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GSPC GAS
The Pathway
GSPC Gas Company Ltd., a group company of the Gujarat State Petroleum Corporation has been
established to complete the presence of GSPC in the Energy Value Chain. GSPC Gas always
works towards a principal aim to supply natural gas to retail customers, i.e. Domestic,
Commercial/Non-Commercial, Industrial and CNG. GSPC Gas is playing a vital role to cater to
the natural gas demand up to the last mile of the retail network. GSPC Gas is envisioned to be
complementary to Gujarat State Petronet Ltd. (GSPL), which is evident from the presence of
GSPC Gas retail network starting at every point and location that the GSPL network ends.
Core Philosophy
The GSPC Group's foray into Gas Distribution in a big way bears testimony to the core
philosophy of being 'A Complete Energy Company'.
PNG Domestic
PNG Industrial
PNG Commercial
CNG
Component
Chemical Formulae
Percentage
Methane
Ethane
Propane
Butane
Carbon Dioxide
Oxygen
Nitrogen
Hydrogen Sulphide
Rare Gases
CH4
C2H6
C3H8
C4H10
C02
02
N2
H2S
He, Ne, Ar, Xe
70%-90%
0%-20%
0%-8%
0%-0.2%
0%-5%
0%-5%
Traces
0.56% to 0.67%
Boiling Point
-161C
Melting Point
-182C
Flash Point
-161C
560C
Flammable Limit
Critical Pressure
45.99 Bar
Critical Temperature
-82.59C
I.
Domestic Usage: Most commonly known use of Natural Gas. It can be used for
cooking, water warming, heating and air conditioning. Domestic appliances are
increasingly improved in order to use natural gas more economically and safely.
Operating cost of natural gas equipment is generally lower than those of other energy
sources.
II.
III.
Commercial Purpose: Main commercial centers which use natural gas are Hotels,
healthcare facilities and office buildings for cooking, cooling and heating purposes.
IV.
Natural Gas Vehicles (NGVs): It can be used as a motor vehicle fuel as CNG
(Compressed Natural Gas) and as LPG (Liquefied Natural Gas). Natural gas vehicles
fleet accounts for about one and a half million vehicles worldwide. Concerns about air
quality in most parts of the world are increasing the interest in using natural gas as a fuel
for vehicles. Cars using natural gas are estimated to emit 20% less greenhouse gases than
gasoline or diesel cars. In many countries NGVs are introduced to replace buses, taxis
and other public vehicle fleets. Natural gas in vehicles is inexpensive and convenient.
CNG (compressed natural gas) is natural gas mainly containing methane which is
compressed up to 250 bars and used as vehicular fuel in vehicles running on CNG kits.
It has a Research Octane Number in excess of 120. The excellent knock resisting
property of CNG allows for use of a higher compression ratio resulting in an increased
power output and greater fuel economy when compared to petrol.
CNG can be used in engines with a compression ratio as high as 12:1 compared to normal
gasoline (7.5:1 to 10:1). At this high compression ratio, natural gas-fuelled engines have
higher thermal efficiencies than those fuelled by gasoline. The fuel efficiency of CNG
driven engines is about 10-20% better than diesel engines.
1. Green Fuel
Commonly referred to as the green fuel because of its lead and Sulphur free character, CNG
reduces harmful emissions. Being non-corrosive, it enhances the longevity of spark plugs. Due to
the absence of any lead or benzene content in CNG, the lead fouling of spark plugs and lead or
benzene pollution are eliminated.
4. Safety
CNG is less likely to auto-ignite on hot surfaces, since it has a high auto-ignition temperature
(540C) and a narrow range (5%-15%) of inflammability. It means that if CNG concentration in
the air is below 5% or above 15%, it will not burn.
1. Uninterrupted Supply
PNG offers the convenience of ensuring continuous and adequate supply of NG through pipeline,
without any storage of gas in cylinders.
2. Unmatched Convenience
The domestic consumers have to take upon themselves the tiresome task of booking an LPG
cylinder; refill time and again start the wait for the deliveryman to deliver the cylinder. Switching
over to PNG renders this entire exercise unnecessary. PNG also eliminates the tedious routine of
checking LPG refill cylinder for any suspected leakage, or it being underweight, at the time of
delivery. Precious space, occupied by LPG cylinders is also saved.
3. Safety
The combustible mixture of natural gas and air does not ignite if the mixture is leaner than 5%
and richer than 15% of the air-fuel ratio required for ignition. This narrow inflammability range
makes NG one of the safest fuels in the world.
Natural gas is lighter than air. Therefore, in case of a leakage, it just rises and disperses into thin
air given adequate ventilation. But LPG being heavier will settle at the bottom near the floor
surface.
A large quantity of LPG is stored in liquefied form in a cylinder. With PNG, it is safer since PNG
installation inside your premises contains only a limited quantity of natural gas at low pressure
i.e. 21 millibar.
On leakage, LPG expands 250 times, which is not the case with PNG. Supply in PNG can be
switched off through appliance valve and isolation valve, which fully cuts off the gas supply.
4. Billing
The user is charged only for the amount of PNG used, and no pilferage is possible with PNG as
the billing is done according to the meter. A unique feature is that the user gets to pay only after
consumption of gas. The domestic consumer pays the PNG bill only once in two months.
Moreover, there are no minimum consumption charges i.e., if there hasnt been any consumption,
there shall not be any bill.
The user pays the gas consumption charges based on the exact consumption reading provided by
the meter installed at his premises. The bill is delivered at the users doorstep.
5. Customer Support
Round-the-clock customer support is assured through 24 hours toll free number backed by
control rooms, which are manned by engineers and trained technicians. Thus complaints, if any,
are promptly redressed.
6. A Versatile Fuel
Natural gas is being used predominantly as a versatile fuel in many major cities catering to
domestic and commercial applications, as a cooking fuel, for water heating, space heating, air
conditioning, etc.
7. Environment Friendly
Natural gas is one of the cleanest burning fossil fuels, and helps improve the quality of air,
especially when used in place of other more polluting energy sources. Its combustion results in
virtually no atmospheric emissions of Sulphur dioxide (SO 2), and far lower emissions of carbon
monoxide (CO), reactive hydrocarbons and carbon dioxide, than combustion of other fossil fuels.
8. No Daily Liasioning
The consumer is spared the task of liasioning with oil companies and co-coordinating with them
for ensuring the daily supply of fuel, because PNG is supplied directly through pipes. The daily
bills, settlements and reconciliation are also avoided as the consumer is billed once a month, and
that too as per the meter reading.
A City gas distribution means a distribution system in which CNG & PNG sold to various
segments by interconnecting gas pipeline & related equipments.
Currently the CGD segment constitutes 10 percent of the total gas consumption in India. It is
worth noting that this has been achieved in the past five years itself. It is expected to reach a
share of 20 percent by FY20. The supply of natural gas for CGD is around 13 mmscmd in FY11
against the demand of 15.83 mmscmd in the country. Increasing demand from commercial and
small industrial customers within the city limits, in addition to the automotive and residential
demand, are the key drivers of growth in this segment. Much of the demand in future will
continue to be as a result of customers finding natural gas to be more competitive than other
fuels coupled with ease of handling and lower pollution.
On the supply side expectation of large volumes of gas being made available within the next few
years, though both new domestic finds and imports, has created greater compulsions for
developing the CGD market. With an estimated demand of 100 mmscmd by FY 20, CGD market
is expected to grow by leaps and bounds.
S.
No.
Area Covered
1
2
3
4
5
6
Sonipat
Meerut
Kakinada
Dewas
Kota
Mathura
7
8
9
10
11
12
13
14
15
Chandigarh
Allahabad
Jalandhar
Jhansi
Bhavnagar
Jamnagar
Firozabad
Geographical
Area (U.P.)
Agra
Hyderabad
Entity Authorized
Gail Gas Limited
Gail Gas Limited
Bhagyanagar Gas Limited
Gail Gas Limited
Gail Gas Limited
JV of M/s DSM Infratech Pvt. Ltd. &
M/s Saumya Mining Pvt. Ltd.
M/s IOCL-AGL
M/s IOCL-AGL
M/s Jay Madhok Energy Pvt. Ltd.
M/s Central UP Gas Ltd.
M/s Gujarat Gas Company Ltd.
GSPC Gas Company Limited
GAIL Gas Ltd.
16
17
18
19
20
21
22
Gwalior
Gandhinagar,
Mehsana,
Sabarkantha
Pune City including Pimpri, Pune City
Chichwad CGD Network
INCLUDING
Pimpri,
Chichwad
Kanpur CGD Network
Kanpur GA
Bareilly CGD Network
Bareilly GA
Delhi CGD Network
National Capital
Territory of Delhi
23
Mumbai and
Mahanagar Gas Ltd.
Greater Mumbai
24
25
Vijaywada GA
Thane City and
Adjoining areas
26
Rajkot
27
Surendranagar
28
Navsari
29
Nadiad
30
Khurja
31
Moradabad
31
Surat-Bharuch-Ankleshwar
Rajkot
Geographical
Area
Surendranagar
Geographical
Area
Navsari
Geographical
Area
Nadiad
Geographical
Area
Khurja
Geographical
Area
Moradabad
Geographical
Area
Surat-BharuchAnkleshwar
Geographical
Area
STANDARD NO.
DESCRIPTION
1.
EN 12186
2.
EN 12279
3.
EN 1776
4.
EN 1594
STANDARD NO.
DESCRIPTION
1.
ASME B16.11
2.
ASME B31.3
3.
ASME B31.8
4.
ASME B16.5
5.
ASME B16.9
6.
7.
8.
9.
STANDARD NO.
DESCRIPTION
1.
OISD-226
2.
OISD-GDN-115
3.
4.
FIRE PROTECTION
MANUAL TAC
OISD STANDARD 141
5.
STANDARD NO.
DESCRIPTION
1.
AGA
2.
IGE/T/1
3.
4.
5.
S. NO.
STANDARD NO.
DESCRIPTION
1.
2.
API SPECIFICATION 5L
3.
API SPEC. 6D
4.
STANDARD NO.
1.
ISO-15590-1
2.
BS 6755:PART 2
3.
4.
DIN 30670
DESCRIPTION
International standard for Petroleum and
natural gas industries Induction bends,
fittings and flanges for pipeline transportation
systems
Testing of Valves
Coatings of corrosion protection tapes and
heat-shrinking products for pipelines for
operational temperatures up to 50C
Polyethylene Coatings for Steel Pipelines and
Fittings
STANDARD
DESCRIPTION
1.
SCHEDULE 1A
2.
SCHEDULE 1B
Welding
3.
SCHEDULE 1C
4.
SCHEDULE 1D
5.
SCHEDULE 1E
6.
SCHEDULE 1F
Corrosion Control
7.
SCHEDULE 1G
Miscellaneous
The selection of design for CGD Network is based on the gas properties, required flow
rates, operating pressures and the environment.
A typical CGD Network shall comprise of one or more or all of the following:
Fi
gure 3 Basic System Flow Diagram (Schematic)
13
5.1.1. Filtration Skid: Dust particle and liquid coming with the gas stream are separated by
high efficient filters in KOD. Gas is maintaining same pressure from the inlet to the filtration
skid. After the filtration two streams are dividing from the main line using a header. Line which
is in function is known as active line where another one is called passive line.
5.1.2. Pressure Reduction Unit: A pressure reduction valve is installed for the reduction
of the gas stream pressure from 40-45 bars to 25-30 bars. Creep relief valve and Slam Shut off
valve is being installed in this skid for the safety purpose.
5.1.3. Metering Skid: Metering skid is installed for the gas flow measurement. Orifice meter
is used in this metering skid; because of the large pressure drop requirement. The various
parameters such as temperature in the various sections of the line pressure at the inlet & outlet
joints, flow inlet & outlet are monitor by the SCADA systems in the control room.
5.1.4. Odorization Unit: An Odorization unit is installed for addition of ethyl Mercaptan in
the gas stream. The dozing unit of the ethyl Mercaptan should be of 9 mg/m3. This unit consists
of mainly two cylinders of capacity of 160 kg, pneumatic panel, level indicator and a filter. This
unit is directly connected to the main line after the metering skid.
5.2. Steel Pipeline It is the Primary Network in the form of Transmission Pipeline (Up
to CGS) and Distribution Pipeline (CGS Downstream, Ring).
This is basically required to derive diameter of pipeline in such a way that required
pressure at all locations can be achieved and future load projections can be ascertained.
Formulae used for hydraulics: Colebrook White / Fundamental pipe equation with flow
dependent friction factor.
Velocity: Max. Allowable velocity of the gas in the steel pipeline Section of CGD
network shall be 30 m/s.
Location Class
Description
Design Factor
Class 1
0.72
Class 2
10 46 buildings
0.60
Class 3
46 or more buildings
0.50
Class 4
0.40
P = 2St FET/D
Where,
P = Design Pressure
S = Specified minimum yield strength
D = Nominal OD of pipe
t = Nominal wall thickness
F = Design Factor
E = Longitudinal joint factor
T = Temperature de-rating factor
17
5.2.3.3. Welding:
1.) Fillet weld: A weld of approximately triangular cross section joining two surfaces
approximately at right angles to each other in a lap joint, tee joint, or corner joint.
2.) Butt weld: It is used to connect the parts which are nearly linear and does not overlap.
3.) Girth weld: It is a complete circumferential butt weld joining pipe or components.
4.) Seam weld: The longitudinal or helical seam in pipe, made in the pipe mill for the
purpose of making a complete circular cross-section.
18
5.2.4. Cathodic Protection - There are two main types of cathodic protection systems:
galvanic and impressed current.
5.2.4.1. Galvanic system: Makes use of the corrosive potentials for different metals.
Without CP, one area of structure exists at a more negative
potential than another, and corrosion results. If, however, a much less inert object (that is, with
much more negative potential, such as a magnesium anode) is placed adjacent to the structure to
be protected, such as a pipeline, and a metallic connection (insulated wire) is installed between
the object and the structure, the object will become the anode and the entire structure will
become the cathode. That is, the new object corrodes sacrificially to protect the structure.
Galvanic anodes are usually made of either magnesium or zinc because these metals have higher
potential compared to steel structures.
5.2.4.2. Impressed current systems: Use same elements structure and is protected by
applying a current to it from an anode. The anode and the structure are connected by an insulated
wire and current flows from the anode through the electrolyte onto the structure, just as in the
galvanic system. The main difference between both systems is that the galvanic system relies on
the difference in potential between the anode and structure, whereas the impressed current
system uses an external power source to drive the current. The external power source is usually a
rectifier that changes input A.C. power to the proper D.C. power. Impressed current cathodic
protection system anodes typically are high-silicon cast iron or graphite.
19
Table 13
Table 14
20
The flow capacity of DRS is in range of 5000-10000 SCMH. The inlet line of DRS is steel
pipeline and outlet is polyethylene pipeline carrying a pressure of 4 bars.
21
22
The control mechanism (Pilot 1) has a latching arrangement holding main valve stem in
open position. The sensing element is pilot regulator (Pilot 2) continuously monitors the
line pressure to be safeguarded.
This pilot spring diaphragm type valve, in case of over pressurization gives signal
pressure to control mechanism which in turn trips off main valve.
In normal condition the Pilot-2 remains in close position. The main valve remains in open
position by holding the plug rod 14 by rack 21 through ball catch arrangement in Pilot-1.
Whenever the pressure monitoring by Pilot-2 exceeds above its set intervention value the
diaphragm 48 moves upward displacing the plug 47.
Thus the pressure passes to Pilot-1 diaphragm 27 pressing it along with push rod 25,
pressing the ball 41.
The rack 21 latched by the ball gets released resulting in downward movement of plug 7
and plug rod 14 closing the valve. The visual indicator 32 will indicate the position as
CLOSE.
The valve can also be shut off manually by pressing knob 33 on pilot-2.
24
25
5.3.4. Non Return valve (NRV) - It is also known as check valve. It maintains
unidirectional flow and restricts reverse flow. It operates by itself by application of pressure
present in line, minimum pressure range is required to operate this valve.
Its functioning would be discussed later.
26
5.4.1. Specifications
28
5.5. PE Laying
MP Network
1. The MP PE network starts from downstream of DRS/CPRS and distributes the Natural
Gas till the different Service Regulator located nearby a cluster of domestic customers or
a main commercial customer or Industrial Customers upto MRS/IMS.
2. The PE mains are subdivided into sections by means of adequately located manually
operated valves (Note: As per PNGRB in MP network minimum one at every 1 Km).
LP Network
1. The LP Network in PE starts from the downstream of Service Regulator (SR) and brings
the natural Gas to domestic customers.
29
Figure 16 - Trench Dimension for PE Pipeline: Size 32mm. Similar for other Pipe Sizes
ii.
90 mm dia. PE pipes can be used without any EF joint in between if the crossing length is
less than 100 mtr.
30
The pipes ends to be welded must be cut at right angle by using proper pipe cutters.
II.
Visually check that the pipe/fitting surface is free of defects such as cuts, abrasion etc.
III.
Avoid using excessive ovalized pipes. Remove Ovality by using Re-round tool. Clean the
pipe ends from dust, grease, dirt etc.
IV.
Mark the scraping area with an indelible marker pen. The scraping area must be 10mm
larger than the insertion depth of the fittings.
V.
Remove the oxidized surface from the pipe, by scraping it. Remove an uniform surface
for a depth of approximately 0.1mm for pipe diameter upto 63mm and 0.2 mm for pipe
diameter higher 63mm.
VI.
AVOID ABSOLUTELY other scraping equipment such as abrasive paper, rasp, emery
wheels, saw blades, etc. other than Mechanical/Manual scrapper.
VII.
Before inserting the fitting on the pipe, clean the scraped surface using isopropyl alcohol.
VIII.
Clean with the same chemical the inner surface of the fitting, which has to be removed
from its protective wrapping only at the moment of use.
IX.
X.
The aligning clamp must be used for all diameters to be welded which, Protects, during
the electro-fusion and the subsequent cooling, mechanical stresses on the jointing.
XI.
Allows revising possible off-centering between both ends to be welded and to recover the
out-of-round of parts, it ovalized.
XII.
In case of EF coupler welding, sign a mark using an indelible pen on the two ends to be
welded corresponding to the depth of insertion, equal to half length of the coupler.
XIII.
Insert the coupler up to the location mark and fasten the pipe into the aligning clamp.
XIV.
Connect the plugs of the control unit to the terminals on the fittings and proceed with the
set-up of the welding parameters, strictly following the instructions of the welding unit.
XV.
When the fusion cycle is completed, verify the fusion indicators coming out. The fusion
indicators are located near the terminal connection of the fitting.
XVI.
Cooling, in order to avoid possible stresses on the jointing, strictly respect the cooling
time indicated on the bar-code and do not remove aligning clamp of the fittings.
31
5.6.2. Installation of SR
A. Installation of Service regulator module shall be done as per the foundation drawing
/specification.
B. 90 degree EF elbow shall be used for hook-up of the Service Regulator for 63mm and
above size pipeline.
32
5.6.3. Testing of SR
I.
Pre-commissioning testing for performance of safety devices i.e. UPSO, OPSO, and
Relief valve, which is integral part of Service Regulator, shall be done.
II.
The set pressure of Service Regulator for different features are as per the below:
Set Pressure: 100 110 mbar
UPSO: 50 mbar
OPSO: 150 mbar
- All electro-fusion joints (SR Hook up joints) shall be checked with soap solution before
commissioning of Service Regulator.
5.6.4. Commissioning of SR
A. Ensure all installation and pre-commissioning activities are completed. Inlet and Outlet
valves shall be kept in closed position.
B. Gas in upto inlet valve of Service Regulator by opening of Valve/squeeze tool.
33
C. Leak test shall be carried out upto upstream of inlet valve. If no leakages found, open
inlet valve of Service Regulator and ensure no leakages upto outlet isolation valve.
D. Monitor Outlet pressure of Service Regulator for 5 min. before opening outlet valve.
E. Ensure positive lock-up pressure (to confirm no leakages or open end during
commissioning) in downstream network before opening outlet valve.
F. Ensure that not a single domestic connection has been connected through downstream of
the network which is to be commissioned.
G. Release lock up pressure before opening outlet valve of SR and by keeping inlet valve
closed.
H. Slowly open inlet valve first and subsequently outlet valve of Service regulator to allow
Gas in the downstream network.
5.6.6. PE Testing
5.6.6.1 MP Network Testing: The MP Network will be tested at 7.0 bars for
A. PE distribution mains of length greater than 1 Km for at least 24 hours.
B. PE distribution mains of length shorter than 1 Km at least 6 hours after pressure
stabilization and the pressure gauge must measure an unchanged pressure during test
duration. The test medium shall be air or nitrogen.
34
5.6.8. Commissioning
A. To check the hot work permit.
B. As laid PE Network drawing / schematic of the section to be commissioned and existing
end cap showing vent point.
C. Ensure pneumatic test report. Check and assure that the positive pressure in the pipeline
stayed equal as the pressure measure after testing.
D. Calibrated pressure gauge is used.
E. Ensure that EF welding machine with ELCB (Earth leak circuit breaker).
F. Ensure availability of additional Squeeze tools for emergency.
G. The gas should be vent continuously by crack opening of valve until two reading confirm
a concentration of gas by methane detector.
35
Maximum two Point in the single kitchen for gas stove only.
Compound gate or doors and windows inside the house shall not hit the Gas pipeline, if
no alternative route found installs proper pipe protection guard.
38
39
Type of Testing
Test Pressure
Duration
1.
Pneumatic Pressure
Testing (PPT)
MMT
Riser Testing
3.5 Kg/Cm2
30 minutes
Gas Pressure
3.5 Kg/Cm2
15 minutes
1 Hour
2.
3.
After pressurization of the whole piping section shall be checked for the leakage with the
help of soap solution.
During the testing, air should reach up to the appliance valve. After completion of testing,
pressurized air shall be released from appliance valve only.
41
Finalize the location of Industrial Metering Skid as per safe installation distance:
Table - 17
Reference Location
Electrical Transformer
Open flame or furnace/ any gas fired
12 meter
15 meter
42
2 meter
6 meter
II.
III.
IV.
Installation of brick Chamber near hook up portion of skid and filling with fine sand to
protect PE pipe as per GSPC Gas requirement.
V.
Chain link fencing to be done surrounding the Industrial Metering skid for restricted unauthorized entry. Minimum distance to be maintained 1.5 meter from the foundation.
II.
Supply and Installation of Regulators, Isolation valves, pipe fittings, fasteners and
consumables shall be done by the customer as per individual equipment flow and
pressure requirement.
43
Supply and installation of Gas train with safety interlocks, Gas Burner and equipment
conversion. Pneumatic testing of Internal Piping.
6.2.2.3. Electrical:
I.
Un-interrupted AC power supply for Metering purpose and two separate earthing for IMS
to be provided and done by customer.
Internal piping installation shall be done through competent steel pipeline contractor.
II.
III.
Jointing of Internal piping shall be done through welding method only. No threaded joints
shall be allowed for internal piping installations. Welding spatter should be removed by
grinding.
IV.
Pipe should not be routed through heated zone like bhatthis / tandoor / furnace etc. For
wall crossing the pipe should be protected with anti-corrosive wrapping tape.
V.
VI.
Pipe support should be firmly fixed on wall and Pipe should be firmly tightened on
support with U bolt or to be installed on proper fabricated structure on ground.
VII.
Pipeline shall not rest on support directly. Rubber sheet piece to be kept between pipe and
support to avoid erosion and leakage.
VIII.
A safe gap of minimum 1" should be maintained between pipe and wall. Pipe support
should not be provided on temporary wall/shed/trees etc.
IX.
Main Isolation Valve to be provided immediately after entering into industrial premise
and branch Isolation ball valve at each tapping from main header.
6.2.4. Testing:
I.
Pipeline should be flushed with air or nitrogen to remove dust, dirt, welding spatter etc.
Meter and regulator should be removed before flushing. Flushing should be done from
each tapping.
II.
Once flushing is completed entire pipeline shall be tested at min. of 1.5 x design pressure
(MOP) or 7 bar whichever is higher with air or nitrogen for 06 Hrs. Testing shall be done
with all isolation valves semi open. Pressure should not drop during testing hours.
44
Once testing is found OK, pressure should be vented out till pipeline pressure becomes
0.5 bars. Positive pressure shall be kept hold till pipeline commissioning.
IV.
6.2.5. Painting:
I.
II.
Entire pipe should be cleaned with wire brush. It should be free of welding spatter, dust,
dirt, rust and moisture.
III.
IV.
Primer and finished coat shall be done as per paint manufacturer recommendations. Final
coat shall be Golden Yellow color for gas pipeline identification.
V.
Direction of gas flow should be marked along the pipeline at the interval of 2 meters.
Location of Industrial Metering Skid as per safe installation distance with various
references.
II.
Portable Fire Extinguisher of ABC type -10 kg. (ISI marked) to be placed nearby
Industrial Metering skid by customer before commissioning of Internal Piping.
III.
NO SMOKING, Safety Instruction Board and other safety signage near Industrial
metering Skid.
Customer internal piping with electrical bonding at joints.
IV.
V.
VI.
Intimation to GSPC Gas in case of plant shutdown/ No usage of NG for long time.
GSPC Gas engineer shall ensure undertaking from customer for successfully testing of
internal pipeline on their letterhead.
II.
GSPC Gas representative need not to certify testing of customer premises internal piping.
III.
I.
GSPC Gas engineer shall ensure undertaking from customer for successfully internal
pipeline testing on their letterhead.
II.
Tool-Box talk shall be conducted in presence of Industrial customer covering Dos and
Donts.
III.
Ensure positive lock pressure in internal piping before opening of Industrial Metering
Skid outlet valve to industrial customer.
IV.
V.
Ensure oil level in case of RPD meter before Industrial metering skid commissioning.
VI.
VII.
VIII.
Table -18
Specification
46
Domestic Meter
Commercial Meter
EN 1359
EN 1359
Capacity
2.5 m3/hr.
1:150 or better
1:150 or better
21 mBar
100 mBar
Domestic Meter: End Connection: as per BS 746, Center to Center Distance: 110 mm
between Inlet and Outlet Connection.
Commercial Meter: Pressure Rating: Suitable to withstand Max. Working Pressure of 200 mBar
Specifications:
I.
II.
III.
IV.
V.
Accuracy +1%
VI.
Not sensitive against Disturbances, Not sensitive against fast changes against flow rates
47
49
Sr.
No.
1.
Description
PNG Connection
50
Frequency
Responsi
bility
Annual
Once in 5 Years
1.5
Once in 5 Years
2.
2.1
2.2
2.3
2.4
Monitoring of Pressure/Flow
Leak Check of all points
Valve Operation & Greasing
Stream Changes & Functional Test of PRV/SSV &
CRV
Maintenance of Filters/KOD
Calibration of SRV/CRV
Testing of Gas Detection System
Calibration of Gas Detection System
Checking of Earth Pit and Earthing Electrodes
Painting/Touch up of A/G Piping
Hydro testing of Filters/KOD
1.3
1.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
3.
3.1
3.2
3.3
3.4
Odorant System
3.5
3.6
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Once in 2 Years
Annual
PE/PNG
O&M Team
Daily
Half Yearly
Yearly
Half Yearly
Yearly
Yearly
Need Base
Variation in
wall thickness
Half Yearly
Yearly
PE/PNG
O&M
Team
Steel
Pipeline
Engineer
Metering
Engineer
Steel
Pipeline
Engineer
Half Yearly
Daily
When required
Half Yearly
If Wall
thickness varies
Yearly
PE/PNG
O&M
Team
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
Daily
Monthly
Quarterly
Quarterly
Yearly
Pre and Post
Monsoon
Need Basis
Half Yearly
As & When
required
5.
5.1
Monitoring of TR
Daily
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
Half Yearly
Half Yearly
Monthly
Yearly
When Required
Yearly
Yearly
Half Yearly
Half Yearly
6.
6.1
6.1.1
6.1.2
6.2
52
PE/PNG
O&M
Team
Steel
Pipeline
Engineer
PE/PNG
O&M
Team
Steel
Pipeline
Engineer
PE/PNG
O&M
Team
NA
NA
Steel
Pipeline
Engineer
(Steel
Pipeline CP
Contractor
)
Legal
ZH/GA
NOC
Air Consent, Water Consent
Authorization for Hazardous Waste Disposal
Submission of Monthly Monitoring Reports to
GPCB
Submission of Annual Environment Reports to
GPCB
Annual Return of Hazardous waste dispatched
during whole year
Once
Half Yearly
Half Yearly
HSE
Yearly
CNG Refueling Station is a facility set-up for supplying CNG mainly as a fuel to
vehicles. The system receives odorized gas at certain pressure (3-19 Bar), through
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CNG is stored at compression stations which are directly connected with the gas pipeline.
Here the gas is compressed to a required pressure and aids fuelling. CNG can also be
transported to other retail outlets by cylinder trucks. These trucks carry a number of
cylinders which provide CNG to fuel stations which are not connected by pipelines.
III.
The system has major assets like, Odoriser Unit, CNG Compressor, Storage facility,
Dispenser, LCV/HCV Filing Point, Mobile cascade vehicle, Electrical Installations, DG
set and Air Compressor. The size, rating and type of the major and sub assets are selected
based on the pressure rating, capacity and other applicable criteria considered for
refueling station for meeting the current and future customer potential, health and safety
of employees, customers and public at large, environmental protection and complying the
statutory, legal requirements, national and international technical and safety standards/
practices.
IV.
Various operation and maintenance activities, as per annual operation and maintenance
plan are carried out for ensuring safe and uninterrupted gas supply.
54
1. Mother Station: A CNG station provided with whole set up (compressors, dispensers,
cascade etc.) along with a LCV filling point is known as a mother a CNG station.
2. Online Station: This CNG station has same set up as a mother station but LCV connection is
not provided for filling.
3. Daughter Booster Station: Daughter station provided with the compressor (known as
boosters) to compress the gas we are getting from the mother station are known as daughter booster
station.
4. Daughter Station: Daughter stations are established in those areas where laying a pipeline is
not possible. In that case gas is delivered from mother station to daughter station; via mobile cascade
van. The gas from mother station is filled in mobile cascade by a LCV filling point.
10.2.4. Cascades
A bank of cylinders used for buffer stock of compressed natural gas is known as cascade.
Stationary cascade is used to store the gas when vehicle is not there at the dispenser then
the gas from compressor flows into a cascade.
Cylinders in a cascade are divided accordingly as:
- High Pressure Cylinders (HP) - 5 cylinders
- Medium Pressure Cylinders (MP) - 11 cylinders
- Low Pressure Cylinders (LP) - 24 cylinders
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1. Stationary Cascade: These are fixed cascades established on CNG station for the storage of
CNG. It has a direct inlet from compressor and outlet to line connected
to dispenser.
2. Mobile Cascade: Cascade is mounted over an LCV and it carries CNG from Mother station
to Daughter station or Daughter booster station as per the requirement.
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10.2.5. Dispenser
Main components of a dispenser:
High, Medium, low bank lines
Gas Filter
SOV
Actuator
Mother Board
Non Returning Valve (NRV), Ball Valve, Pressure Regulating Valve (PRV), SRV
Mass flow meter, Pressure Transmitter
Hose Pipe
Three Way Valve
Hex Nipple, Filling Probe
O-Ring
Working of a Dispenser:
A dispenser has three banks connection namely:- Low pressure Bank (LP)
- Medium pressure Bank (MP)
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61
Name of
Major
Asset
Major Activities
Daily
Odorization
Unit
Suction Skid
CNG
Compressor
CNG
Cascade
Mobile
Cascade
Electrical
Installation
Air
62
Patrolling
Leak
Check
& Oil
top-Up
& Drain
Leak
Checks
Leak
Survey
Check
List
Check &
Replace
parts as in
Check-List
Leak
Checks
& Filter
drain
Leak
Check
CNG
Dispenser
DG Set
House
Keepin
g
Check
Diesel,
Coolant
and Oil
Level
Leak
Half
Yearly
Yearl
y
Emergency
Valve
Chambe
r
Preventi
on
Check
&
Replace
parts
Check
&
Replac
e parts
Damage or
Leakage Part
Repair
Damage or
Leakage Part
Repair
Damage or
Leakage Part
Repair
Damage or
Leakage Part
Repair
Damage or
Leakage Part
Repair
Damage or
Leakage Part
Repair
Compressor
Check
and
Check
oil
Level
Damage or
Leakage Part
Repair
A Natural Gas leakage without associated with fire from potential leakage sources e.g.
flange and valves in the DRS, CNG stations (Cascade connections), Valve Chambers,
MRS and customer premises.
II.
A leak from the main Steel pipeline section (15-25 bar pressure) could be well damaging
and requires quick isolation of gas supply.
III.
Any fire in customer premises (not a very credible scenario because of very low pressure
in the domestic section of pipeline) or a fire explosion in the gas/leak.
IV.
V.
Preventive shutdown action during any Natural calamities, e.g. flood, earthquake,
epidemic, storm etc.
Level 2
a) Emergency / incident cannot be effectively managed and contained at the location.
b) Additional support required.
c) Have potential to effect beyond facilities where external support/ mutual aid required.
d) Likely to be danger to life, environment and industrial assets.
Level 3
a) Emergency / incident with off-site impact, catastrophic.
b) Likely to affect population, property and environment.
c) Control is done by District Administration.
Off-site emergency plan: A responsive plan to control/ mitigate the effects of catastrophic
incidents.
This is prepared by district management based on the data of the installation(s) given by all the
owners.
Site Incident Controller (SIC) or Incident Controller - means the person who
I.
goes to the scene of the emergency and supervises the actions necessary to overcome the
emergency at the site of the accident.
- The City Managers / technical in charges at respective locations will be the Incident Controller.
II.
Chief Incident Controller - means the person who assumes absolute control of the
unit and determines the action necessary to control the emergency.
- Respective Zonal Head of GSPC Gas is CIC for GSPC Gas Company Ltd.
Duty Manager - means the Manager nominated from time to time at corporate office
III.
HSE Policy
II.
HSE Reporting
III.
HSE Manual
IV.
V.
Permit to Work ( Hot Work, Cold Work, Working at Height, Boring, Electrical Isolation
and Energization)
VI.
VII.
VIII.
Risk Register
IX.
X.
Personal Protective Equipment (PPE) Gloves, Safety shoes & glasses, Face Shields, etc.
XI.
XII.
XIII.
XIV.
XV.
ERDMP (Emergency Response & Disaster Management Plan) Each Zone has its own.
XVI.
GPCB Clearance
Infrastructure Exclusivity
The CGD Company will have a lifetime exclusivity of 25 years for the pipeline network.
Eligibility Criteria
Those who want to obtain rights to set up a CGD network would need to meet the following
eligibility criteria:
Body Corporate or Company registered under the Companies Act.
Should have a credible plan for sourcing of Natural Gas.
Should have experience of laying aggregate of over 300 Km of oil and gas pipelines or
form a Joint Venture with a company which has that experience.
The entity should have experience of at least one year in operation and maintenance of a
CGD Network or should have a Joint Venture with 11% holding with another entity
having such experience.
Appropriate technical assistant agreement for at least one year with another party having
experience of operating and maintenance of CGD Network for at least a period of one
year.
An entity interested in developing a particularly City gas project needs to submit Expression of
Interest to PNGRB with Rs 8-12 Lakh as fee depending upon population of the city (NonRefundable), Geographical Area, market potential of CNG and PNG, business plan.
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