenching

At Correct depth
With the help of Machines or Labors as per site requirement

Stringing

With the help of Hydra or Side Boom

Welding & NDE

Welding as per approved procedures by qualified welders

Non Destructive Testing X-ray/UT/MPT/DPT

Joint Coating

Heat Shrinkable sleeves or R-95 (Material TC required)

By qualified insulator

Lowering

Lowering of pipe section

Tie-in Joints

Special Crossings

River/ Drains/Railway/ Highways/ Canals

By HDD or Push Jack Boring

Backfilling &
restoration

Backfilling & Crowning

Manually / with Machine as per site requirement

Construction Stages

Testing & Commissioning, Handover to O&M

Activity

Description / Steps

Cleaning

Cleaning of pipeline prior to start hydrostatic testing

Hydrostatic
Testing

Water filling, Air volume calculation before pressure holding

Pressure Holding & Monitoring (min.24 hours after temp. stab.)
Dewatering & Cleaning

Valves

Installation of Valves
Construction of Valve chambers

TCP

Installation of TCP
Review readings

Readiness

Readiness review of pipeline jointly by Projects/O&M team including

review of documents/records/deviations, route visit, etc
Preparation of punch points, Compliance to HOTO procedure
Intimation to Local Authorities prior to Gas in.

Purging &
Commissioning

Purging with Nitrogen. Ensure <2% O2 before gas in

Commissioning

Hand over

Handover to O&M for routine operations / maintenance

Project Management in GSPC Gas

Execution by Contractor
Inspection & Certification for quality by TPIA

Project Management by PMC

Overall monitoring by GSPC Gas

Photo : Steel pipeline site

CPRS/DRS : typical schematic

Photo : DRS/CPRS

Components
Filter : filter cartridge, DP Gauge
Two streams of :
Active regulator
Monitor regulator
Slam Shut off Valve
Creep Relief Valve

Pressure Gauges
Pilot regulators
Ball Valves

Design Parameters
Maximum inlet pressure: 49 BarG
Differential Pressure (Min.) : 0.5 BarG

Outlet pressure range: 4 BarG

Flow rate @ min inlet pressure: 2000 SCMH/ 5000 SCMH
End Connections : 4/6 depending upon capacity

Land Requirement
30-36 Sq. Meter
No overhead electric lines / min. Distance 6 mtrs from HT/LT
Land should not be in a water logged area
Safe distance from Garbage collection/storage point

Installation & Commissioning

Proper platform to be constructed
Inlet/outlet piping Installation as per the approved layout

Maintain proper alignment of installations

Proper support to inlet/outlet piping
Earthing to be provided
Vent height should be at least 3 meter from the ground level

Fencing of area recommended

Caution Board to be provided
Site Acceptance Testing before commissioning
Readiness review / HOTO with O&M
Gas in

Photo : Steel Valve Chamber

Thank You