CITY GAS DISTRIBUTION

O&M MANUAL
CHAPTER – 3
SOPS / WORK INSTRUCTIONS /
GUIDELINES / CHECKLISTS / FORMATS
B – Critical Tasks
3.15 Handling Gas Leak / Network Damage
3.16 Attending Gas Smell / Leak Complaint In Domestic
Connection
3.17 Commissioning & De-Commissioning Gas
Pressurization / Depressurization, Venting, Draining &
Purging
3.18 Valve Chamber Maintenance
3.19 Patrolling & Surveys
3.20 On Line Functional Test of Gas Stream Valves
3.21 On Line / Repair Maintenance of Service Regulator
Valves
3.22 Odorant Handling – Storage, Local Transportation &
Disposal
3.23 Odorant Transfer from Barrel To Storage Tank

Module 4 of 9

Block - 15, 2nd Floor, Udyog Bhavan, Sector - 11, Gandhinagar – 382 011.
3.16 Handling Gas Leak / Network Damage
Task Procedure :
Task purpose and importance
Handling gas leak / network damage is the activity carried out for quickly and safely
arresting the gas leak and pipe damage and restoration of gas supply to the
customers. The gas leak on the underground network poses the potential hazard of
asphyxiation / fire / explosion and environment concern. Hence timely and safely
attending the gas leak and restoration of gas supply to the customers are very
important as the task has direct effect on company’s operation, safety, quality,
production, customer satisfaction and environment.
Sr. Activity Steps
01 To reach site, quickly, observing law full driving and traffic safety.
To assess the situation and quickly take the following steps
Cordon and secure the affected area
Check the surrounding properties for ingress of gas. if gas concentration is
found to be 20% LEL or above inside any of the properties then evacuate
the said property.
Close off access roads
02 Eliminate possible sources of ignition. Switch off electrical switches if
readings do not exceed 70% LEL. If the LEL is greater than 70% then leave
the electrical switches in as it is position.
Identify or locate suitable squeeze point on main line and valve chambers
for isolation purpose.
Make public announcement for affected customers for stoppage of gas
supply.
To excavate pit for squeezing, ensure zero gas percent in trench, and
prevent further damage to gas line and other utilities. Pit should be of
03
adequate space. . Remove stones etc. which may create an accidental
spark.
For PE pipe of 20MM TO 90 mm dia.
04 To isolate the gas supply in section by squeezing the PE pipe, Use
optimum squeeze pressing. Too hard pressing will damage the pipe and too
 light press will cause gas passing through squeeze. PE pipes shall be
squeezed at a distance of 300mm from fittings / welds on previous
squeezed location.
For PE pipe of above 90 mm dia.
To isolate the gas supply in section by closing the nearest valves.
Ensure positive shut off condition of valve by indicator and reducing
residual gas venting pressure.
To allow venting of residual gas, measure the gas percentage, 3 times. It
05
should be zero.
To prepare pit at leak / damaged point, after complete venting of residual
gas, as measured by detector, take care not to further damage the gas line
06
and other utilities. Pit should be of adequate space. Remove stones etc.
which may create accidental spark.
To provide earthing on both sides of the pipe, from where the pipe is to be
cut, for draining the built up static charge on the PE pipe, Earthing may be
07 provided by wrapping wet cloth, around the pipe and contacting positively to
the soil. Or special earthing wire and grip clips may be used from pipe to
soil.
To cut the pipe after making, initial small cut mark on pipe, recheck the
08
gas presence again, it should be zero
To ensure clean working place before opening new coupler from its packing
09 and further working then after, by placing clean paper or rubber sheet on
the pit bottom.
To check fuel, earthing and wires / cables of the power generating set for
10 prevention of shock and fire. Qualified / experienced wireman should be
engaged for all such electrical jobs.
To start, run and observe the power generator performance. Check the
11 output voltage and current. Voltage b/ current and frequency figures should
match with Electrofusion welding machine. Also output should be constant.
To post one responsible person, at gen. set power board, for emergency
12
shut off of the electric supply, in case of an incident.
To ensure that competent and certified PE welder is engaged for PE
13
welding.
 To mark and carry out the scrapping / degreasing / cleaning area of pipe
ends, by inserting coupler on the ends and using proper scrapping tool and
14
liquid cleaner. Ensure cleanliness of coupler ends. Prevent damage to the
heating coils of EF coupler.
To insert the coupler / couplers on pipe ends and connect the leads wires /
cables. Check the proper and safe connections. To remove PE cap from
the fusion terminal of the fittings. To check proper functioning of power
15
generator and EF welding m/c, condition of fusion cable, power cable,
before connecting the fusion cable. To keep EF m/c minimum 1 meter away
from the joint spot. To ensure proper ratting of gen. set
To fix alignment clamp on the above mentioned set up. Do not disturb the
16
set up.
To start the Electrofusion welding machine and carry out the welding as per
the procedure and check list supplied by EF machine and coupler supplier.
17
Prevent over / under heating and interruption of welding. Do not disturb the
set up.
To allow adequate cooling time for welded joints. Do not touch / move any
18
parts during the cooling time. Do not disturb the set up.
To open downstream low pressure squeeze / isolation valve, by initially
crack opening, and once it is pressurized carry out leak check by gas
19
detector and soap solution. Use soap solution on joint only after confirming
the complete cooling. Do not use ice cold water for soap solution.
If joints are ok,
20 To inform all concerned about readiness of resumption of gas supply,
especially to the customers by public announcement.
To slowly open the upstream squeezes or upstream isolation valve and
allow the pressure to rise to normal working pressure. The squeeze or valve
should be crack opened initially, observing the overall integrity of section at
new joints, vents, drains. After completion of work squeeze tools should be
21
removed from pipe line and PE pipe line should brought to its original round
shape with the help re-rounding tool. Squeeze area of the pipe should be
wrapped with warning tape “Do Not Squeeze” to avoid re-squeezing of the
same area / spot of the pipe.
 To continue public announcement to customers for resumption of gas
22
supply.
To attend the customer complaints in the area, if required to visit the
23 customer door to door, remaining in contact with control room for customer
complaints / other emergency.
To pay special attention to the complaints of gas smell / leak, especially
24
from closed houses of the affected area.
To back fill and compact the pits excavated for squeeze and weld. To
25 restore the original site soil layer and to remove the excess soil. To clean /
clear the site.
To observe / monitor the condition of the section for at least one hour after
26
resumption of gas supply and before leaving the site
To prepare reports and update the records. Especially, Near miss, hazard
27
and lesson learning, if any should be reported and shared with others.
3.17 Attending Gas Smell / Leak Complaint in Domestic Connection
Task Procedure :
Task purpose and importance
Attending gas smell / leak complaints in domestic connection is the activity
carried out for quickly finding the cause / source / place of smell and safely
repairing / arresting the gas leak, and restoration of gas supply to the customer.
The gas smell creates panic to the customer for probable gas leakage and
associated potential hazards. Similarly the obvious gas leak in the domestic
customer connection may pose highest potential hazards of asphyxiation / fire
and explosion, depending up on the volume, time of gas escape and ventilation of
customer premise during the gas escape. Here in the domestic connection the
risk is still higher as all the family members, from child to aged and weak and sick
and formally untrained persons are exposed to the hazards. Hence it is very
important that the gas smell and leak complaint in domestic connection is
attended at the earliest. This task has direct effect on company’s operation and
reputation, customer safety and customer satisfaction.
Sr. Activity Steps
To receive the emergency call, to give important safety instructions to the
customer, like ensuring, closing the control valve / no Smoking, / not to
operate electrical appliances / opening the doors and windows / keeping
01 people away, after noting his address and telephone nos. Initial
instructions to customer are very important in controlling the hazards and
mitigating the consequences, hence check list type ready format should be
always available with control room call receiver, for such communication.
02 To reach site, quickly, observing law full and traffic safety.
To assess the situation, for taking the following steps
Cordon and secure the affected area,
03
Keep the other persons away.
Open the door and windows.
To open the control valve, if the valve is closed by customer previously,
04
ensuring that valve opening does not create any hazard.
05 To identify the smell / leak spot, by carrying out, smell / noise and gas
 detection survey in the various parts of premise in consultation with
customer.
If the smell / leak spot is not found in the customer premise, then,
To carry out the survey in toilets, bathrooms and surrounding area of
drainage, gutters etc. as some times the leaking gas from underground PE
network, travel back in the toilets, bathrooms of customer premise, thru.
drainage and gutters
To close the control valve, after identification of leak spot. Measure should
06
be taken for prevention of accidental opening of control valve.
To arrest the leak by repair / replacement of the component / piping, as per
07
established procedure, and engaging a trained and certified persons only.
To open the control valve, and pressurize the connection, watching smell
08
and noise, from any obvious opening left unattended.
To carry out the vigorous leak check by detector and soap solution, on and
09
around the piping and components opened and refitted.
10 To witness the leak detection tests by an engineer in charge.
To ask the customer to operate his stove, to show him that now it is safe to
11 operate. If possible to explain the customer about what we did and what
might have caused the smell / leak.
To take customer Signature on call note as a conformity of attending the
12
job and handing over the safe operating connection to customer.
To prepare reports and update the records. Especially, Near miss, hazard
13
and Lesson learning, if any, should be reported and shared with others.
3.18 General instructions for Commissioning and Decommissioning
Gas Pressurization / Depressurization, Venting, Draining &
Purging
Task Procedure:
Task Purpose And Importance
Commissioning is the activity for charging the gas supply into the newly installed
network / installation for the first time. Similarly decommissioning is the activity carried
out for removing the gas, by shutting down the network / installation either temporarily
for some specific reasons like repair / maintenance / modification / nonpayment by
customer, or permanently for discarding the facility.
Both the activities if not performed properly, may cause hazards associated with
natural gas like fire and explosion, resulting from accidental gas escape due to unsafe
condition or unsafe practice. Hence both the activities need, good planning, pre and
post checks, apart from carrying out the actual commissioning / decommissioning
activity as per the written controlled procedures, safety precautions and emergency
preparedness. Deploying competent persons thus, the activities of commissioning
and decommissioning have the direct effect on company’s operation, safety and
customer satisfaction.
Commissioning is the term used for activity, carried out for taking machinery and
equipments into service or in operation for the first time. Commissioning activity in
City Gas Distribution system is carried out for charging the gas for the first time into
the newly installed facilities like, City gate Station, Service Regulators, PE network,
and industrial / commercial / domestic customer connections.

Commissioning activity is very important and needs detail planning and pre
commissioning checks, Readiness review and tool box talks, depending upon the
size and criticality of installation / network to be commissioned.

Before commissioning a facility, installation, testing and purging reports and

records must be reviewed to ensure that the condition and integrity of facility as a
whole is fit / acceptable for taking into service.
The commissioning activity consists of many sub activities like sequential operation
of various isolation, drain / vent valves, continuous monitoring of pressure, network
integrity, safety, environment aspects at every step of incremental pressure rise till
the whole installation is commissioned and reports records are prepared.

Written procedures, action plan, should be prepared for commissioning of the

network / installation which should cover not only actual commissioning, but should
also include checks for the use of quality of materials and workmanship, for
installation, testing and purging.
Any defects or leaks discovered during commissioning should be repaired /
arrested before proceeding further and recorded as required.

Decommissioning is the term used for shutting down the facility, temporarily for
repair, maintenance jobs or permanently for discarding the installation / network.
Same as commissioning activity decommissioning activity also needs detail
planning and written procedure to ensure proper isolation, required sealing at end
points and effective purging of whole facility for removal of residual gas as per the
hazards of job to be carried out after shut down. Proper isolation and double
isolation, blinding off, locking and tag out for prevention of accidental operation
and continuous monitoring of presence of hazardous gas should be done for
ensuring the gas free network during the entire shut down job.
For temporary disconnecting the customer connection, isolation and proper locking
device should be provided to prevent the opening of valve by a non authorized
person, or customer’s piping should be physically disconnected and ends sealed.

Both the activities of commissioning and decommissioning are critical and should
be carried out only after obtaining work permit. All safety precaution mentioned in
work permit and control measures required for concerned activities, installations
and site hazard should be taken during execution of job.

Normally N2 is used as inert gas for purging for removal of residual gas and air and
test media, for decommissioning and commissioning activities of city gas
distribution facilities. After purging, the O2 percentage should be less than 2%
similarly after purging the residual hazard gas percentage should be less than 2%.
It is experienced that apart from cleaning the facility, purging sometimes help in
discovering the missed out closing / sealing of isolation, vents, drains etc., which
could have created the uncontrolled escape of gas, resulting into, unsafe
condition, if gas is charged without purging.

Safety precautions should be taken for prevention of accidental inhaling of N2 and

entry into confined space and vault should be made only after checking of
availability enough Oxygen in the inside atmosphere. N2 has the tendency of
explosive nature when stored in the container at pressure for purging & testing
hence precautions should be taken to ensure that facility is fit for applied pressure.

Venting, draining, pressurizing and depressurizing for commissioning,

decommissioning the facility should be carried out as per controlled procedure,
considering network integrity, safety of employees involved and public at large, and
environment aspect.

For large and critical facility, such activity should be started in the early hours of the
day, as per action plan, after engaging competent persons, ensuring availability of
required PPEs, tools, tackles, calibrated pressure gauges, gas detecting /
measuring equipments, communication facility,
At every step of activity, effect and status of pressurizing and de-pressurizing
should be repeatedly verified and confirmed at 2 or 3 locations of gauges and vent,
drains locations.

Safety and Emergency preparedness should be ensured throughout the execution

of complete activity, by posting dedicated safety person and providing required
safety gadgets, PPEs etc. for safety, and security of the facility and employees and
public at large.

Adequate fire prevention and control measures should be taken for preventing the
fire during the execution of activity and controlling the fire / mitigating the
consequences of fire and explosion, if it occurs. It is a safe industrial practice of
documenting the site emergency handling procedure for a gas handling equipment
under commissioning or decommissioning, where possible leakage, of gas
constitutes a hazard of fire or explosion, adequate measures should be taken to
minimize the danger of accidental ignition of gas. (a) When a hazardous amount of
gas is to be vented into open air, each potential source of ignition should first be
removed from the area and adequate fire extinguishers should be provided. All
flashlights, lighting fixtures, extension cords, and tools should be of a type
approved for hazardous atmospheres. Blow down connections that will direct the
gas away from any electrical transmission lines must be installed or used.(b)
Suitable signs and flagmen or guards, if necessary, should be posted to warn
others approaching or entering the area of the hazard.(c) To prevent accidental
ignition by electric arcing, an adequate bonding cable should be connected to each
side of any pipe that is to be parted, tapped, squeezed off, or joined, and any
Cathodic protection rectifiers in the area should be turned off. When plastic pipe is
being parted, tapped, or joined, attention must be given to the static electrical
charges that may be present on both the inside and outside diameters of the pipe.
These charges can be dissipated by using antistatic fluids or a water and detergent
solution in combination with a moisture retaining material that must be in contact
with the exposed pipe and the earth. Cutting tools and squeeze off and tapping
equipment used on plastic pipe where static charges may be present should be
grounded to drain these charges from the pipe.

After completion of activity, the facility should be under observation for at least 1 or
2 hours on the same day and should be visited and monitored for 2 days.
Depending upon the condition of the facility.

After completion of activity, proper reports and records and photographs for
commissioning and de-commissioning should be prepared and maintained /
preserved. Report near miss and hazard and share lesson learning, if any.
3.19 Valve Chamber Maintenance
Task Procedure
Task Purpose And Importance
In the city gas distribution network, valve chambers, house the isolation valves for
stoppage of gas supply in the section or whole network, during gas leakage / pipe
line damage and taking LPT.
Along with main isolation valve there are tiny purge / vent valves located on both
sides of valve.
The valve chamber is covered on the top at ground level, by nos. of sleepers.
The maintenance of the valve chamber mainly focus on gas leak check and
operability of the valve, dewatering, cleaning and housekeeping. The activity of
maintenance thus ensures the gas free atmosphere in the chamber and
operability of isolation valves. Also the sleeper handling needs safety precautions
of not falling / dropping on the tiny purge valves, which may result in the
uncontrolled gas escape, posing hazards of asphyxiation, fire and explosion.
Identification and controlling the site hazards is another safety requirement, while
working in valve chamber that needs, Thus there are many task, if not performed
properly as per the procedure and work instructions, will have effect on
company’s operation, emergency handling capabilities and safety management.

Sr. Activity Step

To carry out planning as per Annual Operation and Maintenance Plan, and
approved by GSPC, required persons are identified and trained for job skill
01
and related safety precautions along with fire and emergency handling, in
the Induction Training.
To arrange Identity cards for the successful employees who have passed
02
the competency test.
To attend meeting with company department for discussing annual
03 Maintenance plan for valve chambers and based on priority, to discuss
and decide monthly plans.
To prepare The list of the valve chambers to be taken under Annual /
04
Monthly Preventive Maintenance Plan.
 Availability of required tools tackles / PPEs and man power is assured one
05
day in advance.
06 To obtain the work permit on scheduled date
To carry out the maintenance of valve chambers as per below given work
07
instruction.
To ensure Site supervision for safe and effective maintenance job as per
08
the instructions and requirements of work permit
09 To intimate about job completion to control Room
10 To update Logbook and history card (in computer) updated
To collect and deposit scrap / garbage from above activities at designated
11
scrap yard.
To prepare maintenance report, & submit to location In charge for
12
verification.
To Monitoring the schedule of maintenance of valve chamber and re-plan
13
and carry out, In case maintenance is not carried out as per schedule.
Work Instruction
Preventive maintenance of valve chamber

To obtain work permit and read / understand instructions and precautions written
in the permit copy.
To reach site with site supervisor, technician, with wireless / mobile, tools tackles,
PPEs and a copy of work permit for displaying and referring at site.
To use PPEs as applicable like hand gloves, goggles, helmet etc.
To identify and control, site hazards.
To check and establish communication with control room.
To measure gas presence above the sleepers, if any. It should be zero.
To lift and shift the sleepers away from chamber to safe place
To remove sleepers one by one, safely, to ensure that none of them drop / fall in
chamber, to remove all sleepers. Take care of body back of all involved, by
changing the person, if required.
To measure the gas presence, from above the chamber and before making any
entry. It should be zero.
To check and take precautions as required for snake , frogs and other rodents,
inside the chamber.
To enter in the chamber, slowly and safely keeping one person outside for watch.
If not required only one person to enter in the chamber.
To carry out general observation of condition inside & if required, to carry out de-
watering from valve chamber into drainage system.
To check any abnormality like damage / corrosion or foreign items, inside the
chamber.
To carry out soap solution test of all joints. To ensure that there is no leak from
anywhere in the chamber.
To operate valve clock-wise / anti clock-wise frequently to make valve free in
operation, ensuring that gas supply is not affected. If required grease plug valve
with grease stick till valve becomes free in operation. No greasing required for
forged ball valve. Clean valve, C.I. cross, valve chamber wall, floor & sleepers.
After operational check, to ensure that main valve is in open condition and purge
valves are in closed condition and plugged.
If required, paint main valve & purge valve with blue colour, vent pipe with yellow
colour, sleepers with black colour & Its frame with yellow colour, to paint arrow for
flow direction & Paint valve chamber no.
To whitewash the side- wall of valve chamber if required.
To make / record final inspection of inside of chamber.
To replace the sleepers one by one in to their original position, slowly and safely,
taking care that sleeper does not drop accidentally inside the chamber.
In case of finding of leakage of gas inside the chamber, if possible arrest the
leakage first before carrying out any other job. If not take the shut down the
section during none pick hours and arrest the leakage.
3.20 Patrolling & Survey
Task Procedure
Task Purpose And Importance :
Pipeline patrolling and leak survey are carried out along the ROU on the road, street
or open fields. The patrol is carried out to find and keep track of damaging activities,
mostly by other utilities, customers, public and some time by nature. Similarly leak
survey is carried out to find out the hidden / unnoticed underground gas leaks.
Thus both the activities of patrol and leak survey are important for preventing
reducing the damage to the network and gas leaks on the network which in turn
prevent / reduces potential hazards of gas leak like, asphyxiation, fire and explosion.
This activity has direct effect on company’s operation, network integrity & safety
management.
Sr.
Activity Steps
No.
A Patrolling
For planned patrol, to decide the network patrolling area and frequency
01 based on the past experience and records, criticality of network, activities
carried out by other utilities
02 To prepare the annual and monthly patrol plan for actual execution.
To identify the person and train / educate them for network geography,
03 effective patrolling procedure, emergency communication for heavy
leakage and preparing report & record
To carry out emergency patrol, for the section / network vulnerable to
04
damage due to sudden development of activities by other utilities.
To check the condition of vehicle like, fuel, tyre pressure, breaks, light, oil
05
level, side light...etc before taking start for patrolling
To ensure availability of drinking water, first aid and other specific
06
requirement if any
07 To wear PPEs like safety shoes, cotton dress and reflective jacket
To carry out patrolling by driving the vehicle along the pipeline route, as
08 per, as-built drawing, markers and valve chamber position, observing
activities on pipeline as per check list, like excavation, construction,
 encroachment

To coordinate with agency/s involve in above activities if found on pipeline

09
route
To understand their work, extent of excavation and its potential hazard to
10
underground gas pipeline
To explain them, about the gas pipeline network / route and precautions to
11
be taken to prevent damage to gas pipelines.
12 To provide them contact number and other detail for assistance
To collect their detail like contact number, address etc for further
13
coordination
14 To prepare report in standard format
B Leak Survey
For planned Leak Survey, to decide the network leak survey area and
01 frequency based on the past experience and records, Post LPT data,
criticality of network, activities carried out by other utilities
02 To prepare the annual and monthly leak survey plan for actual execution.
To identify the person and train / educate them for network geography,
03 effective leak survey procedure, emergency communication for heavy
leakage and preparing report & record
To carry out emergency leak survey, for attending smell complaints and
04 for the section / network vulnerable to damage due to sudden
development of activities by other utilities.
To ensure that the gas detector with at least 1% LEL least count is
06 working, calibrated & with fully charged batteries. To keep the spare
batteries depending on the job to be carried out
To wear PPEs like safety shoes, cotton dress, reflective jacket and I card
07 and ensure your personal safety from vehicle and building under
construction, electrical installation, stray animal like dog
To carry out leak survey by walking along the pipeline route as per, as-
08 built drawing, markers and valve chamber position with gas detector
keeping probe just 2” above the ground.
09 To observe / hear the detector findings carefully and record the same.
To monitor the gas leak in drainage manhole or other such chambers /
10
vaults also
In case of gas leak is observed, to survey surrounding area, manholes,
11 vaults for measuring extent of leakage. To record the leak % and area /
location
In case of gas leak more than 20% LEL, to cordon the area and call
12
emergency team to attend it immediately
To switch the gas detector when not in use. To ensure the security of
13
detector.
14 To prepare survey report in standard format
3.21 On Line Functional Testing / Resetting Of Gas Stream Valves
Task Procedure
Task Purpose And Importance :
The task is performed for checking the working performance of active, monitor ,
slam shut off and safety relief valve of gas stream of CGS / CPRS / DRS, on line,
that is, without removing the valves from their position. The task if performed
properly, ensures the redundancy of gas supply, in case of failure of working
stream, and reduces maintenance time and efforts required for servicing the same
valves in workshop, after removing from their position. Secondly the performance
is tested in position with NG itself; hence less adjustment for fine tuning is
required, after the valves are taken into actual operation. The task has direct effect
on company’s operation, safety, production, customer satisfaction.

Sr. Activity Steps

To fix the date and time of the job, as per the planning shown in Annual
01
Operation and Maintenance Plan, in coordination with GSPC Gas in charge.
To carry out the detail planning of the job, for ensuring availability of spares,
02
Tools tackles, PPEs, and required manpower.
To prepare procedure, action Plan, for who / what and when for each step of
03
the procedure.
To prepare and submit the work request for safety permit, with all required
04 documents such as procedure, action plan, list of tools tackles PPEs and
manpower.

To obtain the work permit and to read and to take care for safety precautions
05
and special instructions written in the permit.

06 To reach CGS, with all required items and a copy of permit to display at site.
To arrange the tool box talk with all involved, to explain the job details, as per
07
action plan, procedure, safety precautions and emergency handling.
To identify and to take control measures for site hazards. To check
08
communication with control room.
To observe and record initial pressures of both gas streams, running and hot
09
stand by.
10 To carry out leak check of all joints of both gas streams so that leaks can be
 arrested during the job of testing valves,
11 To close the inlet and outlet isolations valves of hot stand by stream.
To observe / record the pressures of running stream, for confirming it’s healthy
12
working.
To safely depressurize the stream, by opening all vents and drains, one by
13
one ensuring gas concentration in the air remains safe..
To open the caps of active monitor SSV, SRV and their pilots and to take and
14
record original setting of spring compression screws.
To continue monitoring / recording the pressures of running stream, to
15
ensure continuity of gas supply.
16 To open the bonnets of active monitor SSV, SRV and their pilots.
17 To check condition of rubber diaphragms, for wear and tear, hole, damage,
To check valve internals, especially rubber seats, for wear and tear, damage,
18
score, bending etc. To remove dirt, dust and other foreign particles, if any.
19 To check / clear the breather hole on bonnet body of valves and pilots.
20 To continue monitoring / recording the pressures of running stream.
To assemble all valves, and except SRV, set the spring setting screw of all
21
valves and pilots, to fully open position.
To reset the valves as per valves supplier’s instructions. Add droop value in
22
the locked setting to get the desired operating pressure.
23 To open the isolation valves of the stream and take it on line.
To observe the on line operation of valves for at least 15 minutes, before
24
shutting down the other stream.
To repeat the above steps for second stream, to continue monitoring /
25
recording the pressures of running stream.
To observe the CGS / CPRS / DRS for one hour, after taking both gas
26
streams on line.
27 To monitor the CGS / CPRS / DRS performance for 2 days.
To prepare the report and update the records, including spares used and
28
need to procure for spare inventory.
3.22 On Line Repair Maintenance Of Service Regulator Valves
Task Procedure
Task purpose and importance
The task is performed for repair maintenance and checking of the working
performance of regulator, OPSO & UPSO of a service regulator, during
emergency breakdown and periodical routine maintenance. The gas supply is to
be ensured before taking functional test or repair / maintenance activity

The task if performed properly, ensures the redundancy of gas supply, thru
alternate arrangement, and reduces maintenance time and efforts required for
servicing the same valves in workshop, after removing from their position.
Secondly the performance is tested in position with NG itself; hence less
adjustment for fine tuning is required, after the valves are taken into actual
operation. The task has direct effect on company’s operation, safety and customer
satisfaction.
Sr. Activity Steps
To fix the date and time of the job, as per the planning shown in Annual
01 Operation and Maintenance Plan, in coordination with GSPC Gas in
charge.
To carry out the detail planning of the job, for ensuring availability of
02
spares, Tools tackles, PPEs, and required manpower.
To prepare procedure, action Plan, for who / what and when for each step
03
of the procedure..
To prepare and submit the work request for safety permit, with all required
04 documents such as procedure, action plan, list of tools tackles PPEs and
manpower.

To obtain the work permit and to read and to take care for safety
05
precautions and special instructions written in the permit.

To reach the site of service regulator, with all required items and a copy of
06
permit for display and referring at site.
To arrange the tool box talk with all involved, to explain the job details, as
07
per action plan, procedure, safety precautions and emergency handling.
08 To identify and to take control measures for site hazards.
To open fencing lock and cabin doors and sleepers from upstream /
09 downstream valve chambers. Remove all sleepers one by one, taking care
of not dropping sleeper in the chamber.
To be aware of snake, frog other rodents, if any in the fencing / cabin
10
/installation/ chambers.
11 To check and establish communication with control room.
To measure gas presence in the chambers and cabin with gas detector, It
12
should be zero
To enter the chamber safely for fitting the half inch pipe piece tee and
13
gauge on the downstream purge connection on the LP valve chamber.
14 To observe and record initial pressures of service regulator.,
To carry out leak check of all joints of service regulator so that leaks can be
15
arrested during the job of testing valves,
16 To ensure gas supply arrangement, and observe record the consistency of
supply at least for 15 minutes, before shutting down service regulator.
17 To close the inlet and outlet isolations valves of service regulator
To safely depressurize the SR, by opening all vents and drains, one by one
18
ensuring gas concentration in the air remains safe.
To open the valve cap and to take and record original setting of spring
19
compression screws.
To continue monitoring / recording the pressures of gas supply to customer,
20
to ensure continuity of gas supply in the network.
21 To open the bonnets of valve.
To check condition of rubber diaphragms, for wear and tear, scratch,
22
damage etc.
To check valve internals, especially rubber seats, for wear and tear,
23 damage, score, bending etc. To remove dirt, dust and other foreign
particles, if any.
24 To check / clear the breather hole on bonnet body of valves and pilots.
25 To continue monitoring / recording the pressures of temporary gas supply.
26 To assemble valve, set the spring setting screw of valve, to fully open
 position.
To open the inlet valve of service regulator, and to keep the outlet valve
27
closed to check and set the pressure setting of valve.
To reset the valve & OPSO / UPSO as per valve supplier’s instructions.
28
Add droop value in the locked setting to get the desired operating pressure.
29 To open the outlet isolation valve of SR and take it on line.
To observe the on line operation of valves for at least 15 minutes, before
30
shutting down the temporary gas supply..
To check all joints with soap solution, clean all the valves and pipes, filter
31
etc. To carry out housekeeping in and around SR.
32 To observe the SR for one hour, after taking on line.
33 To monitor the SR performance for 2 days.
To prepare the report and update the records, including spares used and
34
need to procure for spare inventory.
35 Report near miss, hazards and share lesson learning if any,
3.23 Odorant Handling - Storage, Local Transport and Disposal
Task Procedure
Task purpose and importance
The odorant chemical used for imparting smell to natural gas has the noxious smell
and health effect. Leak or spill of the odorant may cause panic in the public in
general apart from inviting mass smell / gas leak complaints and non conformity /
complaints from statutory / local bodies.

Hence thru this task procedure, the storage, a local transport and disposal activity of
odorant handling ensures the safe and lawful storage, safe local transport and safe
and lawful disposal. The task has direct effect on company’s operation, safety
capabilities reputation and statutory compliance.
Sr. Activity Steps
A Storage for odorant barrels.
To construct the safe and secured, single facility, with one room for full barrels
1 and another room for empty barrels and items used for odorant handling,
transfer and emergency.
To setup the storage facility with following considerations,
As far as possible away from population, and considering wind direction to
avoid nuisance to population, in case of accidental leak / spill.
To Keep away from heat or direct sunlight which may increase the vapor
pressure inside the barrel.
2
To protect the barrel from other elements like sharp edges, impact, etc. and
to store on the pallet.
As flash point (-38.9°C) below 20 °C, to store in cool, dry, well ventilated
area free from electrostatic charge, sparks, open flames, open light.
electrical fitting at storage area if any is be explosion proof
3 To provide the barrel lifting provision in the facility for handling the barrel.
Floor level in both rooms and open corridor should be on same level for easy
shifting of barrel but above the surrounding ground level, to avoid ingress of
4
rain water.
To provide ventilators for natural cross ventilation and with windows to shut off.
 Not to fit electric wiring / lights, in the facility to avoid accidental ignition, in case
of odorant leak / spill.

To construct the rooms of optimum size for storing about 4/5 full barrels in one
5 room and about 4 / 5 empty barrels. Odorant transfer pump, pipes and fittings,
neutralizing agents, working buckets and carboys in another room.
As per GPCB requirement, to construct the flooring of empty barrel room with a
6 slight gradient in the corner, where a valve with lit check tank shall be provided
to collect the accidental spillage.
7 To provide the wind indicator, and required fire fighting equipments
. To provide the following in the facility.
For minor leak / spillage, strong oxidant solution used with detergent
• Sodium hypo chloride - NaOCl
• Calcium hypo chloride - Ca (OCl2)
• Hydrogen peroxide - H2O2
Warning - Do not bring undiluted chemical in contact with odorant. Risk of
explosion!
8 For large leak / spillage, use absorbent, Like
• Sand
• Clay
• Sawdust
• Activated charcoal
• Benton
After absorbing, dispose off in closely fitting containers according to GPCB
guidelines
To provide the required PPEs like rubber apron, chemical resistant hand
9 gloves, face mask, goggles, breathing filter mask etc
To provide eye wash and shower facility, in close proximity.
To provide, display, appropriate signage at the facility, especially MSDS of
10
odorant and emergency contact nos.
To ensure the round the clock security of .the facility by providing lock and a
security guard. To allow the entry to only authorized persons.
To prepare and implement annual inspection plan to check and ensure safety
 and leak / smell free barrels by visiting facility periodically.
B Local Transport
Local transportation of barrel is required for shifting full barrel from storage
1 facility to odorant consumption point like CGS. CNG station and returning the
barrel with remaining odorant from CGS / CNG, back to storage facility.
To use / engage the transport vehicle capable in terms of capacity size and
shape to carry the full barrel safely.
2
To ensure that vehicle has valid registration and its driver holds the current
diving license. To give special instruction for slow and safe driving.
To arrange the tool box talk to make aware the criticality / hazards in the job
3 and safety / control measures to be taken for safe transport and handling
emergency of leak and spill.
To guide and park the vehicle at the parking provision at storage facility.
4 Remove the ignition key and place the stop log underneath the tyres to avoid
accidental running away of vehicle.
To check and ensure that barrel that is to be transported is full and not leaking
5
from the leads as checked by smells and soap solution.
6 To Shift and lift barrel slowly and safely, by engaging enough manpower.
To place the barrel just behind the driver’s cabin in upright position, with leads
7
on top.
To tie the barrel with the vehicle body, using suitable ropes. And to hold the
8
barrel by 2 / 3 persons to monitor the position and minimize the shaking.
To start vehicle and travel from storage facility to the place of requirement,
9
taking care on the way.
10 To guide and park the vehicle at spot, where it is safe to un load the barrel.
11 To place the nos. of truck tyre on the ground where the barrel is to be lowered.
To shift and lower the barrel, slowly and safely, by holding it, by strong
12
persons, at required positions.
To place the barrel in the hand pulled trolley and shift it to the place of transfer.
13
Remove the trolley away.
After completion of transfer activity, to ensure that both the leads of the barrel
14
are tightly fixed and there is no smell / leak. To ensure cleaning and
 neutralizing of pump, pipes, fittings, and to close tight the buckets and carboys.
To return the empty barrel from transfer place to storage facility with the same
15
care and concern as taken, while transporting the full barrel.
16 Prepare report and update the records.
B Disposal
To neutralize the empty barrel, using 5% concentration Hypo solution, mixed
1
in 10 liters water , in the bucket
To neutralize the empty barrel, by using 25 liters of solution of water and
diluted neutralizing agent. and washing detergent. Close both leads of the
2
barrel tightly. Never to use highly concentrated or dry agent, as the reaction of
odorant with neutralizing agent is exothermic and may produce fire.

3 To shake well and roll the barrel for ensuring effective neutralizing.
To open the lead, after 10 / 15 minutes of shaking and rolling and to check the

4 smell coming out. Keep the barrel lead open, If very mild smell still persists
which will dissipate in the local atmosphere.
Fix suitable data sticker on the barrel, after completion of neutralization

5 process. The sticker must contain the barrel no, content, date, company name
etc...
To store the neutralized barrel in the local storage facility, till the nos. of empty
6
barrels reaches to tempo / truck load.
To arrange the transporter for sending the empty barrel to approved land fill
side. To ensure that the transporter is approved by GPCB and driver holds the
7
valid driving license and carries required papers like TREM card, emergency
contact nos.
To note that timely disposal of empty barrel is a safe practice. As the residual

8 content is toxic and corrosive, In case of delayed disposal, there is a potential

danger of leak and small resulting into complaints and public nuisance.

9 Prepare the report and update the records.

.
3.24 Odorant Transfer from Barrel to Storage Tank
Task Procedure
Task purpose and importance :

The purpose of the odorant transfer procedure is to transfer the odorant from full
barrel to odorant storage tank for dosing in the gas. The odorant chemical used for
imparting smell to natural gas has the noxious smell and health effect. Leak or spill
during transfer process of the odorant may cause panic in the public in general apart
from inviting mass smell / gas leak complaints and non conformity / complaints from
statutory / local bodies.

Hence through this task procedure of the odorant transfer ensures the leak free and
safe operation. The task has direct effect on company’s operation, safety
capabilities reputation and statutory compliance.
Sr. Steps
To ensure that Written intimation regarding transfer of odorant is given to
1.
Location, GPCB, 48 Hrs. in advance, stating date and time of transfer.
2. To obtain safety work permit before starting the transfer procedure.
3. To inform Control room before starting the Job.
To check the emergency preparedness / availability of saw dust, dry sand,
4. detergent powder, sodium hypochlorite in required quantities and fire
extinguishers etc. are ensured.
To use personal protective equipments like chemical resistance hand
5.
gloves & apron / cover all, mask respirator, face mask etc.
To dilute the Sodium Hypo Chloride solution, by adding water and Surf
washing powder, to measure the PH of the solution, it should be more
than 7PH.
6.
To prepare such solution in 4 nos. of full buckets. Never to use
concentrated and dry powder of neutralizing agent like Sodium Hypo
Solution. The reaction being exothermic will produce the fire.
To connect the one end of vent tube to the vent point on tank and another
7. to the carbon / charcoal filter immersed in bucket full with Hypo solution,
for neutralizing the vapour from tank.
 To safely transport the full Odorant barrel / drum to the Platform at the
specified location, using transporting truck / trolley. Never to roll the barrel
8.
and to shift the barrel with minimum shaking to minimize the generation of
vapour.
To place the ice on barrel / drum as well as on tank to settle / condense
9.
the vapour of EM.
To connect air motor inlet of the pump to N2 cylinder. And check the
10. functioning of barrel pump by actual operating it with the water. Also to
observe / record the minimum N2 pressure required for safe pump speed.
To start / continue depressurizing the odorant tank by crack opening the
11. vapour vent valve & checking the bubbling in the solution bucket and smell
in the surrounding area to ensure effective neutralizing of odorant vapour.
To open all 4 nos. of valves on glass level indicator of the tank. Observe /
12.
Record the current odorant level in the tank, if any.
To slowly open the bigger lead of the barrel and insert the pump pipe into
13. the barrel, ensuring neutralizing of vapour from barrel by wrapping the wet
cloth of solution around bigger lead
To connect the pump discharge to the odorant tank & check the integrity of
14.
discharge piping by slowly opening of the tank and pump liquid valves.
If everything is normal, to start filling by operating the barrel pump, by
opening and setting N2 regulator on cylinder, to predetermined value, set
15.
during trial run on water. Always to keep the pump speed to lowest
possible to minimize the vapour generation for effective neutralizing.
During pump operation, to continue depressurizing of the tank, ensuring,
vapour pressure in the tank remains near to zero and there is effective
16.
neutralizing of vapour in solution bucket. If required change solution /
carbon filter.
17. To observe the rise of odorant level in the tank.
To continue Monitoring the EM vapour pressure in the tank and smell in
18. the surrounding to ensure effective transfer and neutralizing of EM vapour
from tank.
 To Stop the N2 supply as soon as transfer of odorant from drum to tank
gets completed & the same is confirmed by net rise in odorant level in the
19. tank. Never to fill the storage tank above 80% of its capacity. Always keep
some vapour space in storage tank. To observe / record the final odorant
level in the tank.
To close vapour valve / liquid fill valve and all 4 nos. of level indicator
valves of the tank. To fit the plugs on tanks and lead on barrel and check
20. for leakage by soap solution. To ensure cleaning of tank and associated
piping using wet cloth of sodium hypo solution, for removing residual
smell.
21. To disconnect all the arrangements made for transferring Odorant.
To clean / neutralize barrel pump & its associated components by running
22. in 1/2 to 5-percentage concentration Sodium hypochlorite solution and
then in clean water.
If the barrel still contains some odorant then to shift & store it in full barrel
room, after fixing information sticker.
23. If the barrel is empty then neutralize it as per the standard work instruction
and shift & store it in the Hazardous Waste Room, after fixing informative
sticker
 CHAPTER – 3 C
OTHERS / UTILITIES

3.24 Fire Extinguishers

3.25 First Aid
3.26 Self Air Breathing Apparatus
3.27 Maintenance Van
3.28 Portable Generator Set
3.29 Phones & Wireless
3.30 Public Address System