Beruflich Dokumente
Kultur Dokumente
FIRST EDITION
August2007
FOR RESTRICTED
CIRCULATION ONLY
No..
Prepared by :
Oil Industry Safety Directorate (OISD) publications are prepared for use in the oil and gas
industry under Ministry of Petroleum & Natural Gas, Govt. of India. These are the property of
Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and loaned or
exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy and reliability of the data contained in
these documents, OISD hereby expressly disclaims any liability or responsibility for loss or
damage resulting from their use.
These documents are intended only to supplement and not to replace the prevailing statutory
requirements.
iii
FOREWORD
Oil Industry in India is more than 100 years old. Over years, a variety of practices have been in
vogue because of collaboration / association with different foreign companies and governments.
Standardisation in design, operating and maintenance practices was hardly in existence at a
national level. This lack of uniformity, coupled with feed back from some serious accidents that
occurred in the recent past in India and abroad, emphasised the need for the industry to review
the existing state of art in designing, operating and maintaining oil and gas installations.
With this in view, the Ministry of Petroleum & Natural Gas in 1986 constituted a Safety Council
assisted by the Oil Industry Safety Directorate (OISD) staffed from within the industry in
formulating and implementing a series of self regulatory measures aimed at removing
obsolescence, standardizing and upgrading the existing standards to ensure safer operations.
Accordingly, OISD constituted a number of functional committees comprising of experts
nominated from the industry to draw up standards and guidelines on various subjects.
The present document on Cross-country Natural Gas Pipelines and City Gas pipeline were
prepared by the Functional Committee on Natural Gas Pipelines. This document is based on
the accumulated knowledge and experience of functional committee members and various
national and international codes and best practices. This document is meant to be used as
supplement and not as a replacement for existing codes and practices.
This standard in no way supersedes the statutory requirements of bodies like IBR, CCE, Factory
Inspectorate or any other Government Body which must be followed as applicable.
This document will be reviewed periodically for improvements based on the new experiences and
better understanding. Suggestions may be addressed to:
The Co-ordinator
Committee on Cross-country LPG Pipelines,
Oil Industry Safety Directorate
7th Floor, New Delhi House
27, Barakhamba Road
New Delhi-110 001
iv
FUNCTIONAL COMMITTEE MEMBERS
------------------------------------------------------------------------------------------------------------
NAME ORGANISATION
------------------------------------------------------------------------------------------------------------
LEADERS
Transmission Pipelines
Sh. Ashwani Soni Engineers India Limited, New Delhi
MEMBERS
Sh. V. K. Khanna Oil and Natural Gas Corporation Limited, Mumbai
MEMBER CO-ORDINATOR
SH. S. K. NANDY Oil Industry Safety Directorate, New Delhi
In addition to the above, several other experts from the industry contributed in the preparation,
review and finalization of this document.
v
PART-1
1 INTRODUCTION 2
2 SCOPE 2
3 DEFINITIONS 2
5 DESIGN 5
8. MATERIALS 17
9 CORROSION CONTROL 18
10 CONSTRUCTION 20
15 ABANDONMENT OF PIPELINE 36
16 MANAGEMENT OF CHANGE 37
17 DEFECT ASSESSMENT 37
18 REPAIR OF PIPELINE 37
19 REFERENCES 38-39
CONTENTS
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S.NO. DESCRIPTION PAGE NO.
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1.0 INTRODUCTION 45
2.0 SCOPE 45
3.0 DEFINITIONS 45
10.0 TRAINING 58
11.0 RECORDS 58
12.0 REFERENCES 59
ANNEXURES
vii
PART-I
-1-
1.0 INTRODUCTION natural gas. Pipeline transporting
liquid petroleum is covered under
There is an imminent need to OISD-STD-141 and Liquid
transport huge quantity of gas from petroleum natural gas is covered
source to consumption centre under OISD-STD-214.
economically and this can be possible
only through building pipeline
infrastructure in the country with a 3.0 DEFINITIONS
view to facilitating the evolvement of
nation-wide gas grid and the growth Authorized person
of city or local gas distribution newt A person or representative of the
works. Considering the importance of company trained and assigned to
use of natural gas in various industrial carry out a specific job.
and automotive sectors, major
developments in transportation & Cross country pipeline
distribution of natural gas through Cross country pipeline means all
pipeline systems are in vogue. pipelines (including pipelines after
separator and / or processing plant
The primary purpose of this standard beyond isolation valves) and
is to establish minimum facilities which are used for
comprehensive norms for design, transportation of Natural Gas from
materials, construction, inspection, one point to another except plant
testing, commissioning operation and piping within the limit of isolation
maintenance, corrosion protection, valves of the plant.
modifications, abandonment, safety
of transmission pipelines and city gas Consumer
pipelines and also for protection of The organization or individual to
employees, public and facilities whom Natural Gas is delivered
against the hazard associated with through the cross country pipeline.
transportation and distribution of gas
through pipeline system. Cold Work
It is an activity which does not
produce sufficient heat to ignite a
2.0 SCOPE flammable mixture (mixture of
flammable gas with an oxidizing
This standard outlines the minimum agent ) or a flammable substance.
requirement for safety in design,
construction, inspection, testing, Chief Controller
commissioning, operation, Means Chief Controller of
maintenance, modifications, Explosives.
abandonment, corrosion protection,
safety of onshore natural gas cross Competent Authority
country pipelines including Any person authorized by Central
associated facilities and installations Government , by notification in the
as outlined in Annexure-I. official Gazette, to perform the
functions of the competent
This code does not apply to pipelines authority under the PMP Act1962.
transporting liquid petroleum,
liquefied petroleum gas and liquefied
-2-
Competent Person : is any installation having compressor
A person recognized by the between originating compressor
concerned statutory authority for the station and terminal / final / last
purpose in respect of which the delivery station on the pipeline for
competency is required. boosting the pressure of the gas so
that it reaches to next station.
Custody transfer meter
A gas measuring device which Intermediate Pigging Station (IPS)
measures the quantity and / or An intermediate pigging station is an
energy of gas delivered from one installation having facility for
agency to another agency for receiving and launching of pigs for
transfer of custody. pipeline pigging operations .
3
below, forming the scope of this Regassified Liquid Natural Gas
standard. Feeder lines from Jetty or The natural gas obtained after
other storage point and spur lines gasification of liquid natural gas.
will form part of onshore pipeline.
Spur /Branch Pipeline
Offshore Those pipelines which emanate from
Areas beyond the line of high water cross country pipeline for dedicated
along that portion of the coast that is industry and customer(s).
in direct contact with the open sea
and beyond the line marking the Sectionalizing Valve (SV)
seaward limit of inland coastal Valve used in the cross-country
waters. pipeline system for isolation of a
particular pipeline section whenever
Operating Company required.
The organization owning and
operating Natural Gas cross country Specified Minimum Yield
pipeline system for delivering Strength (SMYS)
natural gas to various Consumer(s). It is the minimum yield strength
specified by specification or
standard under which material is
Originating Compressor Station purchased from the manufacturer.
An originating compressor station is
the first installation having mainline Shall
compressor for boosting the pressure The word shall is used to indicate
of the gas to be transported so that it that the provision is mandatory.
reaches to next station.
Should
Operating Pressure The word should is used to indicate
It is the pressure corresponding to a that the provision is
particular flow rate at which pipeline recommendatory as per sound
is operated. Operating pressure is engineering practice.
less than or equal to MAOP.
4
(PNGRB) Act2006. operation, a programme of
ii. Policy for development of condition monitoring and
Natural Gas Pipelines and maintenance should be
City or Local Natural gas undertaken to ensure integrity is
Distribution Netwroks. maintained.
iii. Guidelines for The selection of design for
Environmental clearance of pipeline system shall be based
new projects 1981 on the following evaluation of
iv. The Environment the properties and required flow
(Protection ) Act -1986 rate of the fluid to be
v. Water ( Prevention & transported, together with the
Control of Pollution) Act environment in which the
1974 pipeline is to be installed.
vi. Air ( Prevention & Control a) Gas composition including
of Pollution) Act 1981 hydrogen sulphide , oxygen
vii. The Petroleum and Mineral and water vapour content
Pipelines (Acquisition of b) Sweet or sour natural gas,
Right of Users in Land) single or multiphase flow
Act, 1962. conditions.
viii. Manufacture ,Storage & c) Operating pressures and
Iimport of Hazardous temperatures.
chemical Rules-1989 d) Type of Pipeline System
ix. National Highway Act, (Gathering/Transmission/Di
1956 stribution/Service lines).
x. Railway Act , 1989 e) Location class through
In addition all other statutory which pipeline shall pass.
approvals required for laying of
the pipelines across rail, road 5.1 Pipeline Design
and water body (canals/rivers Design of Natural Gas pipeline
etc.) crossings and other utility shall be in accordance with
crossings as notified by local ASME B31.8
authorities / State etc shall be
applicable. 5.1.1 A design Life of pipeline shall
be considered by the owner for
5.0 DESIGN designing various system and
The pipelines shall be designed facilities beyond which pipeline
in a manner that ensures system can be considered for
adequate public safety under all abandonment. The life of
conditions likely to be pipeline can be extended
encountered during operating beyond the design life subject to
conditions. All materials and satisfying the comprehensive
equipment shall be selected to pipeline integrity test.
ensure safety and suitability for
the condition of use. 5.1.2 All necessary calculations shall
The initial integrity of the be carried out to verify structural
pipeline is established through integrity and stability of the
proper design, material selection pipeline for the combined effect
and sound construction of pressure, temperature,
practices. After the pipeline has bending, soil/pipe interaction,
been commissioned and is in external loads and other
5
environmental parameters as installations. Pipelines and its
applicable, during all phases of associated facilities shall be
work from installation to designed to meet the
operation. Such calculations requirements of Location Class.
shall include but not limited to The design of the pipeline is
the following: related to the Location class by
an appropriate design factor as
a) Buoyancy control and per para 5.2.1. Determination of
stability analysis for pipeline location class shall be done in
section to be installed in accordance with Annexure- II.
areas subjected to
flooding/submergence, 5.1.4 Design Temperature
b) Crossing analysis of rivers by Pipelines shall be designed for
trenchless techniques, the following temperature limits
wherever soil data is (i) Above ground - Maximum :
favorable for such operation, 65o C ; Minimum: (-) 29o C
c) Evaluation of potential for (ii) Below ground- Maximum :
earthquake occurrence along 60o C ; Minimum: (-) 29o C
pipeline route and carrying Design shall also consider the
out requisite seismic analysis temperature of natural gas
to ensure safety and integrity proposed to be transported
of the pipeline system. through the pipeline. When the
maximum design temperature
exceeds 120o C ( 250o F),
5.1.3 A significant factor contributing particular attention shall be given
to the failure of a pipeline is the to tensile properties of the
damage caused to the pipeline by material to ensure that the
activities along the route of the derating factor for temperature is
pipeline associated with human adequate as per Table-1 below.
dwellings and
commercial/industrial
Table -1
6
5.2 Design of Components D = Specified outside diameter of the
pipe, in mm;
5.2.1 Steel Pipe S= Specified minimum yield strength
The least nominal wall thickness t (SMYS) in N/mm2 of pipe
for the steel pipe, shall be calculated material;
in accordance with ASME B 31.8. F=Design factor obtained from Table 2;
E= Longitudinal joint factor, which for
The internal design pressure shall be electric resistance welded (ERW),
determined by the following formula longitudinal seam submerged arc
welded (LSAW), helical seam
P x D submerged arc welded (HSAW)
t =
2xSxFxExT and seamless types of pipes,
manufactured in accordance with
Where API5L and considered as 1;
t = Nominal wall thickness, in mm; T = Temperature derating factor to be
P= Internal design pressure, in N/mm2. used in design formula is
determined from Table- 1 above;
Table -2
In setting the values of the design factor, F, due consideration has been given and allowance
has been made for the various under thickness tolerances provided for in the pipe
specifications listed and approved for usage in this Code.
The pipe wall thickness less than 6.4 mm should not be used for cross country pipelines.
Pipe diameter 4 and above shall be used in cross country pipelines.
* - Near concentration in Class 1 and 2 means places of public assembly (school, temple,
7
* church, hospital, club etc) used by 20 or more people frequently.
8
(iii) The hazop and risk analysis movement of fire fighting
and mitigation measures equipment.
thereof.
5.3.4 Separation Distances
(iv) The availability of space for Inter-distances for various station
future augmentation of facilities and utilities shall be as
facilities. per ANNEXURE - III.
(v) Approachability, water table
5.3.5 Piping layout
and storm water arrangement
Wherever possible, piping shall be
(vi) Availability of electrical located above the ground. Piping
power shall be designed considering skin
temperature of piping material
under empty conditions as 65 C or
5.3.2 Layout
the design temperature of pipeline,
whichever is higher. Buried piping
The following aspects shall be
inside the terminal area shall have a
considered while establishing station
minimum depth of cover of 1.2 m.
layout
Where buried pipes come out of the
ground, the underground coating on
i. Station equipment and their
the pipe will continue for a length
specification.
of at least 300 mm above ground.
ii. P&I diagram for the station.
Platforms and crossovers shall be
iii. Utility requirement.
provided for ease of operation and
iv. Flaring / Venting wherever
maintenance.
required.
v. Operation & maintenance
5.4 Protection of Facilities
philosophy of station
equipment.
5.4.1 Properly laid out roads around
vi. Fire station & allied facility
various facilities shall be provided
wherever required.
within the installation area for
vii. Over head power lines shall
smooth access of fire tenders etc in
not pass over license area.
case of emergency.
HT Pole structure,
Transformers, Breaker and
5.4.2 Proper industry type boundary wall
MCC room etc to be located
at least 3 M high with 0.6 M barbed
in non hazardous area.
wire on top shall be provided all
around the installation i.e dispatch
5.3.3 Location of compressor station
station, compressor station, tap-off
The compressor station should be
points and sectionalizing valve
located at such clear distances
stations in line with MHA (
from adjacent property not under
Ministry of Home Affairs)
control of the company as to
guidelines.
minimize the hazard of
communication of fire to the
5.4.3 Emergency exit with proper gate
compressor station from structures
shall be provided in the earmarked
on adjacent property. Sufficient
zone wherever required.
open space should be provided
around the Compressor
5.4.4 Natural Gas pipeline system should
shed/building to permit the free
be equipped with following:
9
a) Limit the hazard and damage
(1) Supervisory Control And Data from accidental discharge from
Acquisition (SCADA) System. pipeline system;
(2) Leak detection system with b) Facilitate maintenance of
provision for identification / pipeline system.
location of leak and isolation
of affected section. 6.1.1 Station Block valves
(3) Facilities for controlled flaring. Block valves with remote shut off
(4) Accessories & kit for arresting provision from the control room
leak shall be provided at the boundary of
station pipeline inlet and outlet
5.5 SCADA REQUIREMENTS locations to isolate the station
facility.
5.5.1 The pipeline should be monitored and
controlled from SCADA system to 6.1.2 Mainline Block Valves /
ensure effective and reliable control, Sectionalizing Valves
management and supervision of the Sectionalizing valves shall be
pipeline. installed where required for
5.5.2 All remote SV stations, IPS, dispatch operation and maintenance and
& receiving stations will have control of emergencies. Factors such
suitable field signals connectivity as topography of the location, ease
with SCADA. of operation and maintenance
5.5.3 Application software modules/ including requirements for pressure
functions shall be based on the relief, security, proximity to
requirement of pipeline operating occupied buildings shall be taken
company. into consideration in deciding the
location of the valves. The
6.0 PIPELINE SYSTEM & maximum distance between the
COMPONENTS location of any two section isolation
valve stations shall be as given in
6.1 Isolation Valves Table -3 below, based on the
Isolation valve shall be provided for location class and taking into
isolating sections of pipeline in order consideration factors like the terrain
to: features, requirement of safety and
operation, etc.
Table - 3
Location Class Maximum Distance in km
1 32
2 24
3 16
4 8
Note : Based on the above location class no. of Block / Sectionalizing valves
to be installed shall be worked out. Valve spacing adjustments should not
exceed 10% of the applicable distances listed above (due to non availability of
land). However, the total number of valves as per the design requirement shall
remain same.
10
6.1.3 Sectionalizing valves shall be valves used in mainline shall be with
installed on upstream and down butt-weld ends. Flanges may be used
stream of perennial river crossings where frequent access or removal of
and public water supply reservoirs. equipment is required. Valves used in
buried portion shall be with butt weld
6.1.4 The valve stations shall be located at joints only, except at the locations
a readily accessible location such as where hot tapping operation is to be
near roads and shall be provided carried out for which, buried flanged
with an access road from the nearest end valve may be provided. Valve
all weather metalled road. The surface shall be provided with
facilities within valve station shall corrosion protection coating.
be secured by providing a suitable
boundary wall around the 6.1.7 Sectionalizing Valve(s) shall be
installation with a gate.. The location provided with blow down or vent
of valve station shall be clear of line connection to isolate the
overhead power lines. Pipeline to be pipeline section and evacuate the
located within the section isolation pipeline section in case of an
valve station limits shall be of wall emergency and repair. The size and
thickness appropriate for the capacity of the connections for
applicable Location Class, but in no blowing down the line shall be such
case shall be less than that applicable that under emergency condition the
for Location Class 3. The provisions section of line can be vented as
of remote operated feature shall be rapidly as practicable.
as per the operation and control
philosophy to be adopted for the 6.1.8 All joints between the mainline pipe
pipeline. At locations where valve and the first valve, including the
stations are combined with inlet to first valve , should be welded
compressor/repeater stations, the in order to restrict possible future
requirements of safe distance and leakage which can not be isolated by
statutory clearance, as applicable, the closure of the valve.
shall be followed.
6.2 Pigging Facilities
6.1.5 Valve shall be installed buried and 6.2.1 The pipelines shall be designed to
provided with a stem extension in meet the requirements for pigging
such a way that the center of considering the following:
actuator is at approximately 1.0 m a) location of the permanent pig
above the finished ground level traps or connections for
considering ease of operation. temporary pig traps;
Sectionalizing valve on the main b) access to the pig traps;
pipeline shall preferably be ball c) handling facilities;
valves of full bore type conforming d) isolation requirements necessary
to the minimum requirements of API for pig launching and receiving;
6D / ISO-14313. e) venting and draining
requirements for pre-
6.1.6 Pipeline sectionalizing valve may be commissioning and operation;
either gas actuated or f) direction of pigging including bi-
manually/electrically/pneumatically/h directional pigging;
ydraulically operated. In order to
minimize potential leak sources,
11
g) minimum permissible bend and receiving barrels and its closures
radius and the distances between shall be designed in accordance with
bends/fittings; ASME or equivalent standard.
h) maximum permissible changes Arrangements for launching,
in diameter and tapering retraction, handling and lifting of
requirements at internal diameter pigs, cleaning and instrumented pigs
changes; shall be provided at the scraper
j) fittings/branch connections and station. These stations shall be
compatibility of line pipe provided with access road from the
material; nearest metal road.
k) internal coatings; and
m) pig signallers. 6.2.3 Barrel for the launcher shall be at
least 2 sizes higher than main pipe
The safety of access routes and size and receiver barrel shall be at
adjacent facilities shall be least 3 sizes higher. Centerline
considered when determining the elevation of scraper trap shall be at
orientation of pig traps. least 1 mtr higher from grade level.
Table 4
12
6.5 Check valves reinforced gaskets shall not be used.
Check Valves shall be installed to
provide automatic blockage of 6.8.4 Steel butt welding fittings shall
reverse flow in the piping system, comply with ANSI 16.9 / MSS-SP-
within the station, wherever 75 or equivalent. Steel socket
required. welding fittings shall comply with
ANSI B 16.11.
6.6 Flow/Pressure Control Valve
Design of control valves shall meet 6.9 Metering facilities
the requirement of part I of API 550 Positive displacement meters ,
/ API-RP-553 , ISA ( Instrument turbine meters or equivalent
Society of America) S- 75.01 -75.03, measuring device and their proving
IEC -79 and IEC-529. facilities shall be designed and
installed at all stations except
6.7 Branch Connections sectionalizing valve stations. Dry
Minimum size of any tapping from gas filters shall be installed at the
the underground pipeline shall be of upstream of the meters.
50 mm nominal bore and shall be
provided with an isolation ball valve 6.10 Supports and Anchors
located at a minimum distance of 50 Supports and anchors shall be
mm from the pipeline. All branch fabricated from durable
connections or side tap on the incombustible materials. Each
piggable lines having branch line support on the above ground piping
diameter equal to or exceeding 40 system shall comply with the
percent of the main pipe diameter, following:
shall be provided with flow tees/bar
tees in order to enable smooth (i) If the pipe is designed to
passage of cleaning, gauging, operate at a hoop stress of less
instrumented and other pigs. All than 50% of SMYS, supports
flow tees/bar tees shall comply with or anchors shall be directly
the requirements of ASME B 16.9, welded to the pipe.
MSS-SP-75 or equivalent. (ii) If the pipe is designed to
operate at a hoop stress level of
6.8 Flanged or threaded joints, Bolts, 50% or more of SMYS,
Nuts , Gasket and other fittings Structural support shall not be
welded directly to the pipe.
6.8.1 Threaded joints shall not be used in Support shall be provided by a
cross country pipelines, spur lines member that encircles the pipe
and branch lines. The number of and encircling member shall be
flanged or threaded joints for station welded to the pipe
piping shall be to the extent continuously and cover the
minimum. The threaded joints, after entire circumference.
tightening, may be seal welded.
Flanges shall conform to ANSI 16.5 6.11 Electrical Installations of Pipeline
or ASME B 16.47 or MSS-SP 44 or Station
equivalent.
6.11.1 Area Classification of Pipeline
6.8.3 The flange joint shall have either Installation, as basis for Selection
spiral wound metallic gaskets or ring of Electrical Equipment for Natural
joints. Plain asbestos sheet / Gas Pipeline Station shall follow
13
IS-5572 and OISD STD-113 designed and installed and
standards . The specification of maintained to ensure safe
Electrical equipments shall be in operations under both normal and
line with IS : 5571, Guide for emergency situations.
selection of Electrical Equipment
for Hazardous Area. Safety in 6.14 COMPRESSOR STATION
electrical system to be designed as
per OISD-RP-149. Fire protection 6.14.1 Compressor Design
in Electrical installations shall be
designed as per OISD-STD-173. The compressor station shall be
designed in accordance with the
6.11.2 All electrical equipment, systems, requirements of ASME B 31.8.
structures and fencing shall be
suitable earthed conforming to IS Centrifugal type process gas
3043. The earthing system shall compressors shall be designed in
have an earthing network grid with accordance with API-617.
required number of electrodes. All Reciprocating Compressors shall
Electrical equipment operating be designed in accordance with
above 250 volts shall have two API-618 and other compressors
separate and distinct connections to shall be designed in accordance
earth grids. Separate earthing grid with API-11P.
shall be provided for instrument and
electrical power. Lightning Compressor station shall consist of
protection shall be provided as per following:
the requirements of IS:2309. Self
conducting structures having metal 6.14.1.1 Compressor Piping
thickness of more than 4.8 mm
may not require lightning protection The gas piping for compressor
with aerial rod and down station shall be designed in
conductors. They shall, however, accordance with Para 5.2 of this
be connected to the earthing standard.
system, at least, at two points at the
base in line with OISD-STD-173. The piping for auxiliary
components including air,
lubricating oil & hydraulic power
6.12 Instrument and Control System piping etc. shall be designed in
Instrumentation and control system accordance with ASME B 31.3,
for the Pipeline system in totality API 614 and other applicable
shall meet the requirement as per codes.
API Standard API-RP-551 to API-
RP-556 "Manual on Installation of 6.14.1.2 Feed Gas Compression System
Refinery Instruments and Control
Systems. Facilities shall be provided for
compressing the feed gas using
6.13 Communications centrifugal compressors upto
A reliable and dedicated required pressure level. Coolers
communications system to interact shall be installed to bring down the
between all stations including feed gas temperature to desired
sectionalizing valve station across level before it is introduced in the
the entire pipe line shall be down stream pipeline.
14
ASME Section VIII of the
6.14.1.3 Fuel Gas Treatment System Boiler and Pressure Vessel
The fuel gas treatment system Code.
shall meet fuel gas quality
requirements of gas turbines. The 6.14.1.6 Condensate handling system:
various facilities shall include Facilities shall be provided for
filter separator unit, condensate removal of condensate received
handling system & fuel gas in the form of liquid as impurity
conditioning system etc. including in the filter separator. Liquid
gas measurement system, gas accumulated in separator shall
heating system ( if required for be sent to blow down drum
gas engines) & pressure control when required
system. The fuel gas conditioning
system shall also meet the 6.14.2 Building / Shed Requirements
requirements specified by OEM
(Original Equipment The compressor station should
Manufacturer) before its use in have have following main
gas turbines for generation of buildings/sheds, in general:-
power.
(i) A compressor
6.14.1.4 Power Generation System building/shed to house the
compressors.
The compressor station shall (ii) Switchgear building for
have its own gas based power electric power.
generation system or an alternate (iii) Power generator
power supply system. In building/shed.
addition, minimum one diesel (iv) Workshop building.
generator shall be provided to (v) Warehouse store.
meet the emergency power (vi) Office building.
requirement in case of failure of (vii) Control room building.
normal power supply system.
All compressor station buildings
6.14.1.5 Instrument and Plant Air which house gas piping in sizes
System larger than NPS-2 or gas
handling equipment shall be
The compressor station shall constructed in accordance with
have an instrument air supply OISD-STD-163.
system for instrumentation
system, control valves and seal 6.14.3 Typical layout of compressors
air system etc. and plant air stations is enclosed at
system. For SV stations and IP Annexure- IV
stations gas at instrument air
pressure can be used. Electrical 7.0 SAFETY DEVICES &
motor driven or diesel driven air FEATURES
compressors shall be used. Air The safety system for compression
receivers, air storage bottles and facilities and gas transportation
instrument air dryer units shall system shall consist of following:
be provided. Air receivers or air
storage shall be designed and
installed in accordance with
15
7.1 Emergency Shutdown Facilities for TRVs shall have lock open type
compressors isolation valves on both sides of
safety valve.
7.1.1. Compressor station shall be provided
with an emergency shutdown system 7.2 4 Pressure safety valves or other
by means of which the gas can be devices of sufficient capacity and
vented out of the system. Operation sensitivity shall be installed to
of the emergency shutdown system ensure that the normal operating
shall also shutdown all gas pressure of the system does not
compressing equipments, all gas exceeded by more than 10%, or the
fired equipment, gas delivery system maximum allowable operating
and shall de-energize the electrical pressure by more than 2 kg / Cm2.
facilities located in the vicinity of
gas headers and in the compressor 7.3 Vent Lines
shed, except those that provide
emergency lighting and those that 7.3.1 Vent line shall be designed and
are necessary for protection of the installed to exhaust the gas from
equipment. relief valves to atmosphere in
7.1.2 Emergency shutdown system shall be accordance with OISD-STD-106 .
operable from at least 2 locations Blow down piping connected to vent
away from the gas area of the station line shall extend to location where
out of which one should be located the discharge of gas shall not create
in the field out side the compressor a hazard to the compressor station or
building. the surrounding area.
7.2 Pressure limiting devices 7.3.2 The discharge from safety valve shall
be vented vertically upwards to
7.2.1 Over pressure shut off valves shall atmosphere at an elevation of 3
be provided upstream and down meter (minimum) above grade or the
stream of controlling regulators tallest structure within a radius of 15
along with alarm provision incase of metre which ever is higher for
failure of the regulator. effective dispersion of hydrocarbons.
In this case, isolation valves on
7.2.2 Pipe size shall be such that gas down stream of PSVs are not
velocities in the piping shall not be required.
more than 20 mtr / sec for unfiltered
gas and 40 mtr/ sec for filtered gas at 7.4 Fuel gas control
peak condition. Sound pressure level
shall be the maximum limit 7.4.1 An automatic device designed to
prescribed by environment dept. shut off the fuel gas when the gas
engine/turbine stops shall be
7.2.3 Any equipment or section of the provided on each gas
pipeline containing Natural Gas in Engine/turbine operating with
the form of trapped volume shall be pressure gas injection. The engine
protected against excessive pressure distribution manifold shall be
developed due to rise in surrounding automatically vented
temperature by installing Thermal simultaneously.
Relief Valves (TRVs). The
discharge of TRVs shall be 7.4.2 All fuel gas lines within a
connected to vent line system . All compressor station shall be
16
provided with master shutoff valve
located outside of the building. An 7.10 Conventional break glass type fire
automatic device designed to shut alarm system shall be installed at all
off the fuel gas when the engine strategic locations of the stations.
stops shall be provided on each gas .
engine operating with pressure gas 7.11 Fire water network with fire
injection. hydrants, long range monitors and
fire water storage shall be provided
7.5 Station bye pass inline with clause 13.0.
Compressor station bye pass system
shall be provided to facilitate flow of 8.0 MATERIALS
gas in the pipeline without entering
the compressor station. 8.1 General
Materials for use in the pipeline
7.6 All gas compressor units shall be system shall comply with the design
equipped with shutdown or alarm requirements and be suitable for the
devices to operate in the event of intended fabrication and / or
inadequate cooling or lubrication of construction methods.
the units.
8.2 Steel Pipe
7.7 All compressor buildings or Line Pipe for use in Natural Gas
Compressors skids shall have fixed Pipeline System shall be Seamless,
gas detectors to detect leakage of gas Electric Welded (EW) or
inside the unit and generate alarm Longitudinal/Helical Submerged Arc
and trip signals for the unit in case Welded (LSAW/HSAW)
the gas concentration in air is more conforming to Line Pipe
than 20% of lower explosive limit. Specification API 5L (PSL-2) or
equivalent.
7.8 Ultra Violet & Heat detectors shall
be installed in the compressor
buildings or compressors skids to 8.3 Carbon Equivalent
initiate shut down of the unit,
isolation of the compartment and Maximum limits on Carbon
release of clean agent inside the Equivalent for Steel line pipes shall be
unit in the event of occurrence of as follows:
fire.
CE(Pcm) : 0.20
7.9 Smoke detectors shall be installed in CE (IIW) : 0.40
the control room of compressor Carbon Equivalent shall be calculated
station building, cable trenches in based on the formula given below:
electrical sub station to initiate alarm
in case of detection of smoke.
CE (Pcm) = C + Si + Mn + Cu + Ni + Cr + Mo + V + 5B
30 20 20 60 20 15 10
If heat analysis indicate that boron content is less than 0.01%, then product analysis need
not include boron.
17
For Carbon content more than 0.12%,
CE = C + Mn + (Cr + Mo +V) + Ni + Cu
6 5 15
18
coatings and cathodic requirements for testing and
protection. inspection, and repair procedures
where relevant.
For plant piping, depending upon the
requirement underground piping 9.2.3 Field joint coating
should be protected by anti-
corrosion coating and / or cathodic The field joints shall be protected with
protection system. a coating material that is compatible
with the line pipe coating material.
9.2 External Corrosion The coating shall be such that it can be
easily applied in field conditions. The
9.2.1 External coating for underground coating shall be carried out with heat
pipeline shrink wrap around sleeves or cold
tape or any other suitable type of
Anticorrosion coating shall be coating .
selected reflecting the varying ground
conditions found during soil
resistivity survey carried out along 9.2.5 Cathodic Protection System:
the pipeline route. Coating shall be In addition to protective coating,
selected based on following criteria: buried pipelines shall also be
provided with cathodic protection
(i) Electrically isolate the external system. CP system shall be designed
surface of the pipeline system in accordance with NACE-RP-0169.
from the environment.
(ii) Sufficient adhesion to a) During construction period
effectively resist underfilm pipeline shall be protected by
migration of moisture. temporary sacrificial anode
(iii) Sufficient ductility to prevent based cathodic protection
cracking. system. This may not be
(iv) Strength to resist damage due to provided in case Permanent
handling & soil stress. Cathodic Protection system is
(v) Be compatible with Cathodic provided within 6 months of start
Protection System. of pipeline construction.
b) Permanent Cathodic protection
9.2.2 All coatings shall cover the system i.e. Sacrificial anode or
following requirements: impressed current shall be
a) type of the coating; brought into operation as soon as
b) thickness of the individual layers possible following pipeline
of coating and its total thickness; construction.
c) composition of the coating/base
material; c) For Impressed Current Cathodic
d) mechanical properties; Protection System, it shall be
e) temperature limitations in use; ensured that continuous power
f) surface preparation supply is maintained in cathodic
requirements; protection system.
g) adhesion requirements for
materials, application and d) Test leads points (TLPs) shall
curing, including possible be installed at 1 km interval and
requirements for health, safety at all crossings on pipeline for
and environmental aspects and taking electrical measurements
19
to indicate adequacy of the CP fault currents when the pipeline is
system. installed near electric transmission
e) Test lead points shall not be tower footings, ground cables etc.
attached to the pipe by brazing.
Thermit welding or other 10.0 CONSTRUCTION
suitable methods shall be used. 10.1 Pipelines shall be buried below ground
Cathodic protection shall be level, unless construction above
such that it does not damage the ground is found to be desirable for
protective coating, pipe or exceptional technical, economic or
components. topographical reasons. Construction
plan shall be prepared before
9.2.6 Electric Interference commencement of construction to
assist in control of the work. The plan
a) The anode beds shall be shall contain a description of the
located such that there is construction; the health, safety and
minimum interference to the environment plan; and the quality
existing underground metallic requirements, personnel and
structures. equipments required for the
b) The pipeline shall be protected construction and working procedures.
against stray DC or AC current All facilities, which include existing
induced corrosion by providing roads and railways, rivers/canals,
metallic bonds, increased footpaths, pipelines, cables and
cathodic protection, buildings and are affected by the
supplementary protective construction of the pipelines shall be
coatings, insulating flanges or identified prior to the beginning of
galvanic anodes or such other the work. Temporary provisions and
methods as technically safety measures necessary to protect
required. the identified facilities during
c) Protective devices shall be construction should be established.
provided to protect against All safety precautions during
lighting, induced voltage at construction shall be followed as
HT pipeline crossings and specified in OISD-GDN-192, OISD-
stray current interference from STD-147 .
foreign objects.
d) Pipelines laid or proposed to be 10.2 Excavation
laid parallel to an AC In cultivable land and other areas
transmission supply line / DC specifically designated, the top soil
traction, shall have suitable on the pipeline trench top width shall
protective devices installed to be excavated and stored separately.
reduce induced potential to This top soil shall be replaced in
acceptable level. During original position after backfilling and
construction special protection compacting the rest of the trench. The
shall be taken to minimise width of trench shall be such that a
possible effects of alternating minimum clear distance of 200mm
current potentials. for trench in normal soil and 300mm
for trench in rock is maintained
9.2.7 Safety devices in line with NACE- between edge of pipe and the trench
RP-01-77 shall be installed for wall at the bottom of trench.
preventing the damage to the CP
system of pipeline due to lightning or
20
10.3 Minimum Cover For Buried the Minimum Cover for Buried
Pipelines Pipelines, as specified in Table 5
All buried pipelines shall be installed below:
below the ground level in line with
Table 5
Minimum Cover Requirements for Pipelines
NOTES:
(i) The depth of cover shall be measured from the top of the pipe coating to the top of the
undisturbed surface of soil or the top of graded working strip, whichever is lower. The fill
material in the working strip shall not be considered in the depth of cover;
(ii) The cover shall be measured from the top of road or top of rail, as the case may be;
(iii) For river/watercourses that are prone to scour and erosion, adequate safe cover shall be
provided below the predicted scour profile expected during the life time of the pipeline;
(iv) When scour level is not known, an additional cover of at least 1 m shall be provided from
the existing bed of the river/water course except in case of rocky river bed;
(v) The minimum cover requirements shall be applicable for all Location Classes;
(vi) Whenever the above provisions of cover cannot be provided due to site constraints,
additional protection in form of casings, bridging, etc shall be provided.
(vii) Soft soil/sand padding of minimum 150 mm thickness to be provided around the pipe where
gravel or hard soil is encountered. In case of rocky areas rock-shield along with 150 mm of
soft soil / sand padding around the pipe should be provided.
In case the pipeline is to be laid through populated area (which otherwise could not be
avoided), additional protective measures to be provided be by way of providing higher wall
thickness pipe or laying at a greater depth or by providing casing pipe.
21
10.4 Crossing of Utilities heavy conventional construction
equipment is expected to be utilized.
10.4.1 When a buried pipeline has to cross This distance may be reduced after
any existing underground pipeline, careful assessment of construction
cable, drain or other services, the methodologies so that it does not
pipeline shall be laid at least 300 result in unsafe conditions during
mm below such services in a manner construction. In any case the
that will not obstruct access to such minimum clear distance shall not be
services for inspection, repair, or less than 3.0 metres. These areas
maintenance. Where it is not shall be distinctly identified on
practicable to obtain the above ground during construction. All
mentioned clearance, special design caution sign shall be in bi lingual
and construction shall be used. (local language and Hindi / English)
10.4.2 When laid parallel to, along or near 10.5.2 No pipeline should be located within
underground power and /or 15.0 metres of any private dwelling
communication cables, conductors or any industrial building or place of
or conduit, underground pipes shall public assembly in which persons
maintain a vertical clearance of at work, congregate or assemble,
least 300 mm and horizontal unless it is provided with at least 300
clearance of 500 mm. Where these mm of cover in addition to that
clearances cannot be maintained, provided in para 10.3 above.
extra precaution shall be taken to
ensure the maximum possible 10.6 Cold field bends
clearance and to prevent future
contact. In laying parallel pipelines 10.6.1 The radius of cold field bends shall
in the same trench, a minimum clear be as specified in clause 6.3. Pipes
distances between the pipelines shall with measured wall thickness
be 500mm. greater than the nominal wall
thickness (with positive tolerance)
10.4.3 A clearance sufficiently large to shall normally be used for making
avoid electrical fault current cold field bends.
interference shall be maintained
between the pipeline and the 10.6.2 The ends of each bend length shall
grounding facilities of electrical be straight and not involved anyway
transmission lines. in the bending. In no event shall the
end of the bend be closer than 0.5 m
10.4.4 A minimum separation of 3.0 metre from the end of a pipe or within one
should be maintained between meter of a girth weld. The ovality in
pipeline and transmission tower each pipe due to bending shall be
footings. less than 2.5 percent of the nominal
diameter, at any point. A check
10.5 Location shall be performed on all bends by
passing a gauge consisting of two
10.5.1 The location of a new underground discs with a diameter equal to 95
pipeline, when running parallel to an percent of the nominal internal
existing underground pipeline, diameter of the pipe connected
should be at a minimum clear rigidly together at a distance equal
distance of 5.0 metres from the to 300 mm.
existing underground pipeline when
22
10.6.3 Pipes with longitudinal welds shall roads, cart-tracks, etc) shall be as
be bend in such a way that weld lies close to 90 as possible, but in no
in the plane passing through neutral case less than 45 to the centre-line
axis of the bend which shall be of the roads. Additional protection
installed positioning the shall be provided in case the angle of
longitudinal weld in the upper the crossing is less than 45 .
quadrants.
10.7.2 Water Crossings
Crossings shall be located in a
10.6.5 Cold bend pipes on site shall have comparatively straight reach of the
the corrosion coating carefully river, where the banks are stable,
checked with the aid of a holiday minimum evidence of erosion of
detector for cracks in the coating bed, sufficient area for construction
down to the pipe wall. Any defects is available. Angle of crossing shall
or disbonding of the coating caused be as close to 90 as possible. For
during bending (including forced canals/drainage/ditch / nala /stream
ridges in the coating) shall be and other water courses, the angle of
repaired. crossing shall be in no case less than
60 to the centre-line of the
10.7 CROSSINGS canal/drainage ditch.
As far as possible, crossings shall be
made at right angles. Turning Points Special considerations shall be
(TPs) provided near crossings shall required for submerged crossings
be located at least 50 m from the which are characterized by their
boundary of the crossings, on stable perennial nature, meandering course,
and firm ground except for the steep and potentially erodable banks,
stretches which runs parallel to road. potentially scouring bed, large
erodable flood plain and wide water
10.7.1 Rail and Road Crossings course (high water mark to high water
mark) both during the design and
Installation of carrier pipe at rail / installation of such crossings. For
road crossings with casing shall be river crossings the following
in accordance with API RP-1102. additional requirements shall be
Carrier pipe shall be independently considered.
supported outside each end of the
casing section and casing ends shall a) To ensure the stability of the
be sealed using durable, electrically underwater pipeline, it may be
non conductive materials. Insulators necessary to add weight to sink
of appropriate size and numbers and hold the pipeline in position.
shall be fitted between carrier pipe b) A detailed stress analysis for
and casing pipe. The angles for all the pipe section for river
railway crossings shall be as close to crossings should be carried out,
90 as possible, but in no case less taking into consideration the
than 85 to the centre-line of the effect of all loads during laying
railway. The angle of crossings for and it shall be ensured that the
national and state highways shall be stresses remain within
as close to 90 degrees as possible, permissible limits in accordance
but in no case less than 80 to the with ASME B 31.8.
center-line of the road. The angles of
crossing for other roads (like
seasonal roads, unpaved village
23
10.8 Welding and Inspection girth weld joints shall be
Acceptance Criteria nondestructively tested over their
entire circumference by
10.8.1 Welding procedures or welders shall radiographic examination,
be qualified inline with API 1104, or ultrasonic testing, magnetic
section IX of the ASME Boiler and particle testing or other equivalent
Pressure Vessel Code. Requirements comparable method.
in ASME Boiler and Pressure Vessel (i) 100% of welds in location
Code, Section IIC and section V or class 1, 2, 3 & 4.
API 1104 shall apply for filler (ii) 100% of welds in
materials and non-destructive compressor station,
examination of welds. Welder re- crossings and tie-in joints.
qualification shall be required if the
welder has not performed any 10.8.3.3 Weld repair areas shall be
welding for the welding process subjected to radiography testing .
qualified for the past 6 months . If required, ultrasonic testing or
magnetic particle testing shall be
10.8.2 The open ends of welded sections of required to confirm/clarify the
pipeline shall be closed by use of defects indicated in radiographic
suitable night caps to prevent the examination. Repair welders shall
ingress of foreign bodies and water. be qualified inline with clause
10.8.1.
10.8.3 The weld joints shall be numbered
and marked along with the welder
10.9 Dents
identification , adjacent to the weld
joint on the progressive direction of 10.9.1 All dents that affect the curvature
main line . of the pipeline at the longitudinal
weld or circumferential weld shall
10.8.3 Welding Inspection be removed. The depth of dent
shall be measured as the gap
10.8.3.1 No cut piece of mainline pipe of between the lowest point of the
length less than two (2) meter shall dent and the original contour of the
be used in the pipeline and it shall pipe. The maximum permissible
be ensured that there shall not be depth of dents in pipes up to and
more than three (3) circumferential including 12.75 inch (324 mm)
welds in eight meters. Cut pipes nominal outside diameter shall be
shall have details of pipe reference 5 mm. For pipes over 12.75 inch
numbers painted to the inside of (324 mm) nominal outside
each pipe end. All NDT (non diameter, the permissible depth of
destructive testing) including dent shall be 2 percent of the
Radiographic examination and nominal pipe diameter. Length of
destructive method of examination the dent in any direction shall not
shall be performed in accordance be more than one-fourth of
with the requirements of API nominal diameter of the pipe.
1104. Dents shall be removed by cutting
out the damaged portion of the
10.8.3.2 The quality of each weld shall be pipe as cylinder and replacing with
examined by visual inspection. a pre tested pipe.
The following minimum
percentage of each days field
24
10.9.2 All dents as mentioned in para 10.11 BACKFILLING
10.9.1 and a dent containing a 10.11.1 Backfilling shall be carried out
stress concentrator, such as a immediately after the pipeline has
scratch, gouge, groove, or arc been laid in the trench. Top soil
burn, shall be removed by cutting from the Right-of-Use be used for
out the damaged portion of the this purpose, should be restored.
pipeline as a cylinder and The backfill material shall contain
replacing with a pre tested pipe no extraneous material and/or hard
section. Buckled pipe shall also be lumps of soil, which could damage
replaced as a cylinder. the pipe and/or coating or leave
10.9.3 Notches or laminations on pipe voids in the backfilled trench.
ends shall not be repaired. The
damage portion shall be removed 10.11.2 Breakers shall be installed in
as a cylinder and re-beveled to the trenches in steep areas (slope of
pipe properly generally 10 percent and more) for
the purpose of preventing erosion of
10.10 LOWERING the back fill. When backfilling the
trenches in sloping terrains or steep
10.10.1 Before lowering operations are areas, wherein the chances of wash
commenced, particular attention out of backfill exist, sheet piling or
shall be paid to the suitability of the other effective water breakers
trench to allow the pipeline to be across the trench shall be provided.
lowered without the coating being
damaged and to give a reasonably 10.12 Markers
even support to the pipeline. Pipeline markers shall be provided
on each side of road, railway
10.10.2 Before lowering in, a complete crossing, water crossings and at a
check by a full circle holiday maximum spacing of 1 km along
detector set at an appropriate the right of way of the remainder of
voltage to provide sufficient arc the buried pipeline along the right
length for the thickness and nature of way.
of coating for whole of pipe
coating and for field joint coating At the entrance to all pipeline
shall be carried out. All coating stations, all road and railway
defects and damages identified by crossing locations, caution signs to
holiday detection shall be repaired. be displayed indicating hazardous
All points on the pipeline where the area, name of the operating
coating has been in contact with company emergency telephone
either the skids or with the lifting contact nos. etc.
equipment during the laying
operation, shall be carefully
inspected for damages, dents or 11.0 TESTING & COMMISSIONING
other defects and shall be
completely repaired.. Short 11.1 Hydrotesting of Pipeline
completed sections of the pipeline
shall be cleaned with compressed a) All Pipelines shall be tested in-
air in order to remove dirt from the place after construction except
inside of pipe sections. for pre-tested pipes used in tie-
in spools.
25
b) Cased crossings (rail/road) and corrosion inhibitors and oxygen
river crossing sections shall be scavenger are added depending
hydrotested before and after upon quality of the water.
installation at least for 4 hours
at 1.25 (for Class 1 & Class 2) g) API-1110 shall be used for
OR 1.4 times (for Class 3 & guidance for the hydrostatic
Class 4), the design pressure. test.
d) A gauging pig shall be passed 11.2 Test Pressure and Test Duration-
through the pipeline to prove Mainline
the internal diameter of the The minimum hydrostatic pressure in
entire pipeline. The gauging any section shall be as given in Table
plate shall have a diameter of 6. The maximum hydrostatic pressure
95% of the internal diameter of shall not however exceed the pressure
the pipeline. The gauging plate required to produce a hoop stress
thickness shall be mimimum10 equal to 95 percent of SMYS of the
mm. pipe material based on minimum wall
thickness in the test section. The test
e) All electrical connection and duration shall be a minimum 24
monitoring points on the hours or as specified by respective
pipelines have been completed. code to which pipeline is designed
and accepted by statutory authority.
f) Water used for the test medium Mainline valves shall be installed
shall be inhibited water i.e after successful completion of
water to which suitable doses of hydrostatic pressure testing.
26
11.3 Test Pressure and Test Duration- 11.7 Documentation
Stations Following records should be made:
Hydrostatic pressure testing of (i) A complete pipe book including
terminals shall be carried out hydrotesting data and location
separately. Dispatch / Receipt of leaks or failures and
terminals as well as other description of repair action
intermediate facilities shall be tested taken.
at minimum test pressure of 1.4 times (ii) As built drawings like Route
the design pressure. The hydrostatic and profile map of the pipeline,
pressure test duration shall be for a pipeline alignment, crossings,
minimum period of 4 hrs. P&IDs, Layouts , Isometric,
Earthing grid, Single line
11.4 Acceptance Criteria diagrams etc.
Pressure variations during testing (iii) Equipment supplier Manuals.
shall be acceptable, if caused by (iv) Complete Asset of each location
factors other than leakage, like with identification.
temperature variations. Pipelines not (v) Radiographs of weld joints
meeting the requirements shall be (vi) Calliper survey reports and
repaired and retested in accordance repairs, if any, carried out.
with the requirements of this
standard. 11.8 Commissioning
27
pipeline section completed and a
base line data has been obtained. (i) Nitrogen plug shall proceed
h) Coating survey has been carried before charging of natural gas.
out either by Pearson , Direct (ii) Natural gas shall not be
current voltage Gradient (DCVG) directly used for displacement
, Close interval potential logging of air in pipeline / vessels.
survey (CIPS) or Current (iii) The commissioning operation
Attenuation Test (CAT). shall be controlled and
i) Temporary modifications supervised by authorized
required at the stations for personnel.
commissioning have been (iv) Venting shall be controlled at
completed in all respect. the pig-receiving end so that
j) Commissioning check list proper backpressure is
prepared and ensured availability maintained to control pig train
of all materials tools , tackles and speed of 3 to 4 km /hr. The
consumable. desired portion of the pipeline
k) Fire fighting facilities shall be shall be commissioned in this
kept ready. manner. The pipeline system
l) Caution boards shall be displayed shall subsequently be slowly
while venting in progress. pressurized up to its operating
m) Complete removal of moisture conditions.
shall be ensured.
n) Trained and experience personnel 12.0 OPERATION &
are deployed to carry out MAINTENANCE
commissioning. A detailed operation and
maintenance procedure for control
11.8.3 Low Pressure Leak Check for system and safety interlocks shall be
Above Ground Piping developed .
The above the ground piping shall
be checked for leaks at flange 12.1 Operating Procedures
points of piping and equipment, A comprehensive operating manual
instrument impulse tubing points, shall be developed which shall
etc. by pressurizing the piping interalia include following:
system / equipment with dry
compressed air or gas at a pressure (i) System Description
of 7.0 kg/cm2 and testing by means (ii) Operation set points
of soap solution/suitable digital (iii) Initial start up
gauge for leaks. (iv) Normal operations
(v) Normal shut down procedure
11.8.4 Nitrogen Filling / Gas Charging (vi) Temporary operations
The inertisation of the entire pipeline (vii) Execution of emergency shut
system including underground down in a safe & timely
pipeline and the above ground manner
piping at dispatch and receipt (viii) Emergency shut down
stations, intermediate pigging (ix) Conditions under which
stations and hook-up/tap-off points emergency shutdown is
shall be carried out using nitrogen required
gas. Inertisation shall be accepted (x) Emergency operations
when the residual oxygen content in
the piping is below 1 percent (vol /
vol).
28
days for location class 3 and 4
12.2 Display of Operating Instructions and once in 30 days for
The gist of operating instructions, location class 1 and 2 to
emergency shut down (ESD), Trip observe surface conditions,
set pressures shall be displayed in leakage, construction activity,
the control room and near all encroachments, soil washouts
important operating equipments and any other factors affecting
the safety and operation of the
12.3 Maintenance Procedure pipeline.
A detailed maintenance procedure (b) Line Walk by the official of
shall be developed for entire pipeline the company at least twice in a
system considering the year shall be carried out before
recommendations given by the and after the monsoon.
original equipment manufacturer (c) The operating company shall
keeping in mind the local conditions. analyze the existing pipeline
To facilitate the maintenance for new anticipated external
services to be rendered in a planned loads, when the pipeline is to
manner, a preventive maintenance be crossed by a new road or
schedule covering necessary work to railroad. The operating
be done, mentioning the periodicity company shall install
i.e daily, weekly, monthly, half mechanical reinforcement,
yearly and yearly schedule shall be structural protection, or
worked out and adhered to. This suitable pipe, in case the
should also include procedures for design parameters considered
repair by clamping, removal and are exceeding in order to
replacement of pipe / hot tapping ensure redistribution of the
and stoppling etc. Adherence to external loads acting on the
work permit system inline with pipeline.
OISD-STD-105 shall be followed. (d) Villagres / public along the
right of away shall be
12.3.1 Right of Way, crossing Inspection adequately made aware of the
& Maintenance possible consequence of gas
There shall be proper maintenance leaks and this shall be included
of Right Of Way to have reasonable as a part of regular audit.
access to maintenance crews. Valve
location access shall be properly 12.3.3 Pigging
maintained. Road and highways Pigging operation shall be carried
crossings shall be inspected once in out for all pigable pipelines at least
3 months. Water course crossings once in a year for we gas and once
shall be inspected twice in a year i.e in 3 years for dry gas. Records of
prior and after monsoon or flash quantity and quality of deposits (pig
flood for sufficiency of cover, residue) collected after pigging
accumulation of debris, or for any shall be chemically examined.
other condition affecting the safety Depending upon the out come of
and security of the crossings. the chemical analysis and review
pigging frequency shall be
12.3.2 Patrolling increased.
29
12.3.4 Intelligent Pigging electrolyte. The
Intelligent pigging survey ( IPS) formation of decay of
shall be carried out once in 10 years polarization can be
and this data shall be compared measured to satisfy this
with the data collected during condition..
electronic geometric piging / caliper (c) Over protection of
pigging before commissioning to coated pipelines shall
asses the health of the pipeline. In be avoided by ensuring
case IPS is carried out once in 5 that polarisation
years then pigging operation as potential is not more
sated in clause 12.3.3 for dry gas negative than (-) 1.2
may not be required. volts with respect to
copper/copper sulphate
12.3.5 Inspection of Cathodic Protection half cells..
System iii) Instant pipe to soil OFF
potential readings at test lead
A. Pipe to Soil Potential (PSP) points of entire pipeline shall
Readings shall be taken as be taken once in a year. For
follows: the purpose of logging the
i) PSP readings at feeding instant OFF PSP, care shall
points shall be monitored be taken to minimize the
fortnightly. effect of polarization decay.,
ii) The PSP reading ( ON by logging the reading within
potential) at the test lead the first 1 or 2 seconds of
points for entire pipeline simultaneous switching of all
shall be taken once in a Cathodic protection station
quarter. The PSP survey affecting that section of the
results shall be plotted pipeline. The PSP survey
graphically to identify and results shall be plotted
locate cathodic holidays. graphically to identify and
locate cathodic holidays.
The Criteria of protection iv) Current consumption data
shall be as under should be taken at the test
stations where current
(a) Pipe to soil potential of measurement facility exist.
at least ( - ) 0.85 volts B) Cathodic protection rectifiers shall
with respect to be inspected once in two months.
copper/copper sulphate C) All protective devices shall be
half cell. In areas where inspected once in two months.
anaerobic bacteria are D) Interference bonds shall be
active, minimum PSP inspected once a year.
shall be more negative
than - 0.95 volts instead 12.3.6 Coating Survey
of - 0.85 volts. Pearson Survey / Direct Current
(b) A minimum of 100 mV Voltage gradient (DCVG) /
of cathodic polarization Continuous Potential Logging
between the structure (CPL) survey / Current Attenuation
surface and a stable Test ( CAT) shall be carried out
reference electrode once in 5 years. Insulating joints
containing the and couplings shall be inspected
30
once in a year. i. All records as per para 11.7 of this
document.
12.3. 7 Internal Corrosion Monitoring ii. Necessary operation data
Following monitoring techniques iii. Pipeline patrolling records
should be used in the pipelines for iv. Records and maps showing the
internal corrosion monitoring. location of CP facilities and
a) Corrosion coupons piping.
b) Corrosion monitoring v. CP monitoring report, test and
equipment based on Electric survey reports.
resistance (ER) technique, vi. Leak burst & repair records
electrochemical noise (ECN) vii. Records pertaining to
technique, & Linear polarisation inspections, such as external or
(LPR) technique internal line conditions
c) Iron count analyses viii. Pipeline repair records
d) chemical analysis of pig residue ix. History cards of equipment
for other parameters x. Near miss, minor and major
e) UT measurement at critical incidents.
locations
f) Intelligent pigging of pipeline in 13.0 SAFETY & FIRE PROTECTION
line with para 12.3.4 above. SYSTEM
31
minimum for 288 cubic mtr /hr i.e shall be minimum 4 hrs
flow through 2 nos. of fire water aggregate capacity of the
monitors which ever is higher. pumps. Where make up water
Entire compressor area, Pig supply system is 50% or more
launching and receiving area, filter this storage capacity may be
area, metering area, condensate reduced to 3 hrs of aggregate
collection area shall be covered capacity of pumps.
with medium velocity water spray (ii) Storage tank/reservoir shall be
system. in two interconnected
(i) Compressor area : 20.4 lpm / compartments to facilitate
sq. mtr considering area based cleaning and repairs. In case of
on outer foundation column steel tanks there shall be a
measurements (length x minimum of two tanks.
breadth)
(ii) Scraper area / Metering area / 13.1.5 Fire Water Pumps
filter area : 10.2 lpm/ sq mtr of
surface area. (i) Centrifugal fire water
(iii) Other area : 3 lpm / sq. mtr of pumps shall be installed to
surface area meet the designed fire
water flow rate and head.
13.1.3 Fire Water System Design Pump shall have flooded
suction.
(i) The Fire water pressure system (ii) Motor driven Jockey pump
shall be designed for a (not more than 10 M3 / Hr
minimum residual pressure of of water flow) shall be
7.0 Kg/cm2. installed to maintain the
(ii) A fire water ring main shall be fire network pressure at 7.0
provided all around perimeter Kg/Cm2 at farthest end of
of the plant facilities with the network.
hydrants/monitors . There shall (iii) The fire water pumps
be minimum 2 nos. of monitors including the stand by
to be located in such a way that pumps shall preferably be
it covers the compressors area, diesel driven. Where
scrapper area and filter area. electric supply is reliable
Fire hydrant network shall be 50% of the pumps may be
in closed loops to ensure motor driven.
multidirectional flow in the (iv) A minimum of 50% stand
system. Isolation valves shall by pump(s) (minimum one
be provided where the length no) of the same type,
of the pipe section is more than capacity and head as the
300 mtr. main pumps shall be
provided.
13.1.4 Fire Water Storage (v) The fire water pumps shall
be provided with automatic
(i) Water requirement for fire starting facilities.
fighting shall be met through
water storage tanks of steel or 13.1.6 Fire Hydrant Network
concrete or masonry. The
effective capacity of the tanks (i) Fire water ring main shall
above the level of suction point be sized for 120% of the
32
design water flow rate. (viii)Fire water monitors shall
Velocity of the water shall be provided with
not exceed more than 5 m/s independent isolation
in the fire water ring main. valves.
In case of sea water (ix) Hose Box with 2 Nos. of
service, the fire water main hoses and a nozzle shall be
pipes shall be concrete / provided at each hydrant
mortar lined internally. points.
(ii) Fire water steel pipe ring (x) The deluge valve shall be
main shall be laid above located at 15 mtrs. from the
ground at a height of 300 risk being protected. A fire
mm to 400 mm above wall shall be provided for
finished ground level. the protection of the deluge
Pipes made of composite valve and for operating
material shall be laid personnel.
underground. (xi) Fire Hydrants/ monitors
(iii) The mains shall be shall be located at a
supported at regular minimum distance of 15
intervals not exceeding 6 mtrs from the hazardous
mtrs. For pipeline size less facility / equipment. Case
than 150mm diameter, of buildings this distance
support interval shall not shall not be less than 2 mtr
be more than 3 m. and not more than 15 mtr
(iv) The steel pipe ring main from the face of building.
shall be laid underground Provisions of hydrants
at the following places: within the building shall be
(a) Road crossings provided in accordance
(b) Where above ground with IS:3844.
piping is likely to cause (xii) At least one hydrant post
obstruction to shall be provided for every
operation, vehicle 30 mtr of external wall
movement and likely to measurement or perimeter
get mechanical damage. of the battery limit.
(v) Under ground fire water Monitors shall be placed at
mains shall have at least 1 45 mtr interval.
mtr earth cushion in open
ground and 1.5 mtrs under 13.1.7 Medium Velocity Sprinkler
roads with concrete / steel System
encashment.
(vi) The underground fire water The medium velocity spray
steel pipe network shall be system provided at all critical
provided with suitable areas shall have spray nozzles
coating / wrapping or directed radially to the facilities
concrete / masonry. intended for cooling at a
(vii) Double headed hydrants distance of 0.6 mtr from the
with two separate landing surface of the equipment /
valves on 3 / 4 standpost facility. Only one type of spray
shall be used. All hydrant nozzles shall be provided in a
outlets shall be 1.2 mtr particular facility. All spray
above ground level. nozzles shall be inspected for
33
proper positioning, corrosion 15 LR / API 15 HR or its
and cleaned if necessary at an equivalent shall be used.
interval of not more than 12
months or earlier based on the In case saline / brackish water /
experience. treated effluent water is used , the
fire water main of steel pipes
shall be, internally cement mortar
13.2 Gas Monitoring System lined or glass reinforced epoxy
A gas detection system equipped coated or made of pipe material
with sound and visual alarm suitable for the quality of water .
shall be installed in the control Alternatively, pipes made of
room to indicate that one-fifth of composite materials shall be used.
lower flammable limit is
reached. Cast lron pipes shall not be used
(i) The Gas Monitoring system for fire water services.
shall be located close to the
potential source of leakage. b) Isolation valve , Deluge Valve, -
(ii) Detectors shall be placed in Gate / butterfly type isolation
the compressor and near valve with open / close indication
scraper/filter & other made of cast steel. Other material
hazardous areas. such as cupro-nickel for saline /
brackish water may be used.
13.3 Fire Alarm System c) Hydrant Stand post, Monitors
Carbon Steel / Gunmetal
(i) Manual call points shall be d) Outlet valves/ landing valves-
installed at strategic Gunmetal / Aluminum/ Stainless
operating locations. steel / Aluminium-Zink alloy
(ii) Electric operated fire sirens e) Fire Hose- Reinforced rubber
with audible range of 1 km lined hoses (63 mm), 15 mtr std
shall be installed. Provision length conforming to IS: 636
shall be made for (type A ) / Non percolating
continuous availability of synthetic hose (Type B) / UL or
power during emergency equivalent standard.
shut down. f) The above ground fire water
(iii) Manual operated fire sirens main, hydrant post shall be
shall be provided at painted with corrosion resistant
strategic places. fire Red paint as per IS: 5
(iv) Smoke detectors shall be g) Water monitors, hydrant point
provided in control room, and hose box shall be painted
MCC, utility room with Luminous Yellow as per IS: 5
provision of indication,
alarm & annunciation. 13.5 FIRST AID FIRE FIGHTING
EXTINGUISHERS
13.4 MATERIAL SPECIFICATIONS
All material used in fire water system The fire extinguishers shall be
using fresh water shall be of the type provided at various location as under.
indicated below (i) Compressor area - 1x 10Kg DCP
a) Pipes - Carbon Steel (CS) IS: and 1 x 6.8 Kg CO2 extinguishers
3589 / IS :1239 / IS : 1978 or per two compressors and 1 mobile
Composite materials as per API 75 kg DCP.
(ii) Scraper Barrel - 1x 10Kg DCP ,
34
Metering area / filter area -1x (g) Fire proximity suit- 1 no.
10Kg DCP (h) Resuciator - 1 No.
(iii) Air compressors - 1 x 2 Kg CO2 (i) Red / green flags 2 nos. in
extinguishers and 1x 5 Kg DCP each colour
(iv) Office/ Canteen/Stores- 2x 10Kg (j) Self contained breathing
DCP in each building. apparatus with one spare
(v) MCC/DG Room/HT room- 2 x 4.5 cylinder (cap 30 min) 1 set
Kg CO2 in each room or per 100 with spare cylinder.
m2 floor area. 4 sand buckets & (k) Water jel blanket- 1 nos.
stand shall be provided near to (l) Portable Gas detectors 2
DG room nos.
(vi) Repeater / CP stations - 1x 10Kg (m) Explosive meter 1 No.
DCP , 1 x 2 kg CO2 extinguisher. Inspection of fire fighting equipment
(vii) 100% spare for CO2 cartridges and system shall be carried out inline
and 50% DCP cartridges shall be with OISD STD-142.
stored. 13.7 Windsock
(viii) A trolley containing first aid fire Windsock shall be provided on an
protective accessories shall also appropriately elevated structure like
be provided the control room / fire-water pump
All fire extinguishers shall bear ISI or house in such a manner so as to
equivalent mark. avoid blind areas.
35
shall be conducted at least once (a) Internal inspection tool or tools
in a year. The emergency plan capable of detecting corrosion
shall be prepared based on the and deformation anomalies
following: including dents, gouges,
grooves eg Geometric Survey.
a) Risk Analysis & Hazop (b) Hydrostatic Pressure test in
Study accordance with clause 11.2 of
b) Risk scenarios this standard.
c) Flow balance
d) Organisation structure 14.5 The integrity assessment during the
e) Emergency Trainings lifetime shall consist of an initial
f) Responsibility (base line) & continual assessment.
36
(ii) Pipeline system and facilities conditions by the use of appropriate
to be abandoned shall be repair methods. The selection of the
purged with nitrogen gas or most appropriate repair method,
inert materials and ends hall be consistent with safe operation, shall be
sealed. If the facilities are based on assessment of the defect and
purged with air, it shall be categorizing the damage like,
ensured that combustible Superficial Damage, Moderate
mixture is not present in the Damage, Severe Damage, Extreme
system Damage.
37
be applied to replacement pieces
(iv) In case of repair of coated pipe, of pipe, welded patches and full
all damaged coating shall be encirclement welded split
removed and new coating shall sleeves used in making repairs.
19.0 REFERENCES
This standard shall be read in conjunction with the following standards, codes and
publications:
38
(xxviii) OISD-STD-132 Inspection of Pressure Relieving Devices.
(xxix) OISD-STD-137 Inspection of Electrical Equipment.
(xxx) OISD-STD-141 Design and Construction requirements for cross
country hydrocarbon pipelines.
(xxxi) OISD-STD-142 Inspection of Fire Fighting Equipment.
(xxxii) OISD-RP-149 Design aspect for safety in Electrical system
(xxxiii) OISD-STD-153 Maintenance and Inspection of Safety
Instrumentation.
(xxxiv) OISD-GDN-178 Guidelines on Management of Change
(xxxv) OISD-STD-195 Safety in design , operation, Inspection and
Maintenance of Hydrocarbon Gas Compressors
stations and Terminals.
39
Annexure -1
40
ANNEXURE -II
C-1 Population density index along the pipeline route shall be determined as follows:
As zone, 400 m wide, shall be considered along the pipeline route with the pipeline in the
centre-line of this zone. Then the entire route of the pipeline shall be divided into lengths of
1600 m such that the individual lengths will include the maximum number of dwellings intended
for human occupancy. The number of such dwellings which are intended of human occupancy
within each 1600 m zone shall be counted and reported along with other survey data.
b) Class 2 Location A class 2 Location is any 1 600 m section that has more
than 10 but less than 46 dwellings intended for human occupancy;
C-3 In addition to the criteria contained in C-2 a) to d), while classifying areas, additional
consideration must be given to possibilities of increase in concentration of population along the
pipeline route such as may be caused by the presence of schools, hospitals, recreational areas of
an organized character, places of assembly, places of worship, etc. If one or more of these
facilities are present, the area shall be classified as a Class 3 location.
C-4 Notwithstanding the above, while determining class location of an area due consideration
shall be given to the possibility of future development of the area during the design life of the
pipeline. If it appears likely that future development may cause a change in the location class,
this shall be taken into consideration while determining its class location.
C-5 : When cluster of building intended for human occupancy indicates that a basic 1.6 km
should be identified as a location class 2 or 3, the location class 2 or location class 3 may be
terminated at 220 mtr from the nearest building in the cluster.
41
ANNEXURE- III
S.No. From / To 1 2 3 4 5 6 7 8 9 10
1 Small Compressor / Pump - 15 15 15 16 60 15 15 30 15
House
2 Main Compressor House 15 - 15 15 16 60 15 15 30 30
3 Scraper Launcher 15 15 - x 16 30 15 15 15 30
4 Scraper Receiver 15 15 x - 16 30 15 15 15 30
5 Control Room / Office building 16 16 16 16 - 30 15 30 30 -
/ Store
6 Fire Pump House / Fire water 60 60 30 30 30 - - 60 12 -
storage tanks
7 Water Spray Deluge Valve 15 15 15 15 15 - - 15 - 15
8 Cold Flare 15 15 15 15 30 60 15 - 15 30
9 Compound wall 30 30 15 15 30 12 - 15 - 15
10 Elect Sub station, 15 30 30 30 - - 15 30 15 -
42
ANNEXURE IV.
TO CONSUMERS/
DOWNSTREAM P/L
GAS FROM PRODUCER/
UPSTREAM PIPELINE STATION BY PASS VALVE
FILTER
SEPARATOR
TO DISPOSAL
CONDENSATE TANK
METERING
SYSTEM
GT GENERATOR
GT
POWER
TREATED & COMPRESSED
GAS TO CONSUMEJRS
COMPRESSOR
EXHAUST TO
SAFE LOCATION EXHAUST
AFTER COOLER
43
PART -II
44
1.0 INTRODUCTION
a. Consumer Meter (CM) for
The use of piped natural gas (PNG) Commercial & Industrial Consumers
for domestic, commercial and
industrial purpose in cities is gaining b. First isolation valve down stream of
increased importance as an Consumer Meter for Domestic
alternative fuel. PNG is being used Consumers.
internationally with proven success.
c. Piping and facilities upto the burner
PNG is a mixture of hydrocarbon of gas Oven and /or any Gas
gases and vapours consisting of Appliances for domestic consumer.
principally Methane in gaseous
form. The PNG network consists of The facilities up-stream of CGS Inlet
receiving natural gas from suppliers Valve are covered under Part-1 of
at City Gate Stations (CGS), Steel this standard.
Mains, Pressure Regulating
Installations (PRI), Poly Ethylene d. CNG Dispensing facilities are
(PE) Mains and Supply System to covered on OISD-STD-179
end users. A typical system of piped
natural gas distribution is given at
Annexure-I. 3.0 DEFINITIONS
45
(Monitor) to assume control in the
f. Creep Relief Valve: A relief valve event of failure of the active device
having maximum 1 % flow capacity to the open position.
and is installed to prevent over
pressurization of the downstream n. PNG Distribution System: A
system. natural gas distribution system &
facilities in which the piped natural
g. Emergency Shut Off Valve: A gas (PNG) is distributed to
quick action shut off valve, which residential, commercial & industrial
operates from full open to full closed customers.
condition in less than one complete
turn. o. Pressure Regulating Installation
(PRI):
h. Electro Fusion Joint: A joint made PRI is an installation in the PNG
in thermo plastic piping by heating network where second stage pressure
the parts sufficiently to permit fusion regulation of natural gas takes place
of the materials using electrical coil after CGS. A typical schematic
or otherwise when the parts are layout of facilities/ equipment
pressed together. installed at PRI is given at
Annexure-III.
i. Hazard: A substance or
circumstance which may cause p. Shall : Indicates mandatory
injury or damage due to being requirement.
explosive, flammable, poisonous,
corrosive, oxidizing, or otherwise q. Should: Indicates recommendation
harmful. or that which is advised but not
mandatory.
j. Insulation Joint: A fitting having
high electric resistance, which can r. Service Line: A pipe connecting a
be fitted in a pipeline to insulate one gas main up to and including a
section of pipe from another meter control valve. A service line
electrically. may supply more than one meter in a
particular building or in two adjacent
k. Mains: A pipe, other than an buildings.
installation or service pipe, used for
conveying gas in a distribution s. Service Regulator: Regulator
system. installed on a gas service line to
control the pressure of the gas
l. Maximum Incidental Pressure delivered to customer.
(MIP): Max. Pressure, which a
system is designed to experience 4.0 STATUTORY REGULATIONS
under fault condition and is less than
or equal to the design pressure. It is necessary to comply with
statutory regulations such as State
m. Monitor/ Active (Regulator): An Pollution Board, Factories Act,
arrangement of two regulating Indian Explosives Act, IE Rules,
devices in series whose pressure Municipal Authorities etc as
settings are stepped so as to allow applicable and requisite approvals
one (Active) normally to control the shall be obtained from the relevant
outlet pressure and the other competent authorities for the PNG
46
distribution system. f. PNG shall be supplied after adequate
filtration to prevent erosion and
5.0 LAYOUT & FACILITIES damage to equipment/ instruments.
The steel mains shall not be pig-
5.1 PRESSURE REGULATING able.
STATIONS (CGS & PRI) g. Minimum 3 numbers gas leak
detectors shall be installed at the
strategic locations in the CGS to
5.1.1 The facilities at the pressure
cover entire facility.
regulating station shall be located in
h. CGS shall be installed outside the
a manner to facilitate operation and
city limit.
ease of maintenance & inspection.
The typical schematic layout of 5.1.2 VENT LINE
facilities/ equipment installed at
CGS and PRI are given at Annexure The relief valve vent line shall be
II & III respectively. Additionally, terminated at a minimum height of 3
the facilities at CGS and PRI shall meters above the equipment for over
conform to the following: ground installations and 3 meters
above the ground level for under
a. For CGS, the minimum separation ground installations.
distance between the nearest
equipment and the boundary wall Vent line shall extend to location
shall be 6 meters. where the discharge of gas shall not
create a hazard to the compressor
b. The PRI shall be inside an enclosure station or the surrounding area.
with sufficient ventilation. For above
ground PRI, the separation distance 5.1.3 ISOLATION OF CGS
between enclosure and the boundary
wall of nearest building/ structure Quick acting isolation valves shall
shall not be less than 2 meters. be provided at CGS for emergency
isolation purpose.
c. There shall be minimum two safety
devices and at least one shall be a 5.2 PIPING AND VALVES
slam-shut valve operating on over
pressure for installations operating at 5.2.1 STEEL PIPING
inlet pressure more than 4.0 barg.
a. All rigid piping, tubing, fittings and
d. The environmental effect and other piping components shall
associated hazards of fire and conform to the requirements clause
explosion due to the release of large 5.2 of part-1 of this standard. Pipe
volumes of gas to atmosphere shall having D/t ratio greater than 96 shall
be considered in case a relief valve not be used.
is installed as a pressure control b. The steel piping shall be designed
device. Creep relief valve can be for maximum operating pressure of
used to prevent over pressurization 19.0 barg. at temperature ranging
of the downstream system. between (-) 29 Deg. C to (+) 65
Deg. C.
e. In case, a monitor regulator is used, c. For underground steel piping
it shall be the first acting device in network, suitable corrosion
the pressure safety system. protection like cathodic protection,
wrapping/ coating etc shall be
47
applied. Provisions of clause 9.0 of 5.2.3 STRATEGIC VALVES
Part -1 of this standard shall be
applicable. Such valves shall be installed to
facilitate maintenance of system and
d. The above ground mains shall be to allow for speedy isolation in the
painted yellow for identification. event of damage. The location of the
strategic valves shall be decided
e. The cast iron pipes shall not be used based on the risk associated with
in the PNG network as a carrier of maintaining the gas supply and to
natural gas. facilitate maintenance, repair,
modification, testing and
commissioning etc. In no case,
5.2.2 POLY ETHYLENE (PE) PIPING distance between two strategic
valves shall exceed;-
The PE piping, tubing, fitting and
other components shall conform to a. 3 KM for steel pipelines.
requirement of ASME B 31.8 or
equivalent as approved by statutory b. 1KM for PE Pipelines of
authority. The PE piping shall be diameter 63 mm and above.
designed for maximum operating
pressure of 4.0 barg. at temperature For PE Pipelines less than 63 mm
ranging between (-) 29 Deg. C to diameter, the distance between
(+) 65 Deg. C. PE piping shall not strategic valves shall be based upon
be used in water / rail crossing. The risk analysis.
value of pipe thickness t shall not
be less than the following table Such valves of appropriate materials
shall also be provided on each riser,
Nominal Minimum wall thickness, mm
upstream of each meter and at both
outside
ends of river & railway crossing..
dia, mm
Dn SDR SDR SDR SDR 5.3 CONSUMER INSTALLATIONS
17.6 13.6 11 9
16 2.3 2.3 3.0 3.0 5.3.1 Gas received through PE Pipeline
20 2.3 2.3 3.0 3.0 undergoes further pressure
25 2.3 2.3 3.0 3.0 regulation at domestic/ commercial/
32 2.3 2.3 3.0 3.6 Industrial consumer end. The
40 2.3 3.0 3.7 4.5 pressure regulator shall be capable
50 2.9 3.7 4.6 5.6 of shutting down the downstream
63 3.6 4.7 5.8 7.1 gas supply in case of low or high
75 4.3 5.5 6.8 8.4 pressure in the system. These
90 5.2 6.6 8.2 10.1 installations include isolation valve,
110 6.3 8.1 10 12.3 pressure regulator and meter etc. The
125 7.1 9.2 11.4 14 isolation valve down stream of
140 8.0 10.3 12.7 15.7 consumer meter shall be easily
160 9.1 11.8 14.6 17.9 accessible. Meters duly certified by
180 10.3 13.3 16.4 20.1 competent authority shall be used.
200 11.4 14.7 18.2 22.4
The pressure ranges for different
consumers should be as under:
48
(a) Domestic Consumer : 19mbar - ii. High stray direct current, typically
28 mbar near DC traction systems.
(b) Industrial / Commercial
Consumer: As per consumer iii. Long runs parallel to high voltage
requirement. overhead conductors.
49
odour, strong enough to detect its a. The entire gas handling equipment/
presence. In case ethyl mercapton is facilities installed in CGS shall be
used as odorant, the concentration covered with water sprinklers.
range shall be 7 to 12.5 PPM.
b. The firewater storage shall be
b. The odourisation and filtration calculated based on following
system shall be located in a separate cooling rates for minimum 4 hours.
working area, but within the same
fencing. There should be a clear Scrappers/Filters:10 lpm/ sq. m of
safety distance of 1.5 M around the surface.
odourisation and filtration system to Other areas : 3 lpm/ sq. m of
facilitate easy maintenance and surface
personnel movement.
c. Adequate fire fighting access, means
c. Risk Assessment of odourant of escape in case of fire and
installation site shall be carried out. segregation of facilities should be
The storage of odorant should be provided so that the adjacent
minimum enough to prevent a major facilities are not endangered during a
risk. The unloading of odorant fire.
should be automated. d. Fire water storage and pump house
shall be located at a safe place from
d. Precautions for handling odorant the gas handling equipment /
shall be prominently displayed. facilities. However, such separation
distance shall not be less than 15 mtr
e. Odourant absorber like activated in any case.
carbon saw dust, dry sand and
odorant neutralizer like sodium e. Additionally, following fire
hypochlorite for spillage handling of extinguishers shall be provided at
odourant shall be provided. the city gate station:
c. Sand Buckets
50
FOOTPATH
5.9 All electrical equipment/ installations ROAD
shall conform to OISD Standards 110,
113, 149 and 173 as applicable.
51
Drainage ditches at 1. 0
roadways and railroads
Rocky Areas 1. 0
Road Crossings 1. 2
500 mm=
Railroad Crossings 1. 7
Inside the building / 1. 0
society premises
NOTE :
52
length shall be used. However,
these pipes shall only be used for c. All Poly Ethylene (PE) pipe and
a maximum pressure of 100 mbar. fittings shall be laid underground
(e) An external PE risers and laterals and shall not be exposed. The
system, not exceeding 63mm service lines, where coming above
outside diameter, should be joined ground, shall be only made of
using wall mounted crimped or GI/Carbon Steel piping, with
compression fittings. adequate anti corrosive coating.
(f) All external PE pipe work should d. Wherever the riser is to be laid
be completely sleeved with half through confined spaces like
an hour fire resistant glss basements, only welded risers shall
reinforced plastic and secured at a be used. Riser shall be installe d with
minimum of 2 m intervals with a minimum gap of 25 mm to wall
wall mounted retaining clips. and supported at every 2 m.
Ventilators shall be provided in
6.4 LAYING OF PE PIPE confined space.
During installation of PE piping,
e. Interface joint shall be provided over
care shall be taken to prevent
ground . In case interface joint is
damage to piping and components.
provided underground , it shall be
Gouge , cuts, scratches, kinks /
protected against corrosion etc.
buckle or other form of damage shall
be removed by cutting out and
replacing the damage portion as a 7.0 TESTING & COMMISSIONING
cylinder. 7.1 Following shall be complied before
commencing the testing &
6.5 BACK FILLING commissioning activities :
Back filling shall be performed in a a. Issue of Work Permit as per OISD-
manner to provide firm support STD 105.
around the pipe. Material used for
back filling shall be free from rock, b. Availability of fire fighting
pieces of pavement, stones or any equipment
other material which can damage the
pipeline. c. Availability of communication
facilities
6.6 Provision shall be made for locating
the buried PE pipe by installation of d. Availability of inspected &
electrical conductive trace wire or calibrated testing equipment /
plastic coated metallic tape or any instruments
alternate proven locating method.
e. Warning Signs
53
pneumatic strength test as given i. For services operating at
below: pressure not exceeding 75 mbar,
an air/ inert gas test at a
minimum of 100 mbar shall be
Design Pr. Strengt Duration applied.
(DP) h Test Hydro.(H)/
(bar) Pr. Pneu. (P) ii. For Services operating at
(bar) pressure in excess of 75 mbar the
Up to 0.1 0.3 P test pressure shall be 1.5 times
30 min the maximum operating pressure.
From 0.1 to 2.0 P
1.0 30 min iii. The pipeline operated above 2
From 1.0 to 3.0 bars shall be tested at 1.5 times
2.0 H (4hrs) the max. operating pressure.
From 2.0 to H
7.0 4hrs iv. Where a service supplies a multi-
From 7.0 to 1.5 DP H storey building, the risers and
100.0 4 hrs laterals shall be tested at a
pressure of 350 mbar or 1.5
Duration of test shall be after times the maximum operating
stabilization of pressure and shall be pressure which ever is higher.
acceptable when no pressure loss is
detected over the required period.
Tightness test shall be carried at b. TEST DURATION
operating pressure for a duration not
less than 30 minutes. The duration of pneumatic testing of
service line and internal installation
shall not be less than 30 minutes.
7.2.2 HYDROSTATIC TESTING
7.3 COMMISSIONING OF
a. Steel Pipelines and mains shall be FACILITIES
tested hydrostatically to a pressure
not less than 1.5 times the Maximum All fire protection and detection
Operating Pressure. Suitable relief facilities shall be in place before
valve set at 5% over the test commissioning.
pressure, shall be fitted to avoid over
pressurization. All facilities i.e. CGS, PRI, Pipelines
etc. shall be purged and
b. The duration of hydrostatic test for commissioned as per approved
steel pipeline shall not be less than procedure after due checks and
24 hrs or as specified by respective certification by the authorised
code to which the pipeline is personnel.
designed and accepted by statutory
authority. 8.0 OPERATION & MAINTENANCE
7.2.3 PNEUMATIC TESTING
8.1 Operating procedures, with suitable
a. Pneumatic testing of PE PIPELINE operational controls based on formal
shall comply with the following: hazard identification & risk
assessment, shall include following
safety aspects:-
54
a. Adherence to work permit system in f. Important operational activities shall
line with OISD-STD-105 be logged and records of such
activities shall be maintained.
b. Management of change in line with
OISD-GDN-178, g. All PNG operations shall be carried
out under the supervision of
c. Selection of electrical equipment as authorised person(s).
per hazard area classification &
maintenance in line with established h. Limits of operating parameters
O & M practices/ statutes, including level, pressure and any
other condition as set for sound and
d. Provision of Personal Protective safe operations shall not be
Equipment (PPE), exceeded. In case any abnormal
operating conditions are
e. Regular Preventive Maintenance encountered, the causes shall be
investigated and corrective actions
f. Availability of Documented taken.
Isolation Philosophy etc. shall be in
place. i. The operating staff shall maintain
vigilance for detection and control of
any leakage.
55
Type Freq. Agency
General Daily Operating s. Calibration of meters/ gauges etc.
Inspection personnel shall be carried out, documented and
Once a Engineering records kept.
month in-charge of
PNG mktg. t. The Functional Test of Active/
Company Monitor Regulator, Slam Shut Valve
Safety Once a Authorised and Pressure Relief Valve for their
Audit year Person (s) / proper operation shall be carried out
Agency once in a year.
Electrical Once a Licensed
Audit year Electrical u. No Mobile phone, No smoking
Agency sign, No lighter / matches shall
be displayed at CGS operational
n. All recommendations of the safety area.
audit/ inspections shall be complied
in a time bound manner and records v. Dos and Donts , safety precautions,
maintained thereof. emergency telephone nos. shall be
displayed at the consumer point.
o. Disassembly or removal of the
8.3 The following safety precautions shall
facilities and components of
be ensured during emergency
equipment whilst any part of the
repairs/ breakdown maintenance of
system is under pressure is
pipelines:
hazardous and shall not be
a. Warning/ cordoning off work area.
undertaken unless the system is de-
pressurised, gas freed and certified.
b. All naked flames, sources of ignition
and mobile phones shall not be
p. The system of permit to work shall
allowed in the immediate work area.
be established for non-routine works
in line with OISD-STD-105 and
c. Gas level should be monitored
such works shall be undertaken with
during the repair work with gas
full knowledge and approval by
detectors.
authorised person.
d. Adequate fire fighting equipment
q. Equipment appurtenances,
shall be deployed during such repair.
protection devices associated with
the PNG system as incorporated in
e. Close Coordination among utility
the design shall be tested,
companies shall be carried out to
maintained, repaired and replaced as
avoid damages to the utilities.
recommended by the manufacturer.
8.4 MODIFICATIONS TO LIVE
r. Preventive maintenance schedules PIPELINES
shall be drawn for all equipment in
accordance with manufacturers All modifications i.e. additions/
recommendations and established alternations shall be carried out in
mandatory / recommendatory accordance with applicable code of
standards. Records of all preventive practice/ approved procedure.
maintenance undertaken shall be Provisions of OISD-GDN-178
maintained and updated from time- (Guidelines on Management of
to-time. Change) shall be complied.
56
iii. Accidents or other emergencies,
8.4.1 PRESSURE CONNECTIONS which can affect the PNG supplies.
57
loss of life/ properties etc. In order
to reduce damages to gas pipeline, b. Familiarization with operational
following measures shall be ensured procedures & practices.
by utility companies:-
c. Commissioning of new facilities and
i. A person should be designated by equipment..
company for utility co-ordination.
d. Hands on experience on operation of
ii. A utility co-ordination team should equipment..
be formed consisting of
representatives from all utility e. Routine checks and maintenance
companies as well as Municipal activities of the facilities.
Corporation.
f. Knowledge of emergency and
iii. Formats should be designed for manual shut down systems.
taking clearance from PNG
distribution company prior to g. Immediate and effective isolation of
taking up any excavation / digging any PNG leak.
activity within the city limits by
other utilities. h. Safety regulations and accident
prevention.
iv. Prompt reporting of gas leak/
damages shall be done. i. Fire fighting facilities, its upkeep
and operation.
v. Use of designated utility corridor
provided by local administration j. Housekeeping
shall be made.
k. First aid.
10.0 TRAINING
l. Emergency plan/drills
10.1 The objective of training is to
10.2 Proper records for the training and
provide good understanding of all
refresher courses shall be maintained.
the facets of PNG distribution
activities including operations,
10.3 Training for employees & contractors
procedures, maintenance and
of other utility companies should
hazards and the risks associated with
be done to make them aware about
its handling. Training shall ensure
hazards associated with leak/
that the jobs are performed in
damages and required actions.
accordance with the laid down
procedures and practices.
11.0 RECORDS
Training shall be imparted to the
staff attached with the PNG The PNG distribution company shall
distribution at the time of induction, maintain following records/
which is to be followed up by documents:
periodic refresher courses. The
training programme shall inter alia a. Design/ specification documents
cover following aspects:
b. Pipeline alignment sheets for MP
a. Hazardous characteristics of PNG. steel pipeline
58
l. Commissioning reports
c. Pipe Book/ Installation Records m. Non-conformance/ deviation reports
d. Vendor and subcontractor n. Calibration records of Inspection,
assessments and records Measuring & Metering and Test
e. Surveillance inspection and equipment
maintenance reports o. Audit compliance reports
f. Material certification including p. Statutory clearances
dimension, metallurgy, DT and q. Approved drawings/documents
NDT, strength, tightness, r. International practices
performance and functional report s. HAZOP/ Risk assessment studies/
g. Welding records compliance to recommendations
h. PQR, WPS & Welder qualification t. All operation & maintenance
records manuals
i. Stage inspection reports u. Interlock testing document/by pass
j. Test reports records etc.
k. Strength, tightness and leak test
reports
12.0 REFERENCE S
i. OISD-STD-117 - Fire Protection Facilities for Petroleum Depots and Terminals and
Pipelines Installations
59
Annexure-I
Typical Piped Natural Gas (PNG) Distribution System
Steel
Mains
INLET PRI Combined Meter Appliances (Domestic,
FROM
Comm.& Industrial
SUPPLIER PE/ Steel PE/ Steel/
Mains Copper
Service
City Gate
PRI Industrial Meter Industrial Appliances
Station
(CGS) PE/ Steel PE/ Steel
Mains service
Steel
Mains PRI
Residential/ Meter Dom./ Comm.
Commercial
PE/ Steel PE/ Steel/
Appliances
Mains Copper
Service
Steel
Mains Compressed
Natural Gas
Dispensing
Station
NOTE : Compressed Natural Gas Dispensing Station is not covered under the scope of this standard
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Standard on Natural Gas Transmission Pipelines and City gas distribution networks
Annexure-II
Filter
KOD PSV
Isolation
Valve
INLET
Stand by Stand by
Odourant
Injection
STAND BY
STREAM
OUTLET
Meter
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Standard on Natural Gas Transmission Pipelines and City gas distribution networks
Annexure-III
Slam Shut
Valve Isolation
Valve
INLET
Filter
Active/ Monitor
Regulators
Outlet
Stand-by Stream
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Standard on Natural Gas Transmission Pipelines and City gas distribution networks
ANNEXURE - IV
1. Recommended specification of GI pipes used for domestic gas piping above ground up to the isolation valve after the meter
Pipes shall be conforming to IS: 1239 (Part-1) 1990. The manufacturer shall have a valid license to use ISI Monogram for manufacturing of
pipes in accordance with the requirements of IS: 1239 (Part-I) 1990.
NOMINAL 15 mm 25 mm 50 mm 80 mm
BORE
GRADE HEAVY HEAVY HEAVY HEAVY
(C CLASS) (C CLASS) (C CLASS) (C CLASS)
O.D. mm
max. 21.8 34.2 60.8 89.5
Min. 21.0 33.3 59.7 88.0
THICKNESS mm
3.2 4.0 4.5 4.8
NOMINAL
WEIGHT 1.44 2.93 6.19 9.90
Kg / mtr
Note:
Maximum tolerance on thickness (-)10%, Tolerance on weight for single tube 10% and for quantities per load of 10 tonnes, 7.5%.
Pipes shall be designed to withstand a test pressure of 5 MPa (50 Kgf / cm2), maintained for at least 3 second without showing any kind
of defects.
Eddy Current test may be done in place of hydrostatic test as per the procedure given in Annex - C of IS: 1239 (Part-1) - 1990.
All Galvanised Tubes shall be Zinc coated by hot dip galvanising in accordance with IS: 4736-1986 & its relevant parts.
Minimum mass of zinc coating determined as per IS: 6745-1972 shall be 400 gms / m2.
The zinc coating on external and internal surfaces shall be adherent, smooth and free from such imperfections as flux, ash & dross
inclusions, bare patches, black spots, pimples, lumpiness, runs, rust stains, bulky white deposits and blisters.
Rejection and acceptance for these defects shall be as per Appendix-A of IS: 2629-1985
The galvanised coating when determined on a 100 mm long test piece in accordance with IS: 2633 - 1986 shall withstand 4, one -
minute dips.
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Standard on Natural Gas Transmission Pipelines and City gas distribution networks
The adherence of zinc coating on tubes above 50 mm nominal bore, shall be determined by the pivoted hammer test given in IS : 2629 -
1985.
Each pipe shall be legibly and durably marked at intervals of not more than one metre with the following information (i) Manufacturers name
or trade mark, (ii) Class of Pipe HEAVY, (iii) Indian Standard mark ISI, (iv) Batch No. of Production, if any.
2. Recommended specification of copper pipes used for domestic gas piping inside the residence up to the isolation valve after the
meter
For a copper service in domestic natural gas installations, materials supplied shall be in accordance with BS EN 1057:1996, it has replaced
the copper tube standard BS 2871 Part 1. BS EN 1057 ensures the quality of the copper product by specifying the pipe in terms of its
chemical composition, mechanical properties (tensile strength, hardness, elongation etc.), dimension and tolerance, surface quality, freedom
from defects and suitability for pipe bending.
Copper pipe work shall be jointed by soldering or brazing, using mechanical compression or capillary type fittings. Fittings for use in joining
copper tube shall be as per BS EN 1254 Parts 1 and 2. Fittings for capillary soldering and brazing are specified in Part 1 and compression
fittings are specified in Part 2.
Soft soldering utilises filler metals with melting points at temperatures up to 450C. Filler metals shall be as per BS EN 29453:1994 - Soft
solder alloys - Chemical compositions and forms. Solders for use with copper tube and fittings generally melt within the temperature range
180C to 250C. Compression fittings shall be comply with BS 864 Part 2 or BS 2051 Part 1.
Height limit for copper risers: Although there is no specific guidance regarding maximum height of copper risers, IGE/UP/2 only allows the
use of steel for risers above heights of 15 meter. Thus, unless local information is available to the contrary, 15-meter maximum height shall
be considered safe due to weight and mechanical strength of material.
General guidance in BS 6891 also states that copper pipe work is not acceptable inside a protected shaft. Requirements for ventilation and
fire stopping shall apply to ducts conveying copper pipe work. For an external copper riser system, protection against lightning conductors
shall be considered.
Last but not least, a copper gas line shall never be used as a ground for an electrical system.
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Standard on Natural Gas Transmission Pipelines and City gas distribution networks
3. Recommended specification of rubber hose used for connecting the Gas Stove after the isolation valve to the Gas Stove.
Rubber hose shall be conforming to IS: 9573 Type IV. The hose shall consist of lining, reinforcement and cover.
The Hose should not be exposed to internal or external temperature exceeding the recommended limits, as high heat conditions can cause
an adverse effect on the hose by degrading the Elastomer and thereby reducing fitting retention.
The hose size must be capable of handling the required flow volume. Using the smaller than required diameter of hose for a given volume of
flow would, result in excessive fluid turbulence, pressure drop, heat generation and tube damage.
The hose should not be bend or flex beyond the specified parameter (refer, Table 1 Dimensions and Bend radii for Rubber Hoses, IS: 9573),
as this would put excessive stress on the reinforcement and severely reduce the ability of the hose to withstand pressure.
Hoses in service should be checked every year, for leakage, kinking, corrosion, abrasion or any other signs of wear and damage. Any hose
worn or damaged must be removed from service and replaced immediately
The gas stove shall be manufactured and checked in accordance to IS: 4246, IS: 11480 and IS: 5116. The following tests are conducted, (i)
strength testing, (ii) thermal efficiency, (iii) combustion, (iv) gas soundness test, (v) floor wall & ceiling temperature measurement (vi) gas
consumption test.
The jet nozzle of the gas burner shall be designed for a standard length of 11mm, with a tolerance of 0.2mm. The bore at the bottom of the
hose is of 2.38 mm diameter (tolerance +0.1, -0.15). The hole on the top of jet is of diameter 1.25 mm or 1.10 mm (tolerance +0.02, -0.01)
based on the capacity. (Refer fig. 1 & 2)
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Standard on Natural Gas Transmission Pipelines and City gas distribution networks
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Standard on Natural Gas Transmission Pipelines and City gas distribution networks
Annexure - V
Details of the online procedures for Steel pipelines where hydro testing is not recommended. Hot tapping
Procedure for Hot tapping on pipelines in-service shall comply to IS: 15679 : 2006. Hot tapping is the technique of attaching a mechanical or
welded branch fitting to piping or equipment in service, and creating an opening in that pipeline by drilling or cutting a portion of the piping
within the attached fitting.
Hot tapping shall be performed when it is not feasible, or impractical to take the piping out of service, or to purge or clean it by conventional
methods. A hot tap connection can often be safely made without interfering with the process operation.
Prior to conducting hot tapping, a written plan shall be prepared which includes the following,
Connection design
Hot tap procedure
Detailed written welding procedure
Health, safety, fire protection, emergency response, and other appropriate procedures & instructions.
Additional information when developing a written plan may be obtained from Section IX of the ASME Boiler and Pressure Vessel Code for
qualification of welders and the fundamental ASME Code welding procedure to be employed.
Note: Section IX does not cover the condition encountered while welding on in service piping containing flammable and combustible liquids.
Refer to API Recommended Practice 1107 for qualification of welders and the welding procedures to be employed when welding on in-
service flammable and combustible liquid piping.
The tightness of bolts, packing, packing nuts and any by-pass line shall be checked to avoid any possible leakage. The test pressure should
be atleast equal to the operating pressure of the line or vessel to be tapped. But it shall not exceed the present internal pressure by more
than approximately 10%, in order to avoid possible internal collapse of the pipe or vessel wall.
67