Standard Work Procedure (SWP) G I

1. Route Survey

1 Initial route survey to be done with TPI/PMC/EIC to confirm feasibility aspects agreement of customer.
2 Hand sketch of route finalized must be signed by customer.
3 Route finalized must be at ventilated areas.
4 conceled piping is strictly not allowed

2. GI Installation

1 All pipes should be vertically plumbed.

2 clamping must be provided on either sides of each fitting with maximum of 150mm gap.
3 Minimum 2 Clamps must be provided in 1.5m (1/2") GI pipe below regulator
4 One clamp must be provided above regulator with maximum gap of 150mm.
5 At each & every service tee there must be provision of isolation valve(3/4").
6 Minimum offset distance from riser and hole piece should be 150mm.
7 Hole piece must pass through PVC pipe.
8 In case of approach riser all droppings must have individual valves.
9 All pipings must be visual and installed in ventilated area.
10 Piping inside kitchen must have sufficient ventilation.
11 One coat Zinc based primer

12 Tow coats paint of caneery yellow( Asian,Nerolack or Burger) per coat 30 micron must be applied prior to
13 All fittings must be painted after testing of instllation.

3. GI Testing

1 At the time of riser testing all isolation valves must be in opened and plugged condition.
2 Riser testing should be done on 2Kg/cm2 & it should be witnessed after two to four hours.
3 Pressure gauge used for testing must be (0-4) Kg/Cm2 and it must be within calibration period.
4 Calibration certificates of pressure gauge must be approved by EIC or PMC and signed seal must be stick
5 After testing of riser it must be socket plugged which indicates that riser had been tested.
6 Riser measurement must be done prior to testing.
7 Customer must be informed about extra piping if applicable and extra piping consent to be signed by custo

4. Meter Installation

1 Meter must be installed in ventilated location.

2 Flexible hose pipe should be used in 3 patterns as shown in fig.-
3 Isolation valve inside kitchen must be on maximum height of 1.5m from ground level.
4 All pipings inside kitchen must be minimum 1.0 m away from electric wires.
5 Gas piping should not cross over any electric line.
6 Distance from appliance valve and gas burner must be minimum of 500mm.
7 piping must not run over any electric wire.
8 Piping must not run over gas burner.
9 PVC clamp must be on either side of each bend in copper piping.
10 One supporting PVC clamp must be provided just before Appliance valve.
 5. Online Tapping

1 All work to carried out in the presence of TPI/PMC/EIC only.

2 Ensure the no connected houses with the riser.
3 Ensure the no. of balance tappings(Probable houses) to be done.
4 Shut down form to be filled and signed by Connected consumers.
5 Disconnect the regulator and plug the isolation valve.
6 Isolation Valve to be installed in balance tap offs, and it must be plugged.
7 Re- connect the regulator & Riser commissioning to be done also ensure no leakage with soap solution.
8 Inform connected consumers that gas is available and take there initials.
9 Internal testing from the "Isolation valve of service tee" upto the "Appliance Valve" with meter to be done at
10 At the time of comissioning ensure that there is no leakage from the Isolation Valve with soap solution.
11 Presence of fire extiguisher must at the time of online tapping.

6. RFC Checklist

1 GI Sleeves properly sand filled.

2 Ensure proper clamping & painting of the installation.
3 Ensure riser testing done/confirm initials of TPI who has witnessed Testing. Also make sure socket must be
4 Hole Cementing Done.
5 Make sure that all other meter control valves are closed except of those whose RFC's are to be done.
6 No leakage in Regulator assembly/soap solution test done.
7 Copper Pipe Clamping properly done
8 Internal Testing done at 100mbar for 5 Min duration.
9 Socket Plugged after RFC.
10 Safety Manual Chart to be provided to the customer.
11 Obtain feed back form duly signed by the customer.
12 Emergency Phone No. stickers to be stuck over the meter bearing the initial of TPI with date.

7. Conversion Checklist

1 Make Sure that socket is plugged and RFC done before NG conversion.
2 Nozzles should be changed to new one.
3 New Hose Pipe provided & clamped on both ends.
4 Old nozzles handed over to the customer.
5 Soap solution test carried out.
6 Portable fire extinguisher to be carried at the time of conversion.
f customer.

applied prior to installation of pipes.

od.
l must be sticked on the gauge.

signed by customer .
 ap solution.
c
to be done at o
p solution.

ocket must be plugged.

be done.
 ELCTRO FUSION MACHINE MSA PLUS 300- Error Messages
E Display
2 MAIN VOLTAGE TOO HIGH

5 AMBIENT TEMP.TOO LOW

6 AMBIENT TEMP.TOO LOW

7 INTERNAL TEMP.TOO LOW

8 INTERNAL TEMP.TOO LOW

9 FITTING RESISTANCE TOO LOW

10 FITTING RESISTANCE TOO HIGH

11 FUSION VOLTAGE TOO LOW

12 FUSION VOLTAGE TOO HIGH

13 FUSION CCIRCUIT INTERRUPTED

14 FUSION CURRENT TOO HIGH

15 POWER SUPPLY TEMP. TOO LOW

16 POWER SUPPLY TEMP. TOO HIGH

21 OUTAGE DURING LAST FUSION

22 FUSION INTERRUPED WITH STOP

27 INCORRECT FUSION PROGRAMME

28 UNIT RANGE EXCEEDED

71 SYS-ER MEASUR.AMBENT TEMP.

72 SHUTDOUN DUE TO MAGN INFLUENCE

74 FUSION POWER TOO LOW

75 FUSION POWER TOO HIGH

76 POWER SUPPLYERROR

BAR CODEREDAR

Barcode reader oprates best when held at an angle of 10-30degrees

POWER SUPPLY

1 single phase alternating current of 230 volts AC and frquency of 50-60 hetz
 2 65degrees celceus requered restert tempreture
3 71degree present power supply unit tempreture
4 power consupmtion maximum 3500 W nominal output
5 fusion voltage 8-42(48) volt Ac galvanically separated

MAIN SUPPLY

1 16 A (inert) AFI swich is recumended

2 only use extention leads with a dia meater of more than 2.5 mm squ.
3 primary lead 3 mtr
4 secondry lead 3 mtr
USION MACHINE MSA PLUS 300- Error Messages
Comments
Check fuctioning generator

Allow MAS plus 300 to warmup in a heated room

Allow MAS plus 300 to cool room

check fitting

check fitting

Check generator out put /extension cord

If this occurs frequently ,send MAS plus 300 for servicing

check the power connection/ extension cord

If this occurs frequently ,either the fitting is defect or the MAS plus 300 need servicing

Allow MSA plus 300 to Warm up in a heated room

Allow MSA plus 300 to coll of

Check the last fusion opration

Check the last fusion opration

Use barcoad according to standard Iso/tr 13950

Use fitting which can be joined with the MSA Plus 300

send MSA Plus 300 in for serviceing

move MSA Plus 300 away from the genrater

check the genrater out put/extention coad

if the occourse frequently, send the MSA 300 in for servicing

send MSA Plus 300 in for serviceing

when held at an angle of 10-30degrees

nt of 230 volts AC and frquency of 50-60 hetz

estert tempreture
y unit tempreture
3500 W nominal output
galvanically separated

a dia meater of more than 2.5 mm squ.

S. no ISO REMARKS
1 ASME Gas Transmisson piping B- 31.8
2 MDPE 14885
3 HDPE ISO 4427
4 HDD API 1102
5 MDPE Fitting IS 8085
6 G. I Pipe 1239
7 GI Fitting ISI 14329
8 C U Tube BS EN 1057
9 CU Fitting BS EN 1254
10 Brass Fitting EN 1254
11 Flexible Metal Hose BS 6501
12 Ruber Tube IS 9573
13 Solding Material Bs EN 29453
14 Welding API 1104
15 Zinc ( Galvanizing) IS 13229
16 Cement IS 4031
17 RCC IS 456
18 Sand IS 383 Size 0.6 - 2 mm
19 Brick IS 3495
20 NPT Thread ASME B1 20.1
21 CNG sylender ISO 14439
22 GAS Gyser IS 15558
 PTS < Particular Technical Specification
M DPE
1 MDPE I S ;code 14885
2 Grade PE 80 SDR 11

MDPE Carrier Pipe Size Thickness Min. Dia of Max. Dia of HDPE
3 (mm) (mm) Length m HDPE (mm) (mm)
20 3 200 50 50
32 3 150 50 90
63 5.8 100 110 160
125 11.4 50 200 250
180 16.4 12 250 315

ROUTE SURVEY
1
2
3
4
5

TRENCHING
1
2
3
4
5

DEPTH OF TRENCH
1 Minor water crossing/Canal 2.5 meter
2 Uncased/Cased Road Crossing 1.5 meter
3 Rail/Road Cased Crossing 1.5 meter
4 Normal Areas 1.0 meter

CLEARANCES

1 150 mm Wher the gas pipe Crosses other assets/utilities

2 Electric cables Wherupon the clearance shall be 300 mm
3 300 mm Wher the gas pipe similar aligment to the other assets /utilities

TF PROTECTION

1 GI seelev IS 1239 (Heavy Duty) L 300 mm x Dia 2.5 inch For commercial 3 inch
2 Making of Pedestal GI Sleeve (min Size 150x150x150 mm)
3 Half round concrete sleeve ( min size 250x250x150 mm)
4 Material M-20 1:2:4
5 T F Pits Will be must restored siz 0.5x0.5 (LXW)

PE WARNING MAT

1 1mm thick and 300mm wid shall be placed on distribution main and service line in side premises.
2 Use affter backfill of trench up to height of 300mm on the top of carrier pipes.

MOLING

1 manual moling ensure that the size of the hol shall not be mor than 20 / of size of thr casing /carrer pipes.

VALAVE SIZE

Dia Length Valve chamber size

1 180 mm 650 mm
2 125 mm 600 mm 1w x 2L meter
3 63 mm 450 mm
4 32 mm 300 mm 1w x1.5 L meter
 MDPE Fitings Fusion PE -100
Fusion Cooling
S. no MDPE Fiting Dia Make name Bar Code Time Time
1 coupler 180 mm

2 coupler 125 mm innogaz 391414151253391225180330 125 sec 12 min

3 coupler 63 mm innogaz 39440306300431051718010311 76 sec 8 min

4 coupler 32 mm Kimplas 951112300328405704042753 42 sec 4 min

5 coupler 20 mm innogaz 39440302000251151718010300 23 sec 5 min

6 Elbow 180x90 mm

7 Elbow 180x45 mm

8 Elbow 125x90 mm innogaz 39440612531192123705040318 180 sec 12 min

9 Elbow 125x45 mm innogaz 39440712531086723705040319 180 sec 12 min

10 Elbow 63x90 mm Kimplas 981112310638401805070756 70 sec 7 min

11 Elbow 63x45 mm innogaz 39440706300111151706050314 55 sec 9min

12 Equal Tee 180 mm

13 Equal Tee 125 mm Kimplas 971112321258400845200753 200 sec 15 min

14 Equal Tee 63 mm innogaz 39440906300080251706050302 65 sec 10 min

15 Equal Tee 32 mm innogaz 39440903200111007705040310 39 sec 6 min

16 Equal Tee 20 mm innogaz 39440902000061251706050301 23 sec 4 min

17 Saddle 180x125 mm

18 Saddle 180x63 mm

19 Saddle 180x32 mm

20 Saddle 125x63 mm georgafisher 07360534810070205705040342 162 sec 20 min

21 Saddle 125x32 mm

22 Saddle 63x32 mm Kimplas 070628300638407554070755 70 sec 4 min

23 Saddle 63x20 mm

24 Saddle 32x20 mm innogaz 091414150322401048025440 40 sec 5 min

25 Reducer 180x125 mm

26 Reducer 180x63 mm

27 Reducer 180x32 mm

28 Reducer 125x63 mm

29 Reducer 125x32 mm

30 Reducer 63x32 mm

31 Reducer 63x20 mm

32 Reducer 32x20 mm innogaz 09441112600161151706050313 22 sec 5 min

33 end cap 180 mm

34 end cap 125 mm innogaz 391414151253391225180330 180 sec 12 min

35 end cap 63 mm innogaz 39440306300431051718010311 76 sec 8 min

36 end cap 32 mm Kimplas 951112300328405704042753 `42 sec 4 min

37 end cap 20 mm innogaz 39440302000251151718010300 23 sec 5 min

38 Valve 180 mm

39 Valve 125 mm innogaz 391414151253391225180330 125 sec

40 Valve 63 mm innogaz 39440306300431051718010311 76 sec 8 min

41 Valve 32 mm Kimplas 951112300328405704042753 42 sec 4 min

Remarks
 Questionairre for TPI’s

Name : Contact
Location : Date

Q 1. What will be the size of coarse sand to be used for back filling ?

Ans. 0.6-2.0 mm as per IS383

Q 2. What is the Type of Threading used in GI pipes ?

Ans. NPT Thread

Q 3. What is the API Code for execution of HDD operation ?

Ans. API 1102

Q 4. What is the minimum copper and phosphorus percentage in copper tube used by IGL ?
Ans. Copper including silver-99.9 % and phosphorus – 0.015 to .04 %

Q 5. By which chemical we shall clean the pipe surface and bore of fittings before starting fusion.
Ans. Iso propanol/Acetone

Q 6. G.I Pipes shall be as per which specification ?

Ans. IS 1239

Q 7. What does error code E11 & E12 in fusion machine mean?
Ans. E -11 Fusion Voltage Too low , E – 12 Fusion Voltage too High

Q 8. What is the G-Rating of Domestic Meters & their Maximum & minimum Flow in M3/h ?
Ans. G – 1.6, Max – 2.5 m3/h , Min - 0.016 m3/h

Q 9. What odorant is used in the natural gas to detect the smell.What is the chemical formula ?
Ans. Ethyle Mercaptan, C2H5SH

Q 10. What is the ISO/IS Standard for MDPE pipe ?

Ans. IS 14885

Q 11. What is the Minimum Tensile strength of copper tube used by IGL ?
Ans. 250 N/sq mm

Q 12. What is the chemical name of the material TEFLON TAPE is made up ?
Ans. PTFE
Q 13. What is the Flow Rate of Domestic Regulator ? How many normal domestic connections can be given from single
regulator (with explanation) ?

Q 14. What is the LEL limits for Natural Gas ?

Ans. 5 ~ 15 %

Q 15. What is the full form of ------

OISD---
DRS----
FRS—
MDPE--
Ans.
OISD- Oil indian safety directorate
DRS- District regulating system
FRS- Field regulating system
MDPE-Medium density polyethylene

Q16. What is the Grade/class of GI pipe used in IGL & its corresponding standard?
Ans. IS 1239 Class-C Heavy duty

Q17. What is the dia& class of the GI PIPE used for the purpose of sleeve?
Ans. 2.5 inch and C class

Q18. What is the MDPE Grade for pipes used in IGL?

Ans PE 80 (yellow) & PE 100 (orange)

Q19.What is the SDR? What SDR does IGLUse?

Ans. SDR=OD/WT, SDR-11,Standard dimension ratio.

Q20. 100mm of mercury (Hg) pressure is equivalent to how many mbars?

Ans. 133.32 mbars

Q21. What output voltage does Fusion machine operate?

Ans. 39.5-40 volts.

Q22. What is the Manhole cover Dia for valve chamber?

Ans. 560 mm.

Q23. What is the wall thickness for RCC Chamber

Ans. 150 mm.

Q24. What is the Code/Standard for Gas Transmission & Distribution piping system?
Ans. ASME B31.8

Q25. Which is regulator board for petroleum and natural gas industry?
Ans. PNGRB

Q26. Why the Nitogen is use for the purging purpose ?

Ans. Nitrogen cannot react with the hydrocarbons and cannot make some explosive mixture.

Q27. What is a length of a single copper pipe and a single GI Pipe?

Ans. CU- 2.9 MTRS, GI-6 MTRS

Q28. The fusion code of 32mm coupler is of how many digits?

Ans 24 digit.

Q29 The Domestic regulator used in IGL,are of which company?name any two?
Ans Pietro, Mesura

Q30.What is the IS Standard for steel Reinforced Rubber hose pipe?what is the nominal bore
Size of steel reinforced Rubber hose pipe?
Ans. IS-9573 , 8 mm, max wp 1mpa

Q31. What is the minimum bends cyclic life for corrugated flexible metal hose?
Ans. 30

Q32. What is the nominal weight (kg/mtr) for heavy duty GI Pipe with a nominal diameter of 15 mm and 20 mm?
Ans. 15mm- 1.44 kg/mtr
20 mm – 1.87 kg/mtr

Q33. Which day is celebrated as National safety day in India by National safety council?
Ans 4th march.

Q34. Name any company engaged in the business of manufacturing hand held natural gas
Detection system?
Ans. QRAE

Q35 Kindly complete the following word that states the hose material used in corrugated flexible metal hose?
Ans. 304 S
:
:
e given from single
and 20 mm?

al hose?
 G. I Question And Answer

Q. 1 Length of G. I. Pipe All Size

Ans. 6 Mtr

Q. 2 Tickness of G. I. Pipe
Ans. Nominal Dia 15 mm 20 mm
Grade Heavy Heavy
OD Min/ Max 21-21.8 mm 26.5 -27.3 mm
Thickness 3.2 mm 3.2mm
Weght kg/m 1.44 1.87

Q. 3 Is Code of G. I. Pipe.
Ans. I S -1239

Q. 4 Is Code of Rubber Tube.

Ans. I S -9573

Q. 5 Length Size of Rubber Tube.

Ans. 1 -1.5 meter

Q. 6 Dia of Rubbertube.
Ans. Bor 8 mm

Q. 7 What is Copper Pipe Length, Dia, Thikness.

Ans. Dia 12mm L - 2.9 m Thickness 0.6 mm

Q. 8 Meter inlet dia and outlet dia

Ans. In let dia 3/4" out let dia 3/4"

Q. 9 Domestic Meter Size,

Ans.

Q. 10 Trade of the Gas Pipe line

Ans. ASME B 31.8

Q. 11 How many testing of G.I Pipe.

Ans. 2 Kg/cm2

Q. 12 How many testing time Of G. I pipe

Ans. 2 Hours

Q.13 How many Testing of RFC.

Ans. 100 mili bar

Q.14 G.I. pipe Clamp Size

Ans. 1.5" 2" 2.5"

Q.15 Meter Clamp Size

Ans. L-200mm W

Q.16 Domestic Regulator outlet and inlet dia.

Ans. Out letDia IN letDia
20 mm 15 mm

Q.17 Solding Wire is IS Code and dia.

Ans. I S COD- B S E N 29453
Dia 3.25 mm
Solding Tempetrature 1800 C - 2500 C
Q.18 Make brand of MDPE pipe
Ans. Jain Industries

Q.19 Domectic Meter Make and brand.

Ans. Actaris, itron, A. E.M, SANSUS, (G-1.6)

Q.20 Domectic Regulator Make and brand.

Ans. Pietro, Messuure (21 Mbar)

Q.21 Full form of Taphlon Tap

Ans. PTFE (Poly tetra Floro Ethyline)

Q.22 Taphlon Tap Length, size and widh

Ans. L-12m x W -12mm Thicness 0.01 mm

23 Pedesthal Size
Ans. 150X150X150 MM

Q 24 RCC Marker length & Filer material

Ans L 650mm W-300mm Thi-100mm
Pits Size 300x300x300mm
material 1,4,8

Q 25 Pol Marker
Ans L - 2.9 m Dia - 3" Thi- 3mm
Pedesthal Size 400x400x700mm
M-20 1,2,4
Q
Ruber tube use in IGL