Vous êtes sur la page 1sur 81

Basic Concepts of Design & Construction of

Gas Distribution Network

GSPC Gas Company Limited

December, 2009
City Gas Distribution An Overview

CGD is the last component of the Natural Gas

value chain delivering Natural Gas to end users
in town and cities to meet the demand for a
cleaner, more efficient, economical and
environmentally-friendly energy source.
Development of Pipeline Network in a pre-defined
geographical spread
Maintaining Different Levels of Gas Pressure to meet the
Demand of various segments of gas users - Domestic,
Commercial, Industrial and Automobiles.
Designing high pressure and medium pressure network
such that supply to any consumer is possible from either
Design gas storage / Gas sourcing for maximum survival
Consider Health, Safety & Environment at all stages
Steps in the design of Gas Distribution System
Market demand estimated based on comprehensive field
survey of units covering domestic, commercial, industrial
and transport sectors.
Demand forecast projection is carried out for 20-25 years.
Peak hour consumption estimated for network design.
The system is to be designed based on 20-25th year
projected demand at peak load in a phased manner.
Reconnaissance Route Survey within the town to identify
suitable routes for laying pipelines, locations for City Gate
Station, District Regulating Station & CNG Station
Steps in the design of Gas Distribution System
Network design and optimization with available software
Design of Mother Station and Daughter / Daughter booster
station for CNG supply to automobiles
National / International standards adopted for design.
Project implementation done subsequently.
Battery Limits
Transmission Distribution
Transmission Line

Distribution Zone

City Gate Station


HP Network

MPB Network

CNG Mother Stations


MPA Network

Domestic and Commercial

LP Network
Sr. No. Network Component Inlet from Inlet Pressure Outlet to

1 CGS Transmission line 99 - 60 barg 26 barg Steel Grid

2 Steel pipeline CGS 26 barg 26 14 barg DRS / CNG

3 DRS Steel pipeline 26 14 barg 4 1 barg MP MDPE pipeline

4 Service Regulators (SR) MP MDPE Pipeline 4 1 Barg 110 mBarg LP MDPE Pipeline
Industrial MRS &
5 MP MDPE pipeline DRS 4 barg 4 1 barg Commercial
Regulator of Domestic /
6 LP MDPE Pipeline SR 110 mBarg 110 50 mBarg Commercial

1.5 barg or
MP MDPE pipeline 4 1.5 barg customer specific Industrial internal
7 Industrial MRS
Steel pipeline 26 14 barg pressure within pipeline
the supply range
Online / Mother CNG
8 Steel Pipeline 26 - 14 barg 250 Barg Vehicle at 200 Barg

9 Domestic Connections LP MDPE Pipeline 110 50 mBarg 21 mBarg Meter & Gas Stove

75 mBarg or
LP MDPE Pipeline 110 75 mBarg customer specific
10 Commercial Connections Meter & Gas Stove
MP MDPE Pipeline 4 1 Barg pressure within
the supply range
City Gas Distribution
Applicable Codes & Standards
European Standard

Gas supply systems - Gas Pressure Regulating Stations for

1 EN 12186
Transmission and Distribution. Functional Requirements

2 EN 12279 Gas pressure regulating - installations on service lines

Gas supply systems - Natural gas measuring stations - Functional

3 EN 1776

Gas supply systems- Pipeline for maximum operating pressure over

4 EN 1594
16 bar- Functional requirements

1 ASME B16.11 Forged Steel Fittings, Socket-Welding and Threaded

2 ASME B31.3 Process Piping

3 ASME B31.8 Gas Transmission and Distribution Piping Systems

4 ASME B16.5 Pipe line flanges and flanged fittings

5 ASME B16.9 Factory - Made Wrought Steel Butt welding Fittings

Section- IX- Qualification Standard for Welding and Brazing

ASME- Boiler and Pressure Vessel
6 Procedures, Welders, Brazers, and Welding and Brazing

ASME Boiler and Pressure Vessel Part C- Specifications for welding Rods, Electrodes, and Filler
Code- II Metals

8 ASME Boiler & Pressure Vessel Code Section - V, Non-destructive Examination

ASME Boiler and Pressure Vessel

9 Section-II Materials Part A- Ferrous Material Specifications -

International Standard for Petroleum and natural gas industries - Induction

1 ISO- 15590-1
bends, fittings and flanges for pipeline transportation systems

3 BS 6755: Part 2 Testing of Valves

Coatings of corrosion protection tapes and heat-shrinking products for

4 DIN 30672, Part I
pipelines for operational temperatures upto 50oC

6 DIN 30670 Polyethylene coatings for steel pipes and fittings


1 OISD-226 Natural Gas Transmission Pipelines & City Gas Distribution Networks

2 OISD-GDN-115 Guidelines on Fire Fighting, Equipment and Appliances in Petroleum Industry

Fire Protection Manual-

3 Fire Engines, Trailer Pumps and Hydrant Systems

4 OISD- Standard- 141 Design and Construction requirements for cross country hydrocarbon pipelines

5 OISD-Std-118 Layouts for Oil and Gas Installations


1 API Standard 1104 Welding of Pipelines and Related Facilities

4 API Specification 5L Specification for Line pipe

Specification for Pipeline Valves ( Gate, Plug, Ball and

5 API Spec. 6D
Check Valves)

7 API Standard 1102 Specification for steel pipeline crossing & highways.


1 AGA Purging Principles and Practices

2 IGE/TD/1 Steel Pipelines for High Pressure Gas Transmission

5 AGA: Report No. 7 Measurement of Gas by Turbine Meters

6 AGA Report No.3 Orifice metering of Natural Gas and other related Hydrocarbon fluids

Compressibility factors of Natural Gas and other related Hydrocarbon

7 AGA-Report No 8
City Gas Distribution
System Components
CGD - Infrastructure
Major Constituents of CGD are;
City Gate station
Pipeline Network
Steel Pipelines
Poly Ethylene Pipelines
GI / Cu Pipes
Regulating Stations
District Regulating Stations
Service Regulators
Domestic / Commercial / Industrial Regulators
Metering Stations / Metering & Regulating Stations
CNG Stations
CGS is the location of Custody Transfer from
Transmission Company to Distribution
Inlet & Outlet isolation valves
Knock Out Drum (KOD), If required
Metering Unit (Turbine / Orifice / Ultrasonic)
Gas Chromatograph (GC), If required
Pre-heater (if required)
Pressure reduction skid comprising
Active & monitor Regulators
Stream discrimination arrangement
Slam shut valve for over & under pressure protection
Creep relief valves.
Odorising Unit
The Steel Grid pipeline sizes is 12NB & 8NB whereas, spur lines
shall be of 6NB & 4NB.
Steel pipelines used in the distribution system is fully coated. The
coating is extruded polyethylene, with each weld joint coated with
either heat shrink sleeves or field applied tape.
Prior to the pipeline being put into service, the distribution
pipeline to be non-destructively tested by two methods. Firstly,
welds would be radio graphed and, secondly, the completed
pipeline extension would be hydro-statically tested at a higher
pressure than its operating pressure.
After hydrostatic testing, the pipeline to be dried, purged and
filled with natural gas. The testing and commissioning procedures
will be detailed during the detailed design phase of the project.
To protect the pipeline from corrosion, a cathodic protection
(CP) system of impressed current is proposed. During the
detailed design phase, the CP capability of the existing
transmission system will be investigated to establish if it has
the capacity to provide CP to the extension. If it is found that
the existing system does not have the capacity, additional CP
facilities will be designed.
The steel grid is installed at a minimum depth of 1.0 meter
cover, and in accordance with Indian requirements.
The distribution pipe is with Standard Dimension Ratio
(SDR 9) for 20 mm, (SDR) 11 from 32 mm up to 63
mm & (SDR) 17.6 for above 63 mm. The term SDR is
defined as the normal outside diameter (DN) divided by
the minimum wall thickness.
It is standard practice in India to have a minimum 1.0
meter cover. This additional depth in a densely populated
area would be recommended.
All MDPE pipe back filled with sand around it to protect
the plastic material.
Medium Density PolyEthylene (MDPE)
Tech Spec: IS 14885:2001 & ISO 4437
Material Grade & Color: Internationally approved resins of PE 100 grade of Orange
Minimum Required Strength (MRS) of PE 100 grade pipe: 10 MPa
Pressure Class: SDR 9 (dia 20 mm), SDR 11 (dia 32 & 63 mm) and SDR 17.6 (dia 90,
110, 125 and 160 mm).
Operating pressure: 4 bar (g).
Operating temperature range: - 10 0 C to + 40 0 C.
Advantages of PE pipes
High performance (Globally proven leak free system)
More Flexibility, coil ability, ductility, High elasticity
Low density (low weight, high strength to weight ratio)
High resistance to corrosion
Low heat conductivity (small thermal loss)
Smooth surfaces (low pressure losses due to low pipe friction)
Easy to transport, handle and lay
Longer life
Advantages of PE pipes
Easier and speedier joining techniques to ensure leak tight joints by
employing electro fusion techniques
Higher productivity, i.e., reduction in installation time (15 minutes in
case of PE against 4 hours in case of steel), thereby lesser inconvenience
to public
Reduced number of joints, hence safer and leak free system
Less time is consumed to repair PE damages as compared to steel
Good squeeze off properties
Advantages of PE pipes
Longer design life of PE pipes (50 years) as compared to steel pipeline
(30 years)
Avoidance of NDT techniques in building premises, which is very
Size of trench is less in case of laying of PE pipe as compared to steel
MDPE Fittings
Tech Spec: ISO 8085-3 or EN 1555-3
Material Grade: PE 100
Terminal pin size: 4 or 4.7 mm
Voltage: 39 40 Volts.
Color: Black.
PE Stop Off Valves (Typical)
Standard: ASME B 16.40, EN 1555-4
Pressure Class: SDR 11.
Design Pressure: 5.5 bar (g).
Design Temperature: 45 0 C.
Operating Temperature: 10 0 C to 45 0 C
End Connections: PE Material (Spigot Type)
Stem Extension: Integral stem extension required
(Minimum 690 mm from the Top of Pipe)
Valve Design: One piece construction.
Ball position Indicator: Open / Close limits required.
Crimping Fitting (Typical specification)

Used to connect u/g PE pipes with a/g GI pipes

Operating Pressure: up to 4 bar (g)
Operating Temperature: 40 0 C
Hydrostatic Test Pressure: Minimum hold Pressure of 10 bar (g), for 1
hour duration
Pneumatic Test Pressure: Minimum pressure of 6 bar (g), for 1 hour
Pull out Test:
Shall not fracture within the jointed assembly
Shall withstand the Pneumatic pressure leak test
Shall not leak
District Regulating Stations
District Regulating Station
District Regulating Station
Service Regulators
Typical requirements of Pressure Regulators
used for domestic and small I&C customers

Maximum Inlet Pressure: Maximum 4 bar (g)

Nominal Outlet Pressure: 100 mbar (g)
Flow capacities: 50, 150, 200, 250 scmh
End connections: Threaded (& Tapered) as per BS 21
Operating ambient temperature: up to 45 0C
Lockup: Maximum pressure, under no-flow condition, up to 125 mbar (g)
Creep relief valve: To protect against downstream over pressure at low flows or in the
event of valve seat malfunction, preset to 140 mbar (g)
Over Pressure Shut Off (OPSO): Device to protect against downstream over pressure,
preset to 160 mbar (g)
Under Pressure Shut Off (UPSO): Device to protect against downstream under
pressure with a pressure setting range 40 mbar (g) to 65 mbar (g)
Regulator Selection
Information required to select a regulator:

Maximum and Minimum inlet pressure

Required outlet pressure
Maximum flow rate
Tolerance on outlet pressure
Size of pipework
Type of gas
Safety features required
Size of orifice
OPSS, UPSS & Relief settings
Installation indoors of outdoors
Orientation of regulator
Gas Meters
The most common types of meters used are:

Rotary Positive Displacement (RPD)
Diaphragm Gas Meters (Domestic)
Tech Spec: EN 1359
Capacity: 2.5 m3/hr
Rangeability or TD ratio: 1:150 or better
Nominal Working Pressure: 21 mbar (g)
End Connections: , as per BS 746 (Male)
Center to Center distance: 110 mm between inlet
and outlet connections
Diaphragm Gas Meters (Commercial)
Tech Spec: EN 1359
Capacity: 10, 25, 40, 65 scmh
Rangeability or Turn Down ratio (ratio
of Qmax and Qmin): 1:150 or better
Nominal working Pressure: 100 mbar
Pressure rating : Suitable to withstand
maximum working pressure of 200 mbar
Rotary Positive Displacement (RPD) meters
Tech Spec: EN 12480
Volumetric meter
Appropriate for medium size load
Typical Turndown 35:1 to 50:1
Accuracy 1%
Large measuring range
Not sensitive against disturbances
Not sensitive against fast changes in
flow rate
Needs lubrication
Rotary Positive Displacement (RPD) meters
Rotary Positive Displacement (RPD) meters
Advantages Disadvantages

Good flow turndown Filtration essential (50 microns or

Tolerance to installation effects Requires lubrication
and load behaviour
Accuracy 1% Physical size at large capacities

Much smaller than a diaphragm Can create pressure fluctuations

meter on on/off loads
Very long life Can cut off gas supply when it fails

Industrial Metering Station (IMS)
IMS are used to measure gas supplied to Industrial consumers
Main component in IMS is filter, Isolation Valves, RPD Meters
with EVC & Modem, Regulators (If low pressure requirement)
and Non return Valve
Inlet pressure range 1.5 Barg to 4 Barg
Outlet pressure As required by customer
MRS components
Inlet & Outlet isolation
Pressure regulator with a
built in slam shut device
Relief valve
Flow Meter (RPD, Turbine,
GI ERW Pipes

Tech Spec: IS 1239 (Part 1)

Types used: Medium Class and Heavy Class
Material: IS 1387
Pipes shall be screwed with Taper threads
Threads: Tapered and conforming to BS 21
Galvanizing: IS 4736
Coating requirements: Mass of coating is 400 gms / m2
Test Pressure: 5 MPa
Powder Coating:
Powder Material: Pure Polyester
Application: Electrostatic spraying (40 90 KV, Manual / Automatic)
GI Fittings (Malleable Cast Iron)
Tech Spec: IS 1879
Material: IS 2108 Grade BM 290
Dimensions: IS 1879
Threads: IS 554
All Internal & External Threads shall be tapered
Chamfer shall have included angle of 900 +/- 50 for
Internal threads & 700 +/- 100 for external threads
Galvanizing: IS 4759
Coating requirements: Mass of coating is 700 gms / m2.
Forged Fittings (Wrought Steel
Tech Spec: IS 1239 Part 2
Material: IS 1387
Dimensions & Tolerances: IS 1239 Part 2
Threads: IS 554
All Internal & External Threads shall be tapered
Chamfer shall have included angle of 900 +/- 50 for Internal threads &
700 +/- 100 for external threads
Galvanizing: IS 4759
Coating requirements: Mass of coating is 700 gms / m2.
Brass Valves
(Meter Control Valves, Riser Isolation Valves &
Appliance Valves)
Tech Spec: EN 331
Pipe Nominal Diameter :- to 2 NB.
Operating Pressure: 4 bar (g).
Operating Temperature: 10 60 0 C.
Material: Nickel Plated Forged Brass.
Pattern: Full Bore, Quarter Turn Ball Valve.
Handle: Suitable Metallic Handle, Lever / Knob / Cap
Type with yellow coating (Powder / Plastic) on
Surface marked as GAS
End connection: Screwed, As per BS EN 10226-1,
Tapered Threaded, Female
Meter Regulator
Gas flow rate: 2.5 m3/h
Nominal Inlet Pressure: 100 mbar (g)
Maximum Inlet Pressure: 160 mbar (g)
Nominal Outlet pressure: 21 mbar (g)
Lock-up pressure: Shall not exceed 30 mbar (g)
Low pressure Cut-Off: at inlet pressure of 11.5 mbar to 15 mbar (g).
Re-pressurization safety device is fitted which prevents the regulator from re-
opening when the inlet pressure is restored unless there is a downstream
backpressure, i.e., all connected appliances have been turned off.
End connections: Right angled inlet and outlet connections of x BSPT (Female)
Rubber Hose (flexible and steel
wire braided)
Used to connect the appliance, inside the house
of domestic customer
Tech Spec: Type IV of IS 9573
Size: 8 mm NB
Material: It consists of
A. Lining: Synthetic rubber like Nitrile
Butadiene Rubber (NBR) or Chloroprene
Rubber (CR)
B. Reinforcement: Wire reinforced in braided
form in between the lining and the cover
C. Cover: Consolidated by wrapping, and
uniformly vulcanized to give good adhesion
Rubber Hose (flexible and steel
wire braided)
Mechanical Properties:
Tensile strength: Minimum 10 MPa for lining and cover
Elongation at break: Minimum 200% for lining and 250% for cover
Salient features:
Strong (Steel wire reinforced) hence rats can't bite through steel wire Flame
Abrasion, ozone and weather resistant, hence no cracks
Low temperature flexibility
Minimum burst pressure of 0.5 MPa
Long life (5 years)
Grip strength (to nozzle of appliance)
City Gas Distribution Network Design
System Basics
System of units
The International System of Units (SI), also known as the "Metric
System" to be used. The International Gas Union (IGU) has also
recommended to generalize the use of the SI system in all matters
relating to Gas and Gas facilities. The SI system shall be in compliance
with ISO 1 000. The SI system shall be of general use with exception
to the following:
Gas Volumes and Flow,
Heating Value
Pipeline and Piping Nominal Diameters shall be expressed under
either one or both systems where "Common Practice" of Pipeline
and Piping Engineers so suggests;
System Basics
Data relating to equipment shall use that system of unit that
is most common in the relations with suppliers.
Where advisable for good understanding, the corresponding
value in the other System of Units shall be mentioned
between brackets.
Results of technical calculation and related figures issued
from specific software shall remain expressed in that system
of units that is used by the relevant software.
Steel Pipelines
Steel mains
Notwithstanding the major advantages of polyethylene (PE),
steel pipelines remain necessary as follows;
High-Pressure Mains
Location class: the design of High pressure mains shall consider
requirements as for Location Class 4 (ASME 31.8) to allow
timelessness should the environment change in the future.
Wall thickness: according to ASME B31.8 Section 841.11
with Design factor of 0.4. In addition, wall thickness shall, in no
way, be lower than the values below in function of Nominal
Diameter (ND)
Steel Pipelines
4 in. and below - 3.9 mm
6 in. - 4.5 mm
8 in. - 5.0 mm
10 in. - 5.6 mm
20 in. - 6.3 mm
GSPC Gas is using 6.4 MMWall thickness.
Steel Grade: The Design Concept considers API Grade X 52
Steel quality to offer maximum flexibility for line pipes
Bend Radius: to allow pigging under special circumstances
Steel Pipelines
Steel Pipes
API 5 L - Line Pipes
ASTM A 106 - Seamless Pipes
ASTM A 333 - Seamless &Welded Pipes for low temperature services
Location Class
Location Class I - 10 or fewer buildings in 1 mile section
Location Class I I - 10 46 buildings in 1 mile section
Location Class III - 46 or more buildings in 1 mile section
Location Class IV - Areas where multi story building & heavy traffic plus
other underground utilities
Steel Pipe Design Formulae
P = (2 St/D) * FET As per ASME B 31.8, 841.11 (a)

t = PD / 20fs
Steel Pipelines
Above Ground Mains
Polyethylene being forbidden for above ground crossings, if any,
steel mains sections are needed at the crossing with PE/steel
transition fitting to be buried with the adjacent PE mains.
Steel Pipelines
Process Design
Wey-mouth Formulae
Q = 0.0813 * (d)2.6667 * {(p12-p22)1/2 / (S * L)1/2 }

V = Q /A
Velocity for filtered gas to be 40 m/s & unfiltered
gas to be 20 m/s maximum.
P 1 = 15 Barg, P2 = 10 Barg (Min.)

Q = 2,00,000 SCMD
1 2

L = 32,000 m
Q = 2,00,000 SCMD i.e. 9,166.66 SCMH
Using Wey Mouth Formulae: Q = 0.0813 * (d)2.6667 * {(p12-p22)1/2 / (S * L)1/2}
9166.66 = 0.0816 x (d)2.6667 * {(16.0132-10.0132)1/2/(S* L)1/2}
d = 198.52 mm : Calculated Diameter.
We have to select diameter from the available range e.g. 200.1 mm from API 5 L
Now, P1V1 = P2V2
1.013 * 9,166.66 = (9.32+1.013) * V2
V2 = 898.8 M3 / Hr = 0.2497 M3 / Sec.
Now, for Velocity, Q = A * v
0.2497 = (3.14/4) * (200.1 * 10-3)2 * v
V = 7.94 m/s
Now, for Wall Thickness, t = (P*D) / 20fs
t= (16.013 * 219.1) / (20 * 0.29 * 241)
t = 2.5099 mm
P 1 = 26 Barg, P2 = 10 Barg (Min.)
o Q=1 Q = 9250
1 2 3
o L = 12000 m L = 20000

Q = 4000
L = 7000

Polyethylene Pipelines
MRS (Minimum Required Strength)
The MRS value represents the long-term circumferential stress in the pipe
under which the break may occur after 50 years at the earliest.
Stress = MRS / C, where C is overall service coefficient
The minimum value of C for the material to be used for Gas application is 2.
MAOP (Max. allowable Operating Pressure)
MAOP = (20 * MRS) / [C * (SDR-1)].
Standard Dimension Ratio
SDR = Dn / En
SDR used in GSPC Gas is SDR 9, SDR 11 & SDR 17.6
Standard followed by GSPC Gas
IS 14885: 2001
Polyethylene Pipelines
Base resin
The PE resins of Third Generation (PE 100 or MRS 10) in full
compliance with detailed specification is being used. First
Generation is PE 63, second PE 80 & Third generation is PE
Wall thickness
The MDPE network designed and qualified for a MOP of 4 bar.
The Network analysis and resulting structure and behaviors
are based on such design. PE line pipes wall thickness shall be in
accordance with the following SDR
Gas mains (ND 90 mm): SDR 17.6
Gas mains and Service lines (ND 90 mm): SDR 11.
Service lines (ND = 20 mm): SDR 9
Polyethylene Pipelines
Different Material used for PE Pipes
The following materials have been approved to date:
Solvay Eltex TUB 121(Black) or Eltex TUB 125(Orange) PE 100
Borealis HE 2490 PE 100
Fina Finathene XS 10 B PE 100
Dow BG 10050 PE 100
Elenac Hostalen CRP 100 PE 100
Manufacturer Commercial Brand Name Code(*)
DOW BG 10050 D3
Polyethylene Pipelines
Process Design
Wey-mouth Formulae
Q = 0.11672 * (d)2.664 * {(p12-p22)0.544 / (S * L)1/2}
V = Q /A
Velocity for filtered gas to be 40 m/s & unfiltered gas
to be 20 m/s.
Being a complex network, required specialized tools for
Planning & Designing the network. GSPC Gas use
SynerGEE software for designing the PE Network.
PNG Domestic & Commercial
Process Design
Polyflow Formulae
Q = 1.522786 * 10-3 * (d)2.623 * {(h/L)0.541}
Peak Gas flow is assumed @ 0.5 SCMH for one house
Being a standard PNG Connection, we have standardize
the design of PNG Network as follows;
GI pipes up to G + 4 apartments OR 5 connections in case of raw house.
1 GI Pipe above 5th Floor apartment OR above five connections in raw
PNG Domestic & Commercial
Route Selection for GI / Copper Pipe Installation
Route selection for GI pipe installation shall be carried out as per the guideline
given below;
Pipe shall not be installed on un-plastered wall or in the house under construction.
Pipe shall not be installed in an unventilated void space.
Route shall be selected that maximum length of the pipeline shall be installed
Route of the pipeline shall be planned for the shortest possible length.
The gas pipeline shall be away (minimum distance of 200mm) from the electrical
There shall be minimum change of directions and minimum no of threaded joints.
Maximum two Point in the kitchen for gas stove only.
Compound gate or doors and windows inside the house shall not hit the Gas pipeline.
Copper installation should be a minimum 300mm away from heat source and
Electrical installations. If it is not possible for copper installation then suitable
protection should be given.
If the copper pipe installation is carried out inside cupboards, there should be a
provision for adequate ventilation like louvers/holes in cupboard doors.
PNG Domestic & Commercial
Positioning of Valves, Regulator & Meter
Riser IsolationValve:
For apartments, one riser isolation valve shall be provided at a height of 2 meter
From the ground and individual meter control valve shall be installed for each
The riser isolation valve shall be installed at a convenient height so that it is easy to
operate the valve in emergency.
Meter Regulator:
Regulator shall be installed in such a way that it reduces the length of H.P. Line (Max.
pressure 0.1 Bar) to minimum possible.
Wherever possible meter Regulator shall always be installed outside residence and at
a convenient height.
PNG Domestic & Commercial
Gas Meter:
Gas Meter shall be installed in such a way that it shall be protected from direct
rain or waterfall on the meter. Location of the Gas meter shall be decided during
the route selection.
Meter shall be installed at convenient height so that it is easy for the meter
reader to take correct readings.
The meter shall never be positioned very near to Electric Line. A minimum
distance of 200 mm shall be maintained.
Appliance Valve:
The position of the appliance valve shall be convenient to operate and it shall
keep the rubber tube at a safe distance from the heat source.
The orientation and distance from cooking platform/ground shall be maintained
in such a way that the Bending Radius of the Rubber Tube shall be more than
Appliance valve shall be installed in ventilated space and the lever of appliance
valve shall not foul with the wall during the on-off operation.
GI Pipe cutting & Threading
After site and route clearance, the measurements for pipe cutting shall be
taken and pipes shall be cut accurately as per the required lengths.
If the length of pipes is not correct, the threaded joints come under heavy
stresses, which may ultimately cause gas leakage.
Installed piping threaded connections / joints shall be tightened in such a
way that all the joints shall be free from heavy stresses and misalignments
due to incorrect pipe length.
The condition of thread die and pipe vice jaws shall be checked regularly and
shall be free from defects.
Cutting fluids (oils) shall be used while thread cutting.
Threaded pipes shall be handled carefully so that the threaded oily portion
shall be free from dust, mud, water and any damage due to impact of any
Cutting burrs on the pipe shall be removed from the edges. The edges shall
be straight and free from Knife-edge formation.
G.I. Pipe Installation & Clamping
Teflon tapes shall be wrapped on threaded portion of the pipe with minimum
three overlaps.TheTeflon tap should be of approved make and gauge.
The no of clamps shall be adequate. The pipeline portion containing the
Regulator and Meter, either horizontal or vertical, shall have clamps on both
side of the regulator and meter. Clamps shall be fitted in such a way that they
do not create misalignment of pipes.
The clamp shall be installed by drilling 6 mm hole in plastered wall and screwed
using rowel plug.
Distance between two clamps shall not be more than 2 meter; the gap between
riser and wall shall be minimum 25 mm.
Clamps shall be installed in a straight line and shall be parallel to each other.
The clamps shall be fixed properly on the walls and should grip pipe in position.
For wall crossing, drill the hole with the help of electrical drilling machine in
such a way that plaster and tiles shall not be damaged. It shall be ensured that
there is no concealed wiring or any other fitting on the opposite side of the wall
for a particular location of drilling.
G.I. Pipe Installation & Clamping
Self-adhesive anticorrosive tape shall be wrapped on the pipe with 50% overlap.
Casing sleeve shall be installed in wall for wall crossing.
Alignment of the pipeline shall be maintained.
Whenever compound gate, house door or window hits the G.I. pipe protection
clamp shall be installed to protect the pipe.
Concealed piping shall not be done.
All the pipes shall run on walls with clamps. Pipe should not be overhung and
shall not be installed without pipe clamp.
Wherever powder coating is peeled off during fitting and tightening of the pipe,
touch up shall be done after the installation is completed by two coats of
approved paint.
Prior to installation all pipes and fittings shall be checked internally to ensure
that they are free from any obstruction.
PE to GI (transition fitting) joint shall be provided above ground.
Installation of Valves, Regulator &
Union and testing T shall be installed before riser isolation valve.
Meter control valves, Meter regulator and Gas meter shall be
protected from the over tightening of the thread.
Valves, Meter regulator and Gas meter shall be installed with the
clamps on both sides. As far as possible hex nipple shall not be
used for connecting. Both side threaded 3 to 8 long pipe nipple
shall be used.
Gas meter, regulator and installed piping shall be aligned properly.
Flow direction of the gas meter shall be checked before
Flat rubber washer shall be checked and ensure at inlet and out let
of the adaptor joint to the meter.
Pipe nipple shall be installed between elbow and regulator to avoid
direct load of line or riser on regulator and a clamp must be
provided on the pipe nipple.
Testing of Installed Piping Connection
Before carrying out the pneumatic test of the whole installation; testing
assembly, air foot pump with pressure gauge / manometer shall be checked its
calibration and proper functioning.
Before pneumatic testing of the installed connection spacing between two
clamps, tightening of the clamps thread joints, alignments of the whole piping
shall be checked. Valve shall be kept in open position and the appliance valve
shall be kept in close position.
Calibrated pressure gauge shall be used having the range of 0 1 Bar.
Position of the pointer of the pressure gauge shall not be marked with the
marker pen on the glass. It should be recorded in the test records. Pneumatic
testing pressure shall be kept 1.5 times of the working pressure and should be
maintained for 30 minutes.
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.
Conversion of Burner
All the appliance valve and riser isolation valve shall be kept in closed position.
Ensure that meter and regulator adaptor shall be leak proof.
Open the burner knob and remove the plug from the hot plate.
Clean the simmer hole.
Make the simmer hole of 0.6 mm with the help of simmer drill.
At the time of drilling the hole, ensure that it should not be inclined.
Remove the dust from plug.
After greasing, plug and knob should be properly positioned at their original position.
Remove the burner from hot plate and clean it.
Open the existing jet (LPG) and replace it by 125 no jet if it is big burner or 110 no jet if
it is small burner.
Place the burner on its original position and connect the nozzle with appliance valve using
flexible and braided rubber hose.
The length of rubber hose shall not exceed 1.5 mtr.
Both the ends of the rubber hose shall be clamped by metallic clamps on the nozzle.
Check all the joints with soap solution and ensure that the flame color should be blue.
All the Best