Module :
CGS / CPRS-DRS / Steel Pipeline
CGS
CGS is the location of Custody Transfer from Transmission Company to
Distribution Company
Basic Function of CGS is to
Filteration
Pressure Reduction
Custody Transfer metering
Odorization
Preheating of NG if required
CGS Design Criteria
Upstream Pressure
Downstream pressure requirement
Downstream flow requirements including peak flow rates
Future projections of volume growth / flow-rate
Future expansion
Consider safety at all stages
Reference Standards : IGE/TD/13
Major Elements of CGS
Suitable Land
Below facilities with a hot stand by mode :
Filtration (Knockout drum, Filter Cum Separator)
Let Down Skid (PCV or PRV, SSV, CRV/SRV, Pressure Gauges)
Metering (Turbine / Ultrasonic / Orifice)
Odorization
Pre-heating
Ball Valves
Station Piping & Supports
Electrical Work
Instrumentation work (SCADA / Control Panels)
Typical City Gate Station
Typical City Gate Station
Pipeline
Type of Pipelines:
Steel Pipeline
Transmission Pipeline (Up to CGS)
Distribution Pipeline (CGS Downstream, Ring)
Poly Ethylene Pipeline
Medium Pressure (4 Bar)
Low Pressure (110 mBar)
Requirement / Considerations for Steel Pipeline
Delivering Natural Gas at required pressure to :
CNG Stations
CPRS
DRS
Covering entire City / Town by forming a RING in the periphery of the
city/town, to cater existing and forecasted demands
Consideration of future load of outskirts areas / developing areas
Future need of Looping / Interconnections
Steel Pipeline Reference Standards
Standard / Code
Title
PNGRB T4S
Technical Standards and Specifications including Safety Standards - CGD
ASME B 31.8
Gas Transportation and Distribution Piping Systems
ASME B 31.4
Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids
OISD-141
Design & Construction Requirements for Cross-Country Hydrocarbon Pipelines
OISD-214
Cross-Country LPG Pipelines
OISD-226
Natural Gas Transmission Pipelines and City Gas Distribution Networks
API 5L / ISO 3183
Specification for Line Pipe
API RP1102
Recommended practice for Rail and Highway crossings
API 1104
Standard for welding pipeline and related facilities
API 6D / ISO 14313
Pipeline Valves
DNV OS-F101
Submarine pipeline systems
Other References
Applicable Standards / Specs of ASME, API, NACE, MSS, BS and DIN
Stages of Steel Pipeline Project
Conceptualization
Market surveys for deriving basic assumptions on demand
Study Alternatives
Initiation of Feasibility Study for Commercial / Technical viability
Feasibility Report
Route Selection & Surveys
Hydraulics / Simulations
Estimation of Project Cost
Market Demand Assessment
Project Approval
Engineering & Planning
Design & Sizing
Specifications & Tender Document preparation
Material Procurement / Release of Word Orders & Contracts
Acquire RoU / Permissions
Project Execution & Commissioning
Operation & Maintenance
As per AOMP
Route Selection / Surveys
Considerations / Detailing Required
Pipeline Length
Type of Terrain
No of Crossings / Type of Crossings
No of Valves (Section/Tap off/Future Extension)
Obstructions / Limitations
Identification of Authorities for permissions
Type of Surveys
Topographical
Geo-Technical
Population Density Index (Location Class)
Soil Resistivity
Cadastral
Design / Hydraulics / Simulation
Process
Simulation for Network Hydraulics is done in the SYNERGEE software
This is basically required to derive diameter of pipeline in such a way that
required pressure at all locations can be achieved and future load
projections can be ascertained
Formulae used for hydraulics : Colebrook White / Fundamental pipe
equation with flow dependent friction factor
Roughness:
Type of Material
Roughness (microns)
Steel new pipe (</= 10 Yrs old)
With internal coating 10 15
Without internal coating 35 40
Steel old pipe (> 10 Yrs old)
With internal coating 15 20
Without internal coating 40 45
Design / Hydraulics / Simulation
Process
Efficiency factor: 0.85 1, factor shall be determined by duly
calibrating actual field data in the approved flow equation
Velocity: Max. allowable velocity of the gas in the steel pipeline
section of CGD network shall be 30 m/s
STP:
Standard pressure : 1.01325 Bar (a)
Standard Temperature : 15.5 Deg C
Design Life:
Steel pipeline : 30 Years
PE Pipeline : 50 Years
Design / Hydraulics / Simulation
Location Class:
Class I
10 or fewer buildings in 1mile section
Class II
10 46 buildings
Class III
46 or more buildings
Class IV
areas where multistoried buildings and heavy
underground utilities
Basic Design Factor:
Location Class
F (design factor)
Class I
0.72
Class II
0.60
Class III
0.50
Class IV
0.40
Design / Hydraulics / Simulation
Location Class:
Class I
10 or fewer buildings in 1mile section
Class II
10 46 buildings
Class III
46 or more buildings
Class IV
areas where multistoried buildings and heavy underground
utilities
Wall Thickness calculation for steel pipeline
P = 2St FET
D
where
P
S
D
t
F
E
T
Design pressure
Specified minimum yield strength
Nominal OD of pipe
Nominal wall thickness
Design factor
Longitudinal joint factor
Temperature de-rating factor
Line Pipes Selection / Specifications
Type
ERW
Seamless
LSAW
HSAW
Material Grade
Nominal Diameter and Wall Thickness
Length (single random / double random)
Coating
Coal Tar Enamel Coating (BS 4164, AWWA C203)
Primer
Two layers of coal tar enamel & glass fiber Inner wrap
One layer of coal tar impregnated outer wrap
Coating thickness 4.7mm
3 Layer PE/ PP Coating (DIN 30670)
First layer of Fusion bonded epoxy
Second layer of extruded adhesive
Third layer of extruded PE/ PP
Coating thickness 2.0 to 3.7 mm
Fusion Bonded Epoxy Coating (CSA Z245.20)
350-500 micron thick single layer coating
600-800 micron thick dual layer coating
Fittings & Components in Pipeline
Fittings:
Elbows & Bends
Flow Tees
Insulating Joints
Weldolet / Sockolet
Flanges
Gaskets
Fasteners
Valves:
Sectional Valves
Tap Off Valves (future
provisions)
ASTM A 234
ANSI B 16.5 & 16.11
API 6D
Construction Stages
Pre-constructional Activities
Construction Activities
Testing and Commissioning
Handover to Operations
Construction Stages
Pre-constructional Activities
Activity
Description / Steps
Planning
Resource & Equipments
Scheduling
Scheduling of activities & milestones
Material Ordering / Delivery schedule
Mobilization
Mobilization of Manpower & Equipment
Procedures /
Qualifications
Approval of procedures for various activities
Welding Preparedness (WPS/PQT, EQT, Welders Qualification)
Insulators qualification
Training
Safety Trainings
Site Briefing
Readiness to Start
Construction
Kick off Meeting
Construction Stages
Construction Activities
Activity
Description / Steps
Grading
RoU clearance, Marking and cleaning
Trenching
At Correct depth
With the help of Machines or Labors as per site requirement
Stringing
With the help of Hydra or Side Boom
Welding & NDE
Welding as per approved procedures by qualified welders
Non Destructive Testing X-ray/UT/MPT/DPT
Joint Coating
Heat Shrinkable sleeves or R-95 (Material TC required)
By qualified insulator
Lowering
Lowering of pipe section
Tie-in Joints
Special Crossings
River/ Drains/Railway/ Highways/ Canals
By HDD or Push Jack Boring
Backfilling &
restoration
Backfilling & Crowning
Manually / with Machine as per site requirement
Construction Stages
Testing & Commissioning, Handover to O&M
Activity
Description / Steps
Cleaning
Cleaning of pipeline prior to start hydrostatic testing
Hydrostatic
Testing
Water filling, Air volume calculation before pressure holding
Pressure Holding & Monitoring (min.24 hours after temp. stab.)
Dewatering & Cleaning
Valves
Installation of Valves
Construction of Valve chambers
TCP
Installation of TCP
Review readings
Readiness
Readiness review of pipeline jointly by Projects/O&M team including
review of documents/records/deviations, route visit, etc
Preparation of punch points, Compliance to HOTO procedure
Intimation to Local Authorities prior to Gas in.
Purging &
Commissioning
Purging with Nitrogen. Ensure <2% O2 before gas in
Commissioning
Hand over
Handover to O&M for routine operations / maintenance
Project Management in GSPC Gas
Execution by Contractor
Inspection & Certification for quality by TPIA
Project Management by PMC
Overall monitoring by GSPC Gas
Photo : Steel pipeline site
CPRS/DRS : typical schematic
Photo : DRS/CPRS
Components
Filter : filter cartridge, DP Gauge
Two streams of :
Active regulator
Monitor regulator
Slam Shut off Valve
Creep Relief Valve
Pressure Gauges
Pilot regulators
Ball Valves
Design Parameters
Maximum inlet pressure: 49 BarG
Differential Pressure (Min.) : 0.5 BarG
Outlet pressure range: 4 BarG
Flow rate @ min inlet pressure: 2000 SCMH/ 5000 SCMH
End Connections : 4/6 depending upon capacity
Land Requirement
30-36 Sq. Meter
No overhead electric lines / min. Distance 6 mtrs from HT/LT
Land should not be in a water logged area
Safe distance from Garbage collection/storage point
Installation & Commissioning
Proper platform to be constructed
Inlet/outlet piping Installation as per the approved layout
Maintain proper alignment of installations
Proper support to inlet/outlet piping
Earthing to be provided
Vent height should be at least 3 meter from the ground level
Fencing of area recommended
Caution Board to be provided
Site Acceptance Testing before commissioning
Readiness review / HOTO with O&M
Gas in
Photo : Steel Valve Chamber
Thank You
